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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
The following signature indicates that the commissioning test protocol has been executed and reported.
Checked by
Approved by
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Contents
1 Reference Documents 5
1.1 Verification with as built P&ID 5
2 Version History 5
4 Purpose 6
5 System Description 6
6 System Boundaries 9
7 Testing Rationale 9
9 Deviation List 9
11 Test Sheets 12
12 List of Attachments 57
13 Exclusions: 57
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
1 Reference Documents
2 Version History
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
4 Purpose
The purpose of this document is to provide documented evidence that the components of the HSD
Storage Tank and Transfer System are installed correctly and in accordance with the requirements
of design documentation, that supporting documentation is in place and to provide evidence of the
systems proper operation.
5 System Description
Quantity 2 No.
Plate Thickness
Pipe Size
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Design Conditions
Quantity 2 No.
Position Vertical
Location DG Yard
Design Conditions
Quantity 3 No.
Position Vertical
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
No. of Pumps 9
Pipe
Flanges / Blind Flanges MS SORF Flange class 150# made out of IS 226 / /2062
Mid steel hexagonal head bolt with one nut and washer to IS 1364 /
Bolts and Nuts
1367
Gaskets (98% Purity or 1.5mm Graphite / Metal) Metal spiral bond laminated gasket
Carbon steel valve body and body connector to ASTM351 ball and
Screwed ends
stem virgin PTFE seat and body seat to class 800#
Carbon steel valve body and body connector to ASTM351 ball and
Flanged ends stem virgin PTFE seat and body seat to class 800# and flanges rating
of ANSI 150# RF as per ANSI B 16.5
Strainer
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Make Reputed
IP Rating IP 66
MCC Panel
6 System Boundaries
As per system boundary as per mark up with GSK-PID-00-0-MHSDS-001 R2.
7 Testing Rationale
Testing described within this report/protocol is based upon the Commissioning Plan. All acceptance
criteria will be verified for indirect systems.
9 Deviation List
Record each of the deviations raised during the completion of the protocol and the date that the
deviation was resolved.
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Annexure 1_Pre-
The required pre-requisite commissioning/qualification
1 Commissioning
stages have been completed.
Checklist
10.2 Documentation
10.3 Installation
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
10.4 Operational
10.5 Additional
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
11 Test Sheets
This section details the checks to be carried out in support of the system specific acceptance criteria
contained within Section 11.
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Overall Test Outcome (PASS/FAIL) Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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CP-HSD-049-001, Version D
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Objective:
1 To verify if the flow rate is achieved as stated per technical specification.
Pre-requisites: None
Method:
1 Flow Transmitter after the DG transfer pumps is used to measure the flow rate.
Acceptance Criteria:
1 The flow rate is achieved as stated in technical specification
Results:
Instrument Ref Design Flow Rate Acceptance Criteria Met? (YES/NO) Initial/ Date
FT/049/001 3.6m3/hr
Comments/Deviations/Supporting Documentation:
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Title: Alarm and Interlock Verification – Pump (Liquid Transfer) Reference: 0143_03
Objective:
1 To confirm pump trips operate correctly.
Pre-requisites:
Method/Acceptance Criteria/Results:
List of Alarms:
Acceptance Initial/ Date
Equipment/Instrument Alarm Signal Criteria Met?
(YES/NO)
High Level Alarm HH
LT/049/001
Low Level Alarm LL
High Level Alarm HH
LT/049/002
Low Level Alarm LL
High Level Alarm HH
LT/049/003
Low Level Alarm LL
High Level Alarm HH
LT/049/004
Low Level Alarm LL
Unloading Pump TSP/049/001 Flow Switch FS/049/001
Dry run/Low Flow Alarm
Unloading Pump TSP/049/002 Flow Switch FS/049/002
Boiler Transfer Pumps TSP/049/006, 007 Dry run/Low Flow Alarm Flow Switch FS/049/003
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Title: Alarm and Interlock Verification – Pump (Liquid Transfer) Reference: 0143_03
Overflow Alarm Flow Switch FS/049/005, 006
One of these valves has to be opened in order for the unloading pump to
start.
