Addendum 003 - Equipment - Commissioning Plan R0.pdf

COVER PAGE OF SELLER’S SUBMITTAL

City Name: Hanford, WA - MSA

Pall Project No.: 01.000287

Job Number: Project L-897, Subcontract 70816

Task Register 6 (Task 1 – VI Submittal Package)

To: (Contractor)

Mission Support Alliance, LLC (MSA)

PO Box 650

Richland, WA 99352

From: (Subcontractor)

Pall Water

A Division of Pall Corporation

839 State Route 13

Cortland, NY 13045

Patty Willis

Phone: 607-758-1699

Name of Project: Hanford, WA, Central Plateau WTF

Pall Document Number: NYCS000015435 Rev: 00

Description of Item: Commissioning Plan

Specification Section: N/A

Deviations: N/A

INDEX:

Page 1: Cover Page Information

Page 2-116: Tab 1 – NYCS000015435,Large Water Startup & Commissioning Plan,01.287

Date: 12/19/2019

Pall Advanced Separations Systems Division of Pall Corporation 839 NYS Route 13 PO Box 5630 Cortland NY 13045 USA Tel: 607-753-6041 Fax: 607-758-1762 Email: Pall_Technology_CSC@pall.com

MICRO FILTRATION WATER SYSTEM

Project: 01.000287

Hanford WA., Central Plateau WTP

I) GC Installation Checklist

II) Pall Technical Services Commissioning Plan

Hanford WA., Central Plateau WTP.

PALL Project Number: 01.000287 NYCS000015435.00 Page 2 of 115

Pall Advanced Separations Systems

Table of Contents i.) Project Information A) Project Information………………………………………………………………………………… B) Drawings and Documents………………………………………………………… ii.) Introduction A) Purpose & PALL Contact Information

I.) GC Installation Checklist A) Overview of GC Installation Checklist…………………………………………………………………… B) Membrane Filter Rack…………………………………………………………………………………………..

C) Centrifugal Pump………………………………………………………………………………………………….

D) Compressed Air System…………………………………………………………………………… E) Blower System/Compressor………………………………………………………………………………….

II.) Technical Services Commissioning Checklists

0.0 – Commissioning Status…………….....…………………………………………………………………….

1.0 – Commissioning (P&ID Review and Process Verification)…

2.0 – Mechanical & Electrical Installation Review……………

2.1 – Valve Rack and Module Rack Installation………………………………………………………….

2.2 – Feed System‐Feed pumps & Motors Installation Review…

2.3 – Feed System‐Feed Strainers Installation Review…………

2.4 – Reverse Filtration Pumps Installation………………….................……………

2.5 – Compressed Air System Installation Review………….................………………………….

2.6 – CIP System Installation………………………………......……………………………………………….

2.7 – MCC/VFD Installation Review…………………….........…………………………………………….

2.8 – Control System Installation Review………………............………………………………………

2.9 – Preparation for Startup………………………….......…………………………………………………..

3.0 – Control System, HMI, PLC, & Network Configuration

3.1 – HMI Configuration Sign Off……………………………......……………………………………………

3.2 – PLC Configuration………………………………………..…………………………………………………..

3.3 – Main Control Panel Startup……………………………........…………………………………………

3.4 – Valve Rack Control Panel Startup……………….…..........………………………………………..

3.5 – VFD, Starter & MCC Configuration……………..........…………………………………………….

3.6 – Motor/Pump Alignment………………………….......………………………………………………….

3.7 – Compressed Air System Startup………………..........……………………………………………..

3.8 – Control System I/O Checks……………………………………........………………………………….

4.0 – System Testing‐Sequence & Functional Testing…………………

5.0 – System Flushing………………………………………………………….…………………………………….

6.0 – Module Installation………………………………………………….....…………………………………..

7.0 – Instrument Calibrations………………………………………………......………………………………

8.0 – System Functional Testing………………………………………………........………………………..

8.1 – Feed Pumps………………………………………………………………………………………………………

8.2 – Feed Strainers……………………………………………………………….………………………………….

