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HSD Storage Tank and Transfer

System Commissioning Test


Protocol & Report

Shimizu Corporation India Pvt Ltd


Shimizu Detailed Design
CP-HSD-049-001, Issue: D
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

COMMISSIONG TEST PROTOCOL & REPORT


System : HSD Storage Tank and Transfer System

GlaxoSmithKline Equipment ID : HSD/049/001 Shimizu


Pharmaceuticals Corporation India
Pvt Ltd
Date : 29/Dec/2017

Document No. : CP-HSD-049-001

Version :D

The following signature indicates that the commissioning test protocol has been released for execution.

Name Organization Department Signature Date

Prepared by

Reviewed by

Approved by

Page 2 of 57
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.

Name Organization Department Signature Date

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

3 Introduction & Scope 6

4 Purpose 6

5 System Description 6

6 System Boundaries 9

7 Testing Rationale 9

8 List of Execution Personnel 9

9 Deviation List 9

10 Acceptance Criteria Summary 10


10.1 Documentation 10
10.2 Installation 10
10.3 Operational 11
10.4 Additional 11

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

Ref. Document No. Document Title


1 IN5010049-42-SP-0004 [Issue: B] HSD Storage Tank and Transfer system

Mechanical data Sheet for 100KL High Speed Diesel Storage


2 IN510049-42-P-04-001 R3
Tank

2 Pump GA & CS General Assembly and Cross-sectional Drawing of Pumps

3 PTC (DP 16 43033) Performance Test Certificates for Pumps

4 SCIPL/GSK/2017-18/PROC/PO/395 Pumps Technical Data Sheet

5 SCIPL/GSK/MW/TRA/2017/1181 RE – TRA_1181 – MEAR for HSD System

6 SCIPL/GSK/MW/TRA/2017/1490 RE – TRA_1490 – MEAR for HSD Services

7 SCIPL/GSK/MW/TRA/2017/1490B RE – TRA_1490B – MEAR for HSD Controlling Devices

8 SCIPL/GSK/MW/TRA/2016/805 RE – TRA-805 – HSD Control Logic

9 HSD Upper Ground Piping Hydro Test Report

10 Annexure 2 DG Yard Underground Piping Hydro Test Report

11 Annexure 3 HSD Final Tank Inspection Report

12 Annexure 4 HSD Yard Underground Piping Hydro Test Report

1.1 Verification with as built P&ID

Ref. Document No. Document Title


1 GSK-PID-00-0-MHSDS-001 R2 P&ID for HSD Storage Tank and Transfer System

2 Version History

Date Version Revised By Reason for Revision


(dd-mm-yyyy)
25/Oct/2017 A Eddie Initial Issue
29/Nov./2017 B Eddie Client Revision
21/Dec/2017 C Eddie Client Revision
29/Dec/2017 D Eddie Client Revision

Page 5 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

3 Introduction & Scope


This document records the commissioning of the HSD Storage Tank and Transfer System as
Approved Design Specification. These systems have been assessed and have been categorised as
Indirect Impact. Indirect systems shall be subject to commissioning.

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

HSD Storage Tank


Design Conditions

Design Pressure Atmospheric

Test Pressure Water Fill Test

Welding Factor As per IS-803

Quantity 2 No.

Type of Installation Above Ground.

Capacity – Nominal Volume 100KL

Position Cylindrical Vertical

Guides Tee – guides machined 45 × 45 × 5 For Car & CWT

Travel HT. 8000mm. approx..

Design Code IS 803

Material of construction manhole, Lifting


IS 803
lugs, flanges, etc.

Dimension of Tank 5000mm DIa x 6000mm Height

Plate Thickness

Shell 8mm think (Min)

Bottom Plate 10mm thick (Min)

Top 8mm thick (Min)

Pipe Size

Inlet Nozzle 50NB

Outlet Nozzle 80NB

Dip stick nozzle As Per drawing (IN510049-42-SP-04-001 R3)

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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

HSD Storage Tank


Vent nozzle As Per drawing (IN510049-42-SP-04-001 R3)

Manhole (Roof) 508mmdia x 6mm thick

Manhole (Shell) 508mmdia x 6mm thick

Pressure rating for flange 150psi ANSI B 16.5

Nozzle for level sensor 3 no

HSD Day Tank


Operating Conditions

Location Boiler Room

Design Conditions

Design Pressure Atmospheric

Test Pressure Water Fill Test

Welding Factor 0.7 (All welds to be DP tested)

Quantity 2 No.

Type of installation Above Ground

Capacity – Nominal Volume 990 Litres

Position Vertical

Design Code Good Engg, Practive

Material of construction manhole, Lifting


Generally as per IS 10987
lugs, flanges, etc.

Dimension of Tank 1000 x 1000 x 1000mm

Plate Thickness 5mm thick (Min)

Location DG Yard

Design Conditions

Design Pressure Atmospheric

Test Pressure Water Fill Test

Welding Factor 0.7 (All welds to be DP tested)

Quantity 3 No.

Type of installation Above Ground

Capacity – Nominal Volume 990 Litres

Position Vertical

Design Code Good Engg, Practive

Material of construction manhole, Lifting


Generally as per IS 10987
lugs, flanges, etc.

