Beruflich Dokumente
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82 REMOTE VALVE
Commissioning Guide
AFE #
Revision
0.1
Description
Issue Date
By
Approval
1.0
2.0
SAFETY ............................................................................................................ 4
1.2
1.3
LOCATION ........................................................................................................ 4
1.4
Purpose ............................................................................................................. 4
1.5
WARNINGS ...................................................................................................... 6
1.6
1.7
MECHANICAL .................................................................................................. 13
2.1
3.0
4.0
ELECTRICAL .................................................................................................... 14
3.1
GENERAL ....................................................................................................... 14
3.2
3.3
3.4
4.2
4.3
PLC ................................................................................................................. 29
4.4
SCADA/RTUS ................................................................................................. 32
5.0
6.0
6.2
6.3
6.4
6.5
TRANSMITTALS ............................................................................................. 39
APPENDIX I
APPENDIX II
APPENDIX III
Instrumentation Datasheets
APPENDIX IV
APPENDIX V
Reporting Sheets
APPENDIX VI
APPENDIX VII
APPENDIX VIII
APPENDIX IX
Site Safety Plot Plan, Process Flow Diagram and Switching Diagram
APPENDIX X
APPENDIX XII
ATTACHMENT 1:
ATTACHMENT 2:
ATTACHMENT 3:
SAFETY
Commissioning activities pose a significant safety and loss risk due to the
sometimes unpredictable operation of equipment upon energization. As such, it is
of the utmost importance that all steps taken within this Commissioning Guide be
reviewed thoroughly during daily tailboard meetings with the Commissioning Team
members and those involved with other activities at the site. At no time shall the
Commissioning Team be required to perform unsafe activities. It is every workers
right to refuse unsafe work tasks.
Safety policies and procedures applicable to this scope of work are outlined in
section 1.3.2. It is the responsibility of the Commissioning Lead and the
Commissioning Permit Holder (typically the Inspector or Operations Site
Representative), to ensure each member of the team is informed of the safety
risks and mitigating actions applicable to the worksite. Conditions change
frequently as construction transitions to commissioning and all workers are to be
informed of direct and indirect risks as they pertain to the work.
Emergency and project contact numbers, relative to the location of work are shown
in the appendices.
For the purposes of directing emergency personnel, Legal Land Address and GPS
Coordinates can be found below.
1.2
1.3
LOCATION
1.3.1
1.3.2
Coordinates
N 42.910840 W 82.454365
1.4
Purpose
This Commissioning Guide serves as an aid in the safe testing and energization of
Enbridge facilities prior to line fill and/or flooding of product in the system. Upon
completion, the following directives are to be met;
1.4.1
General Requirements
Prior to commissioning, operating areas shall be cleared of all construction
material (scaffolding, tools, waste, and equipment not required).
1.4.2
1.4.3
Defective Materials
Any piece of equipment purchased by Enbridge for the project that is found
to be defective or incomplete shall be addressed by the Site Inspector.
1.4.4
Commissioning Drawings
Commissioning Drawing Sets are to be provided separately for each type of
commissioning or testing contract service required.
Deficiencies
Operations Site Representative (OSR), Commissioning Team Leader and
Site Inspector shall compile and review deficiencies found during
commissioning activities.
1.4.6
Acceptance by Operations
Completion of commissioning will be acknowledged in the Site
Commissioning Summary found in this Commissioning Specifications. This
document is intended as a record to when the facility was placed into
service. The Field Commissioning Team Leader and OSR will complete it
before the Commissioning Team leaves site.
1.5
WARNINGS
1.5.1
General Warnings
1.5.1.1
Data and signal loss shall result in a fail safe shutdown of the system or
device as deemed necessary by Central Control Room Operations, the
SCADA system configuration specialist, the PLC Applications Specialist,
the Station PLC programming contractor and the substation protection
specialist. Impact to the operation of the facility shall not be hampered by
the failure of non-critical devices.
1.5.1.3
Due to higher throughput demands and reliability drivers agreed upon with
CAPP, unplanned pipeline shutdowns shall be avoided. During the initial
phases of station startup and handover to operations, a list will be
developed of non-critical deficiencies to be resolved at the next planned
outage or forced outage resulting from other factors.