8.3 – Clean‐in‐Place System……………………………………………………….....………………………….

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Pall Advanced Separations Systems Division of Pall Corporation

8.4 – Rack Fill Cycle……………………………………………………………

8.5 – Forward Filtration…………………………………………………...……………………………………….

8.6 – Flux Maintenance…………………………………………………...……………………………………….

8.7 – Enhanced Flux Maintenance (EFM)……………………………............………………………...

8.8 – Rack Clean‐in‐Place (CIP)………………………………………......…………………………………….

8.9 – System Operation………………………………………………..………………

9.0 – Customer Control/Communication System………………………………………………………

9.1 – Alarm Function Testing…………………………………......……………………………………………

10.0 – Calculations, Data Logging & Reporting…………….............………………………………….

11.0 – Disinfection……………………………...………………………………………………………………………

12.0 – Training…………………………………………………………………………………………………………….

12.1 – Introduction to Pall Corporation……………………………………………………………………….

12.2 – Water Filtration using Microza Modules……………………………………………………………

12.3 – System Equipment and Functional Control……………………………………………………….

12.4 – Operator Interface…………………………………………...………………………………………………

12.5 – System Setpoints & Alarms………………………….......……………………………………………..

12.6 – Clean‐in‐Place (CIP) & Enhanced Flux Maintenance (EFM)…

12.7 – Maintenance Issues………………………………………...……………………………………………….

12.8 – Microbial Induce Corrosion (MIC)……………………...........……………………………………..

12.9 – Maintenance Issues II……………………………………………………………………………………….

13.0 – Performance Testing………………………………...………………………………………………………

13.1 – Requirements from Specification………………………………………………………………………

14.0 – Project Closeout Setpoints………………………………………………........………………………..

14.1 – Control Mode……………………………………………………………………………………………………

14.2 – Feed System Setpoints……………………………………………......…………………………………..

14.3 – Rack System Setpoints…………………………………………….....……………………………………

14.4 – Filtrate System Setpoints……………………………………………….......…………………………..

14.5 – CIP System Setpoints…………………………………………………....………………………………….

14.6 – Utilities………………………………………………………………….………………………………………….

15.0 – System Performance…………………………………………………………………………………………

16.0 – Final Checklist……………………………………………………………………………………………………

III.) Appendix(s) A) Appendix A‐ Calculations…………………………………...………………....…………………………….

B) Appendix B‐ MF System Reference………………………....……….....……………………………… C) Appendix C‐ Systems Service Training Record……………...............…………………………… D) Appendix D‐ Particle Counter Configuration……………................…………………………….

E) Appendix E‐ Configuration……………………………….......……………………………………………..

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Pall Advanced Separations Systems

Project Information

Project Name:

Customer Name:

Pall Project Number:

Pall Project Manager:

Project Scope:

Site Address:

Piloting Information: Pilot Completed: yes no

System Specifications:

Design Flow Rate: Design Flux (GFD):

Number of Racks:

Number of Modules/Rack:

Initial/Maximum:

Air Scrub Interval: Design EFM Interval:

Design CIP Interval:

Customer Contact:

Contact Number:

Mobile Number:

Customer Representative(s):

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Pall Advanced Separations Systems

Project Drawings and Documents

Document Description Drawing # Rev.

P&ID Drawing

Control System Network Drawing

Main Control Panel Electrical Drawing

Filter Skid Control Panel Drawing

Plant Piping Layout

CIP Panel Electrical Drawing

Filter Skid Mechanical Drawing

CIP Layout/Installation Drawing

Tank Fabrication Drawings

Cable/Conduit Schedule

Electrical One-Line Drawing

System Functional Description (SFD)

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Pall Advanced Separations Systems Division of Pall Corporation

(i.) Introduction

Purpose of This Document

The purpose of the Installation Checklist and Commissioning Plan is to provide and guide the customer, engineer, and installation contractors with respect to:

Installation Checklist