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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

HSD Day Tank


Dimension of Tank 1000 x 1000 x 1000mm

Plate Thickness 5mm thick (Min)

Pumps, Pipe, Pipe Fittings, and Accessories Specifications


Pumps

No. of Pumps 9

Type Twin Screw Pump

Design Capacity 3.6m3/hr or 10m3/hr

Pipe

Pipe / Jacket Pipe MS ERW IS : 1239 Part – 1 Heavy Class

Specials like elbows, tees, reducers, unions, etc IS 1239 Part – II

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

Valves / Non-Return Valves

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

Carbon Steel body with element having a mesh rating of 30 and


Flanged ends material of construction of element is brass and flange rating of ANSI
150# RF as oer ANSI B 16.5.

PLC & MCC System


PLC System

Make and Model Siemens S7 IM 151-8PN PLC system

Power Supply 24VDC, 1000Watts

I/O Modules ET200S (Siemens)

VFD (Variable Frequency Drive) Profinet

Control Panels TS8: IP54

HMI KTP 700 2nd Generation

Field Remote Panel (FPRCP)

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Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

PLC & MCC System


Quantity 1 No.

Make Reputed

Dimensions 600 x 450 x 300 in mm (W x H x D)

Type of Material FRP

IP Rating IP 66

MCC Panel

Make Rittal, Germany

Description PS Compact enclosure

Dimensions 2000 x 1600 x 500 in mm (W x H x D)

Type of Material Sheet Steel

IP Rating IP65 to EN 60529

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.

8 List of Execution Personnel


The following personnel(s) are trained and approved to carry out the commissioning test protocol.

Ref. Name Organization Designation Signature Date


1

9 Deviation List
Record each of the deviations raised during the completion of the protocol and the date that the
deviation was resolved.

Page 9 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Deviation Deviation Description Date Resolved Initial and


Ref. (dd-mm-yyyy) Date

10 Acceptance Criteria Summary


This section, detailing system specific Acceptance Criteria (A/C), should be completed following a
review of the test sheets, within Section 11, and supporting data.

10.1 Pre-commissioning checklist

A/C. Acceptance Criteria A/C Met? Test Sheet Initial


Ref. Yes/No Reference (if any) Date/Sign

Annexure 1_Pre-
The required pre-requisite commissioning/qualification
1 Commissioning
stages have been completed.
Checklist

10.2 Documentation

A/C. Acceptance Criteria A/C Test Sheet Initial


Ref. Met? Reference (if any) Date/Sign
Yes/No
Devices have been calibrated in compliance with the 0022_08-
Device Assessment and have valid calibration certificates Documentation -
1 Calibration
Verification Record
(General)

10.3 Installation

A/C. Acceptance Criteria A/C Test Sheet Reference Initial


Ref. Met? (if any) and Date
Yes/No
The installation has been verified as correct against the N/A for test sheet.
2 design drawings, Verification with P&ID.

Page 10 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

A/C. Acceptance Criteria A/C Test Sheet Reference Initial


Ref. Met? (if any) and Date
Yes/No
System specified installation checks have been completed. 0011_07-Installation
3 Verification (Device) -
General

10.4 Operational

A/C. Acceptance Criteria A/C Deviation Test Sheet Initial


Ref. Met? Reference (if any) and Date
Yes/No
Alarms and interlocks operate to design specification 0143_03_Alarm and
4 Interlock Verification –
Pump (Liquid Transfer)

5 The system performance meets design specification

10.5 Additional

A/C. Acceptance Criteria A/C Test Sheet Initial


Ref. Met? Reference and Date
Yes/No (if any)
Test Instrumentation used during completion of the test 0006_ Support - Test
6 protocol was in calibration at the time of testing and the Equipment Record
calibration certification is referenced.

The signature register has been completed by those 0009_ Support -


7 involved in the qualification activities and training records Signature Record
are available.

Page 11 of 57
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.

Test Sheet Title Test Sheet Ref.

Pre-Commissioning Checklist Annexure 1

Documentation - Pre-Requisite Documentation Review 0013_07


Installation Verification (Device) - General 0011_07

Documentation - Calibration Verification Record (General) 0022_08

HSD Piping Flow Rate Test NA


Alarm and Interlock Verification – Fire Alarm NA

Alarm and Interlock Verification – Pump (Liquid Transfer) 0143_03

Safety- Zero Access Machinery Guarding & Lock-Out/Tag-Out (LOTO) Testing


0044_02
& Verification Requirements

Support - Test Equipment Record 0006_05

Support - Signature Record 0009_03

Support - Training Verification 0007_02

Page 12 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Documentation – Pre-Requisite Documentation Review Refer 0013_07


ence:
Objective:
1 To provide evidence that required pre-requisite commissioning/qualification stages (which must be completed prior to starting testing
within this protocol) have been completed, referenced and the approval status documented. This verification will include the
commissioning or qualification of required supporting facilities, utilities or equipment.
Pre-requisites: None
Method:
1 Record the document reference, version and approval status (conditionally approved or unconditionally approved) of each of the required
pre-requisite documents identified in the results table below.
Acceptance Criteria:
1 The required pre-requisite commissioning/qualification stages have been completed, referenced and the approval status documented,
unresolved snags/deviations do not impact upon the testing within this protocol.
Results:
Document Title Document Reference: Versio Approval Status
n
HSD Storage Tank and Transfer system IN5010049-42-SP-0004
Mechanical data Sheet for 100KL High Speed Diesel
IN510049-42-P-04-001 R3
Storage Tank
General Assembly and Cross-sectional Drawing of Pumps Pump GA & CS
Performance test Certificates for Pumps PTC (DP 16 43033)
Pumps Technical Data Sheet SCIPL/GSK/2017-18/PROC/PO/395
SCIPL/GSK/MW/TRA/2017/1181 RE – TRA_1181 – MEAR for HSD System
SCIPL/GSK/MW/TRA/2017/1490 RE – TRA_1490 – MEAR for HSD Services
SCIPL/GSK/MW/TRA/2017/1490B RE – TRA_1490B – MEAR for HSD Services
SCIPL/GSK/MW/TRA/2016/805 RE – TRA-805 – HSD Control Logic