1.5.2
1.5.2.2
1.5.2.3
1.6
PROJECT OVERVIEW
The St. Claire River Crossing Project scope comprises a new Mainline Block
Valve and Pressure Transmitter located in Sarnia, Canada.
1.6.1
Site Overview
This Commissioning Specification is for the St. Claire River Crossing new
Mainline Block Valve and Pressure Transmitter only. The general
Construction Scope of Work for this portion of the project includes the
following. For detailed information, see the scope of work drawing included
in the Commissioning Drawing Set.
1.6.2
480V MCC
Distribution Transformers
Uninterruptible Power Supply
LV Distribution Panels
Lighting
PLC & SCP cabinets for control, monitoring and communication;
Key Drawings
With the exception of the Safety Plot Plan included in Appendix IX, These
drawings along with others will be included in the Commissioning Drawing
set.
Drawing Number
Description
Plot Plan
VALVE CONTROL SHELTER
SITE LAYOUT
D-4.72-SK002-A-585
Scope of Work
MPC 1849.820-6B
CIA PANEL LAYOUT
PLC I/O
INTERCONNECTION DIAGRAM
CABLE AND CONDUIT SCHEDULE
D-4.72-SK010-B-585
D-4.703-SK012-B-585
D-4.705-SK-016-B-585
D-4.701-SK005-B-585
D-4.703-SK011-B-585
1.6.3
Equipment List
Equipment Type
Description
Quantity
Mechanical Equipment
MOV Body
Building HVAC
Building HVAC
Electrical Equipment
480V MCCs
LV Distribution Transformers
LV Distribution Panels
Pressure Indication
Instrumentation Equipment
Pressure Transmitters
1.7
Commissioning Coordinator
The Enbridge Commissioning Coordinator will coordinate the work of all
groups involved in commissioning activities.
1.7.2
Contractors
1.7.2.1
Provide the Enbridge Commissioning Coordinator with progress updates via the
Excel file created on the CD included with the Commissioning Guide;
Sign off of the Commissioning Guide sections individually once check sheets and
commissioning criteria have been meet, as well as the Affidavit.
Installation Contractor
Grounding connections are to be confirmed to be less than 4 as a quick go/nogo test. This is not intended to be in lieu of the more extensive grounding tests
that may be required.
Process instrument lines are to be pressure tested for leaks. Note: this does not
imply that the contractor will be involved in any final process connections to "live"
piping.
Site Inspector
The Site Inspector's primary responsibility is to represent Enbridge's
interests to the Installation Contractor. He will however, play a role during
construction as the Commissioning Coordinator's delegate. Duties will
include but are not limited to:
Provide site coordination of activities that affect pipeline operations, with the
Control Centre keeping the Area Supervisor and the Regional Office informed;
Schedule and coordinate operation resources as needed for the project through
the Area Supervisor and the Regional Office as necessary;
1.7.5
Contacts
See Appendix II for the Project Contact Directory as it applies to the
commissioning scope of this project.
2.0 MECHANICAL
2.1
General
The following general checks and tests are required, and all data should be
recorded in the appropriate Enbridge check sheets.
Hydrotest Records
Testing Equipment Certification and Calibration Records
Flange Installation Quality control forms
Piping
Specific guidelines and checks exist for Piping within an Enbridge Facility or
Pump Station. General Guidelines and checklists are contained in the
Mechanical Commissioning Guideline: MCG-007; PIPE and PIPE
ACCESSORIES
2.1.3
3.0 ELECTRICAL
3.1
GENERAL
The following general checks have been completed and all data has been
recorded in the Enbridge check sheets.
____________________________________
Field Commissioning Lead
_____________________
Date
Before proceeding with any checks or tests that require energization, the
energization procedures in section 3.5 have been reviewed.
A deficiency list, relative to this section, has been provided to the site
inspector capturing all outstanding pre-commissioning issues.
Maximo Data Sheets are correct and complete. In the instance where a
Maximo sheet has not been provided one must be created from the
template in Section 5.0.
3.2
General Checks
The following general checks and tests have been performed and all data
has been appropriately recorded.
____________________________________
_____________________
Date
All ground wire terminations are solid and as per the design drawings and
specifications.
All cables, conduit and equipment have been tagged by Contractor. The
tags shall be as specified in the construction drawings.
All cables and individual conductors are identified at both ends with a
heat shrinkable, typewritten sleeve.