VB/049/050
Open / Close
VB/049/051
Any of the pumps can be started when both valves are open where none of
the level transmitters in the HSD Storage Tanks are High/H.
Interlock for DG Transfer Pumps (P1A/P1B/P1C)
Sensor Ref Status Acceptance Criteria Acceptance Initial/ Date
Criteria Met?
(YES/NO)
VB/049/049 Open / Close No transfer pumps can be started if VB/049/049 is in closed condition.
Open > LT/049/001 & LT/049/002 should not be in Low/L
VB/049/052
Open / Close Open > LT/049/003 & LT/049/004 should not be in Low/L
VB/049/053
Both open > LT/049/003 & LT/049/004 should not be in Low/L
LS/049/001
TSP/049/003. 004, 005 can start after a delay of Y, if VES/049/001, 002, 003
LS/049/002 Low/L condition
‘Open Signal’ is received.
LS/049/003
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Title: Alarm and Interlock Verification – Pump (Liquid Transfer) Reference: 0143_03
High/H TSP/049/003. 004, 005 will stop and VES/049/001, 002, 003 ‘Close signal’ is
condition received with a time delay of X.
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Title: Alarm and Interlock Verification – Pump (Liquid Transfer) Reference: 0143_03
LS/049/003 High/H signal VES/049/003 close feedback is received with a delay of X from Pump stops
LS/049/004 High/H signal VES/049/004 close feedback is received with a delay of X from Pump stops
LS/049/005 High/H signal VES/049/005 close feedback is received with a delay of X from Pump stops
Interlock for On & Off Valve Operation (Manual mode)
The operator has to open/close the valve from the Flame Proof Remote Control Panel.
Interlock for On & Off Valve Operation (Maintenance mode)
All the interlocks are overridden; a spool piece will be installed in place of the on off valve.
Comments/Deviations/Supporting Documentation:
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Title: Safety- Zero Access Machinery Guarding & Lock-Out/Tag-Out (LOTO) Testing & Verification Reference: 0044_02
Requirements
Objective:
1. To provide documented evidence that the machinery physical guarding and lock-out/tag-out (LOTO) requirements have been designed,
installed and tested safely, to prevent contact with dangerous parts and prevent injury during normal operation or during an intervention, as
defined in Global Engineering Standard - Machinery Safety - GES 110.
Note:
1) Zero Access is a standard of machine guarding where it is physically impossible for anyone to gain access to any dangerous parts of a
machine or equipment without using a tool to remove or disable a safeguard.
2) Lock-out/tag-out (LOTO) is the required standard within GES 110 to ensure that machinery remains isolated from all sources of energy during
an intervention to protect those involved from being injured either by energy sources or unexpected operation of equipment.
Pre-requisites: Global EHS Standard 604 – Use of Work Equipment Assessment completed.
Method:
1. Complete the required checks to assess the equipment against the defined criteria detailed within the results section. Where applicable
checks should be completed with the equipment in normal run mode. If criteria are not met ensure details are recorded.
Note: All tests are to be completed safely and in compliance with site operating & safety procedures.
Acceptance Criteria:
1. Machinery physical guarding and lock-out/tag-out (LOTO) requirements have been designed, installed and tested safely, to prevent
contact with dangerous parts and prevent injury during normal operation or during an intervention, as defined in Global Engineering Standard -
Machinery Safety - GES 110.
Results:
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Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
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CP-HSD-049-001, Version D
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Comments/Deviations/Supporting Documentation:
Overall Test Outcome (PASS/FAIL): Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Comments/Deviations/Supporting Documentation:
Overall Test Outcome (PASS/FAIL): Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Overall Test Outcome (PASS/FAIL) Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
Comments/Deviations/Supporting Documentation:
Overall Test Outcome (PASS/FAIL): Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):
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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017
12 List of Attachments
13 Exclusions:
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