Page 13 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Documentation – Pre-Requisite Documentation Review Refer 0013_07


ence:
HSD Upper Ground Piping Hydro Test Report
DG Yard Underground Piping Hydro Test Report Annexure 2
HSD Final Tank Inspection Report Annexure 3
HSD Yard Underground Piping Hydro Test Report Annexure 4
GSK-PID-00-0-MHSDS-001 R2 P&ID for HSD Storage Tank and Transfer System
Comments/Deviations/Supporting Documentation:

Overall Test Outcome (PASS/FAIL) Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):

Page 14 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


Objective:
1 To provide documented evidence that the installation of the devices, within the HSD System, is in accordance with the approved design
intentions, that the manufacturer’s recommendations have been considered, adequate access for maintenance is available and the
device is correctly tagged.
Pre-requisites: None
Method:
1 Verify the installation of each of the devices identified within the results section below.
Acceptance Criteria:
1 The HSD System components have been correctly installed to the manufactures recommendations with adequate maintenance access
and are correctly tagged.
Results:
A/C
Ensure all components are tagged as per P&ID.
TAG ID Components Design Description Actual result
TSP/049/001 Unloading Pump Pump Make: Roto Pumps
Model: REB01A1015EKPJ
Pump Serial No: ND-2497
MOC: C.S (ASTM A216 Gr. WCB)
Flow rate (m3/hr): 10
Motor Make: Crompton Greaves
Rated Output (kW): 3.7
MOC: Cast Iron

Page 15 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


TSP/049/002 Unloading Pump Pump Make: Roto Pumps
Model: REB01A1015EKPJ
Pump Serial No: ND-2496
MOC: C.S (ASTM A216 Gr. WCB)
Flow rate (m3/hr): 10
Motor Make: Crompton Greaves
Rated Output (kW): 3.7
MOC: Cast Iron
TSP/049/003 DG Transfer Pumps Make: Roto Pumps
Model: REB01A1004EKPJ
Pump Serial No: ND-2498
MOC: C.S (ASTM A216 Gr. WCB)
Flow rate (m3/hr): 3.6
Make: Crompton Greaves
Rated Output (kW): 2.2
MOC: Cast Iron
TSP/049/004 DG Transfer Pumps Make: Roto Pumps
Model: REB01A1004EKPJ
Pump Serial No: ND-2499
MOC: C.S (ASTM A216 Gr. WCB)
Flow rate (m3/hr): 3.6
Make: Crompton Greaves
Rated Output (kW): 2.2
MOC: Cast Iron

Page 16 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


TSP/049/005 DG Transfer Pumps Make: Roto Pumps
Model: REB01A1004EKPJ
Pump Serial No: ND-2495
MOC: C.S (ASTM A216 Gr. WCB)
Flow rate (m3/hr): 3.6
Make: Crompton Greaves
Rated Output (kW): 2.2
MOC: Cast Iron
TSP/049/006 Boiler Transfer Pumps Make: Roto Pumps
Model: REB01A1007EKPJ
Pump Serial No: ND-2500
MOC: C.S (ASTM A216 Gr. WCB)
Flow rate (m3/hr): 3.6
Make: Crompton Greaves
Rated Output (kW): 2.2
MOC: Cast Iron

TSP/049/007 Boiler Transfer Pumps Make: Roto Pumps


Model: REB01A1007EKPJ
Pump Serial No: ND-2494
MOC: C.S (ASTM A216 Gr. WCB)
Flow rate (m3/hr): 3.6
Make: Crompton Greaves
Rated Output (kW): 2.2
MOC: Cast Iron

Page 17 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


TSP/049/008 Overflow Pumps Make: Roto Pumps
Model: REB01A1007EKPJ
Pump Serial No: ND-2493
MOC: C.S (ASTM A216 Gr. WCB)
Flow rate (m3/hr): 3.6
Make: Crompton Greaves
Rated Output (kW): 2.2
MOC: Cast Iron
TSP/049/009 Overflow Pumps Make: Roto Pumps
Model: REB01A1007EKPJ
Pump Serial No: ND-2493
MOC: C.S (ASTM A216 Gr. WCB)
Flow rate (m3/hr): 3.6
Make: Crompton Greaves
Rated Output (kW): 2.2
MOC: Cast Iron
VNR/049/001 Non-Return Valve (Unloading Pump, Make: L&T Valves
TSP/049/001) Type: Lift
End Connection: Screwed End
MOC: ASTM A216 GrWCB
Bore Diameter: 50NB
VNR/049/002 Non-Return Valve (Unloading Pump, Make: L&T Valves
TSP/049/002) Type: Lift
End Connection: Screwed End
MOC: ASTM A216 GrWCB
Bore Diameter: 50NB