Where fire stops are required in cable runs, a seal has been poured using
Dow Corning 3-6548 Silicone RTV Foam or Elasta seal 300, or approved
alternative.
All control wiring is bundled neatly and fastened securely with proper
cable straps.
A deficiency list has been provided to the Enbridge inspector capturing all
outstanding pre-commissioning issues.
and
3.2.2
_____________________
3.2.3
Date
The 600V Motor Starter listed below has been verified according the checks and
tests in this section and all data has been recorded in the Enbridge check
sheets.
MOV STARTER CABINET
____________________________________
_____________________
Date
Section 7.16 of the NETA standard for Acceptance Testing Specifications for
Electric Power Distribution Equipment and Systems shall be used as a reference
for completing the checks and tests.
Nameplate data and model numbers have been checked and recorded in
Table 3.02.
Visual inspection of starter cells has been performed. This shall include
inspection for cleanliness, scratches, and dents, proper closing of all
enclosure doors, proper anchorage and even alignment between cells.
All terminal screws in each cubical have been checked and are tight.
The 600 / 120 208V transformers xx-T-1 have been checked in accordance
with section 3.2.10.
Circuit breaker, MCP and O/L heater settings and selections have been
checked for correct sizing and have been recorded in Table 3.01 of
Appendix I. Each MCP shall be set at least 700%, not to exceed 1300% of
motor FLA.
All load break switches have been function tested in accordance with section
3.2.14.
The checks and tests in Table 3.01 have been completed and the results
have been recorded.
3.2.4
The small transformers listed below have been verified according the checks and
tests in this section and all data has been recorded in the Enbridge check
sheets.
xx-T-1
____________________________________
Field Commissioning Lead
_____________________
Date
Section 7.2.1.1 of the NETA standard for Acceptance Testing Specifications for
Electric Power Distribution Equipment and Systems shall be used as a reference
for completing the checks and tests.
Nameplate data and model numbers have been checked and recorded in
Table 3.02 in Appendix I.
Output voltage has been tested. All results have been recorded.
The checks and tests in Table 3.31 have been completed and the results
have been recorded.
3.2.5
The low voltage distribution panels listed below have been verified according the
checks and tests in this section and all data has been recorded in the Enbridge
check sheets.
xx-LDP-1
____________________________________
_____________________
Date
Nameplate data has been checked and matches drawings and has been
recorded in either Table 3.02 of Appendix I or a contractor supplied data
sheet.
The panel has been inspected for cleanliness, scratches, dents, proper
closing of all enclosure doors and proper anchorage.
All breaker sizes fuse sizes and loads have been checked and
correspond with the drawings.
All circuits feeding loads outside of the substation building have been
individually energized and proven.
The checks and tests in Table 3.25 have been completed and the results
have been recorded.
3.2.6
The Uninterruptible Power Supply listed below has been verified according the
checks and tests in this section and all data has been recorded in the Enbridge
check sheets.
UPS
____________________________________
Field Commissioning Lead
_____________________
Date
Section 7.22.2 of the NETA standard for Acceptance Testing Specifications for
Electric Power Distribution Equipment and Systems shall be used as a reference
for completing the checks and tests.
UPS nameplate information has been verified against the drawings and
specifications and has been entered into Table 3.02 of Appendix I.
All terminals have been checked to be properly identified and all screws
are tight.
Ventilation system has been inspected. (Filters are clean and in place,
vents are clear and fans operate smoothly.)
Ductor contact resistance tests have been performed across all bolted
electrical connections. All results have been recorded in Table 3.05 and
verified to be acceptable.
Start-up tests have been completed and the unit has been verified to
operate satisfactorily.
All UPS settings have been correctly entered, tested and recorded. The
UPS settings record is to be inserted into Appendix VII.
A test of the static transfer function to battery power has been performed
by de-energizing the utility power to the UPS.
A test of a transfer from the inverter to the bypass and back has been
done.
AC and DC voltage and current levels under normal operation have been
recorded.
The checks and tests in Table 3.22 have been completed and the results
have been recorded.
3.2.7
DC Power Supplies
The DC Power Supply listed below has been verified according the checks and
tests in this section and all data has been recorded in the Enbridge check sheets.