Page 18 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VNR/049/003 Non-Return Valve (DG Transfer Pump, Make: Audco
TSP/049/003) Type: Lift
End Connection: Screwed End
MOC: ASTM A216 GrWCB
Bore Diameter: 40NB
VNR/049/004 Non-Return Valve (DG Transfer Pump, Make: L&T Valves
TSP/049/004) Type: Lift
End Connection: Screwed End
MOC: ASTM A216 GrWCB
Bore Diameter: 40NB
VNR/049/005 Non-Return Valve (DG Transfer Pump, Make: AUDCO
TSP/049/005) Type: Lift
End Connection: Screwed End
MOC: ASTM A216 GrWCB
Bore Diameter: 40NB
VNR/049/006 Non-Return Valve (Boiler Transfer Pump, Make: L&T Valves
TSP/049/006) Type: Lift
End Connection: Screwed End
MOC: ASTM A216 GrWCB
Bore Diameter: 40NB
VNR/049/007 Non-Return Valve (Boiler Transfer Pump, Make AUDCO
TSP/049/007) Type: Lift
End Connection: Screwed End
MOC: ASTM A216 GrWCB
Bore Diameter: 40NB

Page 19 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/001 Ball Valve before Unloading Pump, Make: AUDCO
TSP/049/001 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 80NB
VB/049/002 Ball Valve after Unloading Pump, Make: AUDCO
TSP/049/002 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 50NB
VB/049/003 Ball Valve before Unloading Pump, Make: AUDCO
TSP/049/003 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 80NB
VB/049/004 Ball Valve after Unloading Pump, Make: AUDCO
TSP/049/004 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem
Bore Diameter: 50NB

Page 20 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/005 Ball Valve (SUMP) Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 50NB
VB/049/006 Ball Valve after both HSD Storage Tanks Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 80NB
VB/049/007 Ball Valve after VB/049/006 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/008 Ball Valve before DG Transfer Pump, Make: AUDCO
TSP/049/003 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB

Page 21 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/009 Ball Valve after DG Transfer Pump, Make: AUDCO
TSP/049/003 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/010 Ball Valve before DG Transfer Pump, Make: AUDCO
TSP/049/004 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/011 Ball Valve after DG Transfer Pump, Make: AUDCO
TSP/049/004 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/012 Ball Valve before DG Transfer Pump, Make: AUDCO
TSP/049/005 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB

Page 22 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/013 Ball Valve after DG Transfer Pump, Make: AUDCO
TSP/049/005 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/014 Ball Valve between DG Transfer Pump, Make: AUDCO
TSP/049/003 & TSP/049/005 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 50NB
VB/049/015 Ball Valve between DG Transfer Pump, Make: AUDCO
TSP/049/005 & TSP/049/006 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 50NB
VB/049/016 Ball Valve before all DG Transfer Pumps Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB

Page 23 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/017 Ball Valve before Flow Transmitter 003 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/018 Ball Valve parallel to Flow Transmitter 003 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/019 Ball Valve after Flow Transmitter 003 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/020 Ball Valve before Flow Transmitter 002 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB

Page 24 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/021 Ball Valve parallel to Flow Transmitter 002 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/022 Ball Valve after Flow Transmitter 002 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/023 Ball Valve before Flow Transmitter 001 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/024 Ball Valve parallel to Flow Transmitter 001 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB

Page 25 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/025 Ball Valve after Flow Transmitter 001 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/026 Ball Valve before HSD Day Tank 1 (DG Yard) Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/027 Ball Valve before HSD Day Tank 2 (DG Yard) Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/028 Ball Valve before HSD Day Tank 3 (DG Yard) Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB

Page 26 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/029 Ball Valve before Boiler Transfer Pump, Make: AUDCO
TSP/049/006 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/030 Ball Valve before Boiler Transfer Pump, Make: AUDCO
TSP/049/007 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/031 Ball Valve after Boiler Transfer Pump, Make: AUDCO
TSP/049/006 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/032 Ball Valve after Boiler Transfer Pump, Make: AUDCO
TSP/049/007 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB

Page 27 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/033 Ball Valve between Boiler Transfer Pump, Make: AUDCO
TSP/049/006 & TSP/049/007 Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 50NB
VB/049/034 Ball Valve after VB/049/033 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/035 Ball Valve before Flow Transmitter 005 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/036 Ball Valve parallel to Flow Transmitter 005 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB

Page 28 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/037 Ball Valve after Flow Transmitter 005 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/038 Ball Valve before Flow Transmitter 004 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/039 Ball Valve parallel to Flow Transmitter 004 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB
VB/049/040 Ball Valve after Flow Transmitter 004 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 40NB

Page 29 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/041 Ball Valve before VB/049/050 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 25NB
VB/049/042 Ball Valve for Pressure Gauge 001 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 15NB
VB/049/043 Ball Valve for Pressure Gauge 002 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 15NB
VB/049/044 Ball Valve for Pressure Gauge 003 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 15NB

Page 30 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/045 Ball Valve for Pressure Gauge 004 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 15NB
VB/049/046 Ball Valve for Pressure Gauge 005 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 15NB
VB/049/047 Ball Valve for Pressure Gauge 006 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 15NB
VB/049/048 Ball Valve for Pressure Gauge 007 Make: AUDCO
Model: 3PC
Class: 150
End Connection: Flanged End
MOC: AISI 316 (Stem)
Bore Diameter: 15NB

Page 31 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


FT/049/001 Flow Transmitter from HSD Main Tank to DG Make: Emerson
Model: 1700
Maximum Operating pressure: 4 Bar
Temperature Range: -40degC to +140degC
FT/049/002 Flow Transmitter from HSD Main Tank to DG Make: Emerson
Model: 1700
Maximum Operating pressure: 4 Bar
Temperature Range: -40degC to +140degC
FT/049/003 Flow Transmitter from HSD Main Tank to DG Make: Emerson
Model: 1700
Maximum Operating pressure: 4 Bar
Temperature Range: -40degC to +140degC
FT/049/004 Flow Transmitter from HSD Main Tank to Make: Emerson
Boiler Model: 1700
Maximum Operating pressure: 4 Bar
Temperature Range: -40degC to +140degC
FT/049/005 Flow Transmitter from HSD Main Tank to Make: Emerson
Boiler Model: 1700
Maximum Operating pressure: 4 Bar
Temperature Range: -40degC to +140degC
FS/049/001 Flow Switch (before DG Transfer Pump, Make: Switzer
TSP/049/001) Model: GK-BM
Range: 10 to 33LPM – 25NB
65 to 200LPM – 80NB

Page 32 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


FS/049/002 Flow Switch (before DG Transfer Pump, Make: Switzer
TSP/049/002) Model: GK-BM
Range: 10 to 33LPM – 25NB
65 to 200LPM – 80NB
FS/049/003 Flow Switch (after HSD Storage Tank) Make: Switzer
Model: GK-BM
Range: 10 to 33LPM – 25NB
65 to 200LPM – 80NB
FS/049/004 Flow Switch (after DG HSD Day Tank) Make: Switzer
Model: GK-BM
Range: 10 to 33LPM – 25NB
65 to 200LPM – 80NB
FS/049/005 Flow Switch (after Boiler HSD Day Tank 1) Make: Switzer
Model: GK-BM
Range: 10 to 33LPM – 25NB
65 to 200LPM – 80NB
FS/049/006 Flow Switch (after Boiler HSD Day Tank 2) Make: Switzer
Model: GK-BM
Range: 10 to 33LPM – 25NB
65 to 200LPM – 80NB
PDS/049/002 Pressure Switch (after all DG Transfer Make: Switzer
Pumps) Model: Series 200
MOC: Pressure die cast Aluminium
PDS/049/003 Pressure Switch (after all Boiler Transfer Make: Switzer
Pumps) Model: Series 200
MOC: Pressure die cast Aluminium

Page 33 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VES/049/001 Electrical Operated Shut Off Valve (DG1) Make: Micro Pneumatics
Mode: Ball Valve with Electric Actuator: SY1
MOC: ASTM A216 GrWCB
End Connection: Flanged End
Bore Diameter: 25NB
VES/049/002 Electrical Operated Shut Off Valve (DG2) Make: Micro Pneumatics
Mode: Ball Valve with Electric Actuator: SY1
MOC: ASTM A216 GrWCB
End Connection: Flanged End
Bore Diameter: 25NB
VES/049/003 Electrical Operated Shut Off Valve (DG3) Make: Micro Pneumatics
Mode: Ball Valve with Electric Actuator: SY1
MOC: ASTM A216 GrWCB
End Connection: Flanged End
Bore Diameter: 25NB
VES/049/004 Electrical Operated Shut Off Valve (HSD Day Make: Micro Pneumatics
Tank) Mode: Ball Valve with Electric Actuator: SY1
MOC: ASTM A216 GrWCB
End Connection: Flanged End
Bore Diameter: 25NB
VES/049/005 Electrical Operated Shut Off Valve (HSD Day Make: Micro Pneumatics
Tank) Mode: Ball Valve with Electric Actuator: SY1
MOC: ASTM A216 GrWCB
End Connection: Flanged End
Bore Diameter: 25NB

Page 34 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/049 Hand Ball Valve with Limit Switch (Before Make (Valve): Audco
Unloading Pumps) Model (Valve): 819 Series
MOC (Valve): Carbon Steel Body
Make (Limit Switch): Schmersal
Model: EX-T4V10H335-02Y
MOC (Housings): Zinc die-cast
Bore Diamere: 100NB
VB/049/050 Hand Ball Valve with Limit Switch (After Make (Valve): Audco
Unloading Pumps) Model: 819 Series
MOC: Carbon Steel Body
Make (Limit Switch): Schmersal
Model: EX-T4V10H335-02Y
MOC (Housings): Zinc die-cast
Bore Diameter: 50NB
VB/049/051 Hand Ball Valve with Limit Switch (After Make (Valve): AUDCO
Unloading Pumps) Model: 819 Series
MOC: Carbon Steel Body
Make (Limit Switch): Schmersal
Model: EX-T4V10H335-02Y
MOC (Housings): Zinc die-cast
Bore Diameter: 50NB

Page 35 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


VB/049/052 Hand Ball Valve with Limit Switch (HST-001) Make (Valve): AUDCO
Model: 819 Series
MOC: Carbon Steel Body
Make (Limit Switch): Schmersal
Model: EX-T4V10H335-02Y
MOC (Housings): Zinc die-cast
Bore Diameter: 80NB
VB/049/053 Hand Ball Valve with Limit Switch (HST-002) Make (Valve): AUDCO
Model (Valve): 819 Series
MOC (Valve): Carbon Steel Body
Make (Limit Switch): Schmersal
Model: EX-T4V10H335-02Y
MOC (Housings): Zinc die-cast
Bore Diameter: 80NB
LT/049/001 Level Transmitter HSD Storage Tank 1 Make: Vega
Model: PS64.ACTTCAHXANAXX
MOC: SS 316L
LT/049/002 Emergency Level Transmitter HSD Storage Make: Nivelco Instruments India Pvt.Ltd
Tank 1 Model: MBK5506M
MOC: Aluminium Paint Coated
LT/049/003 Level Transmitter HSD Storage Tank 2 Make: Vega
Model: PS64.ACTTCAHXANAXX
MOC: SS 316L
LT/049/004 Emergency Level Transmitter HSD Storage Make: Nivelco Instruments India Pvt.Ltd
Tank 2 Model: MBK5506M
MOC: Aluminium Paint Coated