DC Power Supply PS-1
____________________________________
Field Commissioning Lead
_____________________
Date
Section 7.18.2 of the NETA standard for Acceptance Testing Specifications for
Electric Power Distribution Equipment and Systems shall be used as a reference
for completing the checks and tests.
3.3
DC power supply nameplate data (voltage, current, voltage ripple etc.) has
been checked to match the drawings and system requirements.
Once determined safe, energize from the fused (supply) terminal block and
check that the power supply is working.
The checks and tests in Table 3.07 have been completed and the results
have been recorded.
The following checks shall be performed on all substation cables and conduit. In
addition to the checks listed below, all cables shall be checked and verified
according to section 7.3 of the NETA standard for Acceptance Testing
Specifications for Electric Power Distribution Equipment and Systems.
Cables that were checked during the ESB building pre-commissioning do
not need to be rechecked.
3.3.1.1
The low voltage cables have been verified according the following checks
and tests and all data has been recorded in the Enbridge check sheets.
____________________________________
Field Commissioning Lead
_____________________
Date
All cable test results shall be recorded in either Table 3.16 of Appendix I or an
equivalent contractor data sheet that meets or exceeds the checks specified
in Table 3.16.
All cable and conduit tags have been checked with the drawings.
Each conductor of all 600 VAC rated power and control cables has been
megger tested at 1000 VDC between ground and the other conductors which
form the cable.
Each conductor of all 300 VAC rated power, instrumentation and control
cables has been megger tested at 500 VDC between ground and the other
conductors which form the cable.
All cable wires have been tested and checked for continuity and polarity,
proper securing, correct identification. All cable wires have been verified by
point to point checks. Record results, complete and sign check sheets
supplied in pre-commissioning document tables.
All shielded wire has been tested after installation to ensure that the shields
have not been accidentally grounded or opened.
3.3.2
The motor operated valves listed below have been verified according the checks
and tests listed in this section and all data has been recorded in the Enbridge
check sheets.
C1849.820-6B-V
____________________________________
_____________________
Date
All MOV disconnect switches have been tested as per section 3.3.4.
With the selector switch in Local position, operation of the valves with the
Open and Close buttons at the MOV have been checked.
With the selector switch in MCC position, operation of the valves with the
Open and Close buttons at the MCC have been checked.
With the selector switch in the Remote position, Open/Close operation from
SCADA system (selector switch in Auto) has been checked.
Valves have been cycled and limit switches have been adjusted as
recommended in the Actuator Operations Manual.
All status indication in the SCADA system, in Local, MCC and Remote modes
has been verified.
Results have been recorded in the Motor Operated Valve Check Sheet, Table
3.01, and 3.18 in Appendix I.
PLC/SCADA contractor supplied I/O
assignment has been verified and signed off.
3.3.3
LV Motors
The motors listed below have been verified according the checks and tests listed
in this section and all data has been recorded in the Enbridge check sheets.
C1849.82-6B-V
____________________________________
_____________________
Date
Nameplate data and model numbers have been checked and recorded in
Table 3.02 in Appendix I.
Ductor contact resistance tests have been performed across all bolted
electrical connections. All results have been recorded in Table 3.05 and
verified to be acceptable.
Motor windings have been megger tested for safe insulation levels as
outlined in Table 3.06. All results have been recorded in Table 3.08. The
test duration should be for 1 minute and the dielectric-absorption ratio should
be calculated and recorded.
The motor has been bumped to ensure that the motor direction of rotation is
correct.
The Hand-Off-Auto switch has been function tested and verified to operate
correctly.
All local push button and annunciators have been function tested.
All PLC contacts have been function tested and verified to operate the motor
correctly.
Motor space heaters have been fully function tested and verified to meet area
classification. All motor heater measurement results have been recorded in
Table 3.10.
The checks and tests in Table 3.08 have been completed and the results
have been recorded.
3.3.4
The disconnect switches listed below has been verified according the checks and
tests in this section and all data has been recorded in the Enbridge check sheets.
xx-CB-1
xx-DISC-1
____________________________________
Field Commissioning Lead
_____________________
Date
Section 7.5 of the NETA standard for Acceptance Testing Specifications for
Electric Power Distribution Equipment and Systems shall be used as a reference
for completing the checks and tests.
Correct blade alignment, blade penetration and travel stops and mechanical
operation has been verified.