Page 36 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


LS/049/001 Level Switch DG Day Tank 1 Make: Shridhan Automation
Model: VFS/EJ(SS)2S44
Levels: 4 (HH, H, L, LL)
Type: Magnetic Float Type
MOC: SS304
LS/049/002 Level Switch DG Day Tank 2 Make: Shridhan Automation
Model: VFS/EJ(SS)2S44
Levels: 4 (HH, H, L, LL)
Type: Magnetic Float Type
MOC: SS304
LS/049/003 Level Switch DG Day Tank 3 Make: Shridhan Automation
Model: VFS/EJ(SS)2S44
Levels: 4 (HH, H, L, LL)
Type: Magnetic Float Type
MOC: SS304
LS/049/004 Level Switch Boiler Tank 1 Make: Shridhan Automation
Model: VFS/EE(SS)2S44
Levels: 4 (HH, H, L, LL)
Type: Magnetic Float Type
MOC: SS304
LS/049/005 Level Switch Boiler Tank 2 Make: Shridhan Automation
Model: VFS/EE(SS)2S44
Levels: 4 (HH, H, L, LL)
Type: Magnetic Float Type
MOC: SS304

Page 37 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


PG/HSD/001 Pressure Gauge (Unloading Pump, Make: Baumer
TSP/049/001) Model: Bourdon Type
Wetted Parts: Stainless Steel (MIM)
Operating range: 0 – 10 Bar
PG/049/002 Pressure Gauge (Unloading Pump, Make: Baumer
TSP/049/002) Model: Bourdon Type
Wetted Parts: Stainless Steel (MIM)
Operating range: 0 – 10 Bar
PG/049/003 Pressure Gauge (DG Transfer Pump, Make: Baumer
TSP049/003) Model: Bourdon Type
Wetted Parts: Stainless Steel (MIM)
Operating range: 0 – 10 Bar
PG/049/004 Pressure Gauge (DG Transfer Pump, Make: Baumer
TSP049/004) Model: Bourdon Type
Wetted Parts: Stainless Steel (MIM)
Operating range: 0 – 10 Bar
PG/049/005 Pressure Gauge (DG Transfer Pump, Make: Baumer
TSP049/005) Model: Bourdon Type
Wetted Parts: Stainless Steel (MIM)
Operating range: 0 – 10 Bar
PG/049/006 Pressure Gauge (Boiler Transfer Pump, Make: Baumer
TSP049/006) Model: Bourdon Type
Wetted Parts: Stainless Steel (MIM)
Operating range: 0 – 10 Bar

Page 38 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Installation Verification (Device) - General Reference: 0011_07


PG/049/007 Pressure Gauge (Boiler Transfer Pump, Make: Baumer
TSP049/007) Model: Bourdon Type
Wetted Parts: Stainless Steel (MIM)
Operating range: 0 – 10 Bar
Tank Accessories (Details are attached in List of Attachments – Mechanical Data Sheet for 100KL Storage Tank)
VB/049/054 Breather Valve (Vacuum Relief Valve with Make: Pressure and Flow Control Industries
Inbuilt Flame Arrestor – HST 001) Model: 2053-CV-PVR
MOC: Cast Steel
VB/049/055 Breather Valve (Vacuum Relief Valve with Make: Pressure and Flow Control Industries
Inbuilt Flame Arrestor – HST 002) Model: 2053-CV-PVR
MOC: Cast Steel
Comments/Deviations/Supporting Documentation:

Overall Test Outcome (PASS/FAIL) Tested By (Signature): Date (dd/mmm/yy):

Page 39 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Documentation - Calibration Verification Record (General) Reference: 0022_08


Objective:
1 To provide documented evidence that instruments within the system have been calibrated to the required tolerance across the required
range.
Pre-requisites: None
Method:
1 Review the calibration certification available for each of the instruments; to verify the calibrated tolerance and range against the tolerance
and range required for the routine process or operation (e.g. cleaning, sterilisation etc). Record the calibration certificate reference, and next
calibration due date or calibration schedule reference.
Acceptance Criteria:
1 Instruments have been calibrated and their tolerance and calibrated range meet the process or operation requirements.
Results:
Inst Ref Instrument Description Process / Operation Requirement Calibration Calibration Due
Certificate Date or
Reference Calibration
Toleranc Range
Schedule Ref.
e
LT/049/001 Level Transmitter HSD Storage Tank 1 + 2mm 0 - 30m
LT/049/002 Emergency Level Transmitter HSD Storage Tank 1 + 2mm 0 - 15m
LT/049/003 Level Transmitter HSD Storage Tank 2 + 2mm 0 - 30m
LT/049/004 Emergency Level Transmitter HSD Storage Tank 2 + 2mm 0 - 15m
LS/049/001 Level Switch DG Day Tank 1 + 2mm 0 - 3m (HH, H, L, LL)
LS/049/002 Level Switch DG Day Tank 2 + 2mm 0 - 3m (HH, H, L, LL)
LS/049/003 Level Switch DG Day Tank 3 + 2mm 0 - 3m (HH, H, L, LL)
LS/049/004 Level Switch Boiler Day Tank 1 + 2mm 0 - 3m (HH, H, L, LL)
LS/049/005 Level Switch Boiler Day Tank 2 + 2mm 0 - 3m (HH, H, L, LL)