Ductor Contact Resistance Test has been performed. All results have been
recorded in Table 3.05 and verified to be acceptable.
Insulation Test (Megger from line side to load side across the opened
disconnect) has been performed.
The checks and tests in Table 3.28 have been completed and the results
have been recorded.
3.3.5
Grounding Systems
The grounding system has been verified according the following checks
and tests and all data has been recorded in the Enbridge check sheets.
____________________________________
Field Commissioning Lead
_____________________
Date
Section 7.13 of the NETA standard for Acceptance Testing Specifications for
Electric Power Distribution Equipment and Systems shall be used as a reference
for completing the checks and tests.
The ground system has been inspected for compliance with drawings and
specifications.
All ground wires have been checked for proper and solid connections.
All Teck power cable ground wires have been checked for proper and solid
connections.
All building and equipment grounds have been checked to be as per design
and to have solid connections.
The new ground grid has been checked to be securely connected to the
existing ground and station grids.
The fence grounding has been checked to be as per design. This includes a
check of all bonding jumpers to gates, barbed wire, chain link fence etc. and
across all metallic couplings.
All trays have been checked to be bonded with a ground wire at a maximum
15 m interval and connected to the structural steel. A bonding jumper has
been checked to be installed between tray sections at the same interval.
All equipment has been checked to be solidly connected to the ground grid.
The equipment to be checked includes.
3.4
The checks and tests in Table 3.27 have been completed and the results
have been recorded.
ENERGIZATION PROCEDURES
The intent of the following procedures is to provide a general guideline for the
proper energization of the substation. These procedures are not intended to be
entirely comprehensive as it is impossible to predict all site conditions at the time
of energization. As well, these procedures do not include all of the energization
based commissioning checks that are to be completed during energization. This
energization procedure assumes that the upstream substation has been fully
commissioned and is energized.
Enbridge Operations are responsible for ensuring that the energization is
performed in a safe and orderly fashion and that all necessary precautions
which are not limited to those listed below have been taken to ensure the
protection of personnel and equipment. Energization shall be performed by
Enbridge Operations or under their supervision and consent.
3.4.1
Equipment Energization
UPS (xx-UPS-1)
LV Panels (xx-LDP-1)
1. Ensure that all commissioning checks and tests listed in this guide
have been completed. (The appropriate signature for each section
shall be given and the respective check sheets shall be completed
before energization.)
2. Ensure that equipment (600V, 208V, 120V and control circuits) is
ready for energization:
-
3. Ensure that the starter and circuit breaker in the Motor Starter is open.
4. Ensure that all personnel have been informed that energization is
immanent. Only those people required for energization should be
present.
5. Close the breaker to xx-T-1 to energize xx-LDP-1.
6. Progressively energize the circuits in xx-LDP-1 to bring 120V power to
the building, and PLC.
7. Progressively close the 600V Motor Starter circuit breaker and ensure
that the load is correctly powered and operates properly.
Shipping Tag #
YP-KDW-E-11843
YP-KDW-E-10184
Notes
1. Final MOV datasheets not created. Limitorque job spec sheet
included in Attachment 2 (Vendor Drawings). Preliminary Data sheets
inserted in Data Sheet Section Appendix III.
4.2
General
The checks and tests in Section 4.2.1 have been performed and all data has
been recorded in the appropriate Enbridge check sheets.
xx-ESB-1 Devices
4.2.1.1
____________________________________
_____________________
Date
Calibration Accuracy
Check all instruments for the accuracy of their calibration and adjust as
required. Acceptable tolerances for the various types of instruments are
defined in the following sections and Table 4.01 in Appendix I.
Equipment Verification
Functional/Operations Check
NOTE:
Configuration data.
Reference Data
PLC
Pressure Transmitters
Limitorque Actuators
4.2.2
Miscellaneous Alarms
The following checks and tests for the devices listed have been performed and
all data has been recorded in the appropriate Enbridge check sheets.
Intrusion Detection Switch
Valve Building
____________________________________
Field Commissioning Lead
_____________________
Date
Confirm instrument wiring loops to each device and ensure there are no
shield grounds where applicable.
Manually simulate miscellaneous alarms listed in sign off below and verify the
PLC alarm generation. Observing the PLC registers for the corresponding
input.