Page 40 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Documentation - Calibration Verification Record (General) Reference: 0022_08


PG/049/001 Pressure Gauge (Unloading Pump, TSP/049/001) + 1% 0 – 16 Bar
PG/049/002 Pressure Gauge (Unloading Pump, TSP/049/002) + 1% 0 – 16 Bar
PG/049/003 Pressure Gauge (DG Transfer Pump, TSP/049/003) + 1% 0 – 16 Bar
PG/049/004 Pressure Gauge (DG Transfer Pump, TSP/049/004) + 1% 0 – 16 Bar
PG/049/005 Pressure Gauge (DG Transfer Pump, TSP/049/005) + 1% 0 – 16 Bar
PG/049/006 Pressure Gauge (Boiler Transfer Pump, TSP/049/006) + 1% 0 – 16 Bar
PG/049/007 Pressure Gauge (Boiler Transfer Pump, TSP/049/007) + 1% 0 – 16 Bar
FT/049/001 Flow Transmitter from HSD Main Tank to DG + 0.5% 0 – 3.6m3/hr
FT/049/002 Flow Transmitter from HSD Main Tank to DG + 0.5% 0 – 3.6m3/hr
FT/049/003 Flow Transmitter from HSD Main Tank to DG + 0.5% 0 – 3.6m3/hr
FT/049/004 Flow Transmitter from HSD Main Tank to Boiler + 0.5% 0 – 3.6m3/hr
FT/049/005 Flow Transmitter from HSD Main Tank to Boiler + 0.5% 0 – 3.6m3/hr
PDS/049/002 Pressure Switch (after DG Transfer Pumps) + 2% 1.6 – 16 Bar
PDS/049/003 Pressure Switch (after Boiler Transfer Pumps) + 2% 1.6 – 16 Bar
Comments/Deviations/Supporting Documentation:

Overall Test Outcome (PASS/FAIL) Tested By (Signature): Verified By Date (dd/mm/yyyy):


(Signature):

Page 41 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: HSD Piping Flow Rate Test Reference: NA

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:

Test Equipment Reference:


Overall Test Outcome (PASS/FAIL): Tested By (Signature): Date (dd/mmm/yy):

Page 42 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Alarm and Interlock Verification – Fire Alarm Reference: NA


Objective:
1 To provide documented evidence that the pumps operate as per design specification.
Pre-requisites: None
Method:
1 Fire Alarm is triggered to verify the operation of the pumps.
Acceptance Criteria:
1 Pumps should be completely shut off when fire alarm is triggered and they will restart operation once the alarm is reset.
Results:
A/C Met? Initial/ Date
Pumps Action on Alarm Action after Alarm is Reset Remarks (YES/NO)

TSP/049/001 Completely Shut Off Normal Operation


TSP/049/002 Completely Shut Off Normal Operation
TSP/049/003 Completely Shut Off Normal Operation
TSP/049/004 Completely Shut Off Normal Operation
TSP/049/005 Completely Shut Off Normal Operation
TSP/049/006 Completely Shut Off Normal Operation
TSP/049/007 Completely Shut Off Normal Operation
TSP/049/008 Completely Shut Off Normal Operation
TSP/049/009 Completely Shut Off Normal Operation
Comments/Deviations/Supporting Documentation:

Page 43 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Alarm and Interlock Verification – Fire Alarm Reference: NA


Test Equipment Reference:
Overall Test Outcome (PASS/FAIL): Tested By (Signature): Date (dd/mmm/yy):

Page 44 of 57
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

Dry run/Low Flow Alarm Flow Switch FS/049/003


DG Transfer Pumps TSP/049/003, 004, 005
Overflow Alarm Flow Switch FS/049/004

Low/High Pressure Alarm Pressure Switch PDS/049/002

Boiler Transfer Pumps TSP/049/006, 007 Dry run/Low Flow Alarm Flow Switch FS/049/003

Page 45 of 57
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

Low/High Pressure Alarm Pressure Switch PDS/049/003


Interlock for Unloading Pumps (P3A/P3B)

Sensor Ref Status Acceptance Criteria Acceptance Initial/ Date


Criteria Met?
(YES/NO)
VB/049/049 Open / Close No unloading pumps can be started if VB/049/049 is in closed condition.

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

Page 46 of 57
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.

Interlock for Boiler Transfer Pumps (P2A/P2B)


Sensor Ref Status Acceptance Criteria Acceptance Initial/ Date
Criteria Met?
(YES/NO)
VB/049/049 Open / Close No transfer pumps can be started if HV/049/001 is in closed condition.
Open > LT/049/001 should not be in Low/L
VB//049/052
Open / Close Open > LT/049/003 should not be in Low/L
VB/049/053
Both open > LT/049/003 should not be in L
TSP/049/006, 007 can start after a delay of Y1, if VS/049/004, 005 ‘Open
Low/L condition
Signal’ is received.
LS/049/004
LS/049/005 High/H TSP/049/006, 007 will stop after VS/049/004, 005 received ‘Close signal’
condition after a time delay of X1.

Interlock for On & Off Valve Operation (Auto Mode)


Sensor Ref Status Acceptance Criteria Acceptance Initial/ Date
Criteria Met?
(YES/NO)
LS/049/001 Low/L signal VES/049/001 open
LS/049/002 Low/L signal VES/049/002 open
LS/049/003 Low/L signal VES/049/003 open
LS/049/004 Low/L signal VES/049/004 open
LS/049/005 Low/L signal VES/049/005 open
LS/049/001 High/H signal VES/049/001 close feedback is received with a delay of X from Pump stops
LS/049/002 High/H signal VES/049/002 close feedback is received with a delay of X from Pump stops

Page 47 of 57
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:

Test Equipment Reference:


Overall Test Outcome (PASS/FAIL): Tested By (Signature): Date (dd/mmm/yy):

Page 48 of 57
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:

Physical Guarding Testing


Criteria Criteria Met? Comments
(Yes/No or
N/A)
Guards prevent personal access to all dangerous parts.