4.2.3
Pressure
4.2.3.1
Pressure Transmitters
The following checks and tests for the devices listed have been performed and
all data has been recorded in the appropriate Enbridge check sheets.
C1849-6-PIT-1
4.3
____________________________________
_____________________
Date
Confirm instrument wiring loops to each transmitter and ensure there are no
shield grounds.
Using a digital mA meter and certified pressure test equipment, calibrate and
record the range and output of all pressure transmitters as listed in Appendix
III and complete Tables 4.09 in Appendix I & PLC/SCADA contractor supplied
I/O assignment verified and signed off.
PLC
4.3.1
Checks
4.3.1.1
General
The following checks and tests for the devices listed have been performed and
all data has been recorded in the appropriate Enbridge check sheets.
xx-PLC-1
____________________________________
_____________________
Date
With AC and DC power disabled (fuse terminals open), ensure all PLC
modules are installed as per the Rack Layout drawing(s).
Energize the PLC power supplies by closing the appropriate fuse terminals.
Do not power up the instrument DC power supply or any AC instruments yet.
Ensure PLC program is loaded into the PLC processor(s) (by programmer or
ENBRIDGE).
Once the PLC program is loaded, start the PLC processor(s) and check that
the "Power" light is ON.
4.3.1.2
The following checks and tests for the devices listed have been performed and
all data has been recorded in the appropriate Enbridge check sheets.
Ethernet Network
____________________________________
_____________________
Date
The following checks and tests for the devices listed have been performed and
all data has been recorded in the appropriate Enbridge check sheets.
xx-PLC-1 Inputs
xx-PLC-1 Outputs
____________________________________
_____________________
Date
PLC Inputs
Check PLC inputs by initiating devices as per "PLC Input" check sheets
supplied by the PLC contractor and signed off.
PLC Outputs
Check operation of devices by forcing all PLC outputs as per check sheets
supplied By PLC contractor and signed off.
_____________________
Date
4.4
Control Philosophy
Alarm Listing
Data Registries
Shutdown Keys
Dipswitch settings
O&M Manual
SCADA/RTUS
4.4.1
Data Communications
The following checks and tests for the devices listed have been performed and
all data has been recorded in the appropriate Enbridge check sheets.
All applicable SCADA
points
____________________________________
_____________________
Date
Manufacturer:
Model Number:
Location:
Serial Number:
Equipment Description:
Manufacturer:
Model Number:
Location:
Serial Number:
Equipment Description:
Functional Tag Number:
Manufacturer:
Model Number:
Location:
Serial Number:
Equipment Description:
Functional Tag Number:
Manufacturer:
Model Number:
Location:
Serial Number:
Equipment Description:
Functional Tag Number:
Manufacturer:
Model Number:
Location:
Serial Number:
Equipment Description:
Functional Tag Number:
Manufacturer:
Model Number:
Location:
Serial Number:
6.1
DEFICIENCY LIST
Note: Representation only, actual form by Excel spreadsheet.
Page 36 of 39
6.2
______________________
(Print Name)
_________________________
(Signature)
______________________
(Print Name)
_________________________
(Date)
_________________________
(Company)
_________________________
(Signature)
______________________
(Print Name)
_________________________
(Company)
_________________________
(Date)
_________________________
(Company)
_________________________
(Signature)
_________________________
(Date)
_________________________
(Signature)
_________________________
(Date)
Site Inspector:
______________________
(Print Name)
______________________
(Print Name)
_________________________
(Signature)
_________________________
(Date)
______________________
(Print Name)
_________________________
(Signature)
_________________________
(Date)
Page 37 of 39
6.3
______________________
(Print Name)
_________________________
(Signature)
______________________
(Print Name)
_________________________
(Date)
_________________________
(Company)
_________________________
(Signature)
______________________
(Print Name)
_________________________
(Company)
_________________________
(Date)
_________________________
(Company)
_________________________
(Signature)
_________________________
(Date)
_________________________
(Signature)
_________________________
(Date)
Site Inspector:
______________________
(Print Name)
______________________
(Print Name)
_________________________
(Signature)
_________________________
(Date)
______________________
(Print Name)
_________________________
(Signature)
_________________________
(Date)
Page 38 of 39
6.4
6.5
TRANSMITTALS
Transmittals described below are included in Appendix XII.
6.5.1
6.5.2
Page 39 of 39