Page 49 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

All guards are secured in place via interlock or require a tool


to remove them.
Equipment motion stops on opening of each interlocked
guard.
Equipment does not start when each interlocked guard is
closed after intervention.
Equipment starts when reset & restarted from the control
panel.
Unguarded/uncovered hazards are out of reach at a height of
at least 2.7m.
Safety fences or barriers fixed around equipment are at least
1.6m high.
Gaps under safety fences or barriers are less than 180mm, to
prevent person access
Gaps adjacent to moving parts (nip points) should be less
than 2mm, or guarding should be in place to prevent access.
If apertures in guarding are capable of:
a) Finger-tip entry (gap up to 6mm) then the hazards must be
greater than 10mm away
b) Finger access (gaps between 6mm and 12mm) then the
hazards must be greater than 100mm away.
c) Hand access (gaps between 12mm and 20mm*) then
hazards must be greater than 120mm away.
d) Arm entry (gaps between 20mm* and 120mm) then the
hazards must be greater than 850mm away.
*Note: For round or square openings, the 20mm limit on
opening size to prevent arm entry can be safely increased to
30mm.

Page 50 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Where parts come together there is a risk of crushing. The


gap should be:
a) Greater than 25mm where there is finger access to prevent
finger crushing
b) Greater than 100mm where there is hand access to prevent
hand crushing
c) Greater than 180mm where there is arm/leg access to
prevent arm/leg crushing
d) Greater than 500mm where there is body access to prevent
body crushing
Scissor type shear hazards should be prevented by ensuring
that gap between the moving parts is less than 4mm or
greater than 120mm or guarding must be in place to prevent
access.
Lock-Out/Tag-Out (LOTO) Testing

List all equipment energy sources.

Criteria Criteria Met? Comments


(Yes/No or
N/A)
Are all appropriate warning signs in a visible position where
energy or stored energy is present (e.g. electrical, thermal,
crushing, etc)?
Are all isolation points for hazardous energy are clearly
identified and labelled?
Can all isolation points be locked in their isolated position?

Are all isolation points clearly identified for their state of


isolation (e.g. ON/OFF, OPEN/CLOSED, etc)?
Are all isolation points easily accessible?

Page 51 of 57
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):

Page 52 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Support - Test Equipment Record Reference: 0006_05


Objective:
1 To provide documented evidence that that test instrumentation was in calibration at the time testing took place.
Pre-requisites: None
Method:
1 Record the reference, description, serial no, calibration due date, calibration frequency, calibration certificate no. and calibration certificate
location for each instrument used during completion of the protocol.
Acceptance Criteria:
1 Test instrumentation was in calibration at the time of testing.
Results:
Test Inst Ref Test Instrument Description Instrument Calibration Calibration Calibration Calibration Initial/Date
Serial No Due Date Frequency Cert No Cert Location

Comments/Deviations/Supporting Documentation:

Overall Test Outcome (PASS/FAIL): Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):

Page 53 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Support - Signature Record Reference: 0009_03


Objective:
1 To identify personnel involved in the completion of the protocol and provide documented evidence that appropriate training records are
available.
Pre-requisites: None
Method:
1 Each person involved in the completion of the protocol must enter their name, the name of the company they represent, sign and initial
the table below.
Acceptance Criteria:
1 All personnel involved in the completion of this protocol are identified and have received appropriate training.
Results:
Name Company Signature Initial Training Record Ref

Page 54 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Support - Signature Record Reference: 0009_03


Comments/Deviations/Supporting Documentation:

Overall Test Outcome (PASS/FAIL) Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):

Page 55 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

Title: Support - Training Verification Reference: 0007_02


Objective:
1 To provide documented evidence that suitable training has been carried out to enable the correct operation and maintenance of the
equipment within the system.
Pre-requisites: None
Method:
1 Record the name of the trainees, a description of the training provided, the date training was completed and reference to the training
certification.
Acceptance Criteria:
1 Required training has been completed and training records are available.
Results:
Name of Trainee Description of Training Provided Date of Training Training Cert Ref
(dd-mmm-yy)

Comments/Deviations/Supporting Documentation:

Overall Test Outcome (PASS/FAIL): Tested By (Signature): Verified By (Signature): Date (dd/mm/yyyy):

Page 56 of 57
Shimizu Corporation India Pvt Ltd
Shimizu Detailed Design
CP-HSD-049-001, Version D
Date – 29/12/2017

12 List of Attachments

12. LIST OF ATTACHMENTS


No. Attachment Title Number of Pages
1 Pre-Commissioning Checklist 1
2 Performance Test Certificates for Pumps 8
3 General Assembly and Cross-sectional
12
Drawing of Pumps
4 Mechanical data Sheet for 100KL High Speed 2
Diesel Storage Tank
5 DG Yard Underground Piping Hydro Test 2
Report
6 HSD Final Tank Inspection Report 1
7 HSD Yard Underground Piping Hydro Test 2
Report
8 P&ID for HSD Storage Tank and Transfer 1
System R2

13 Exclusions:

Page 57 of 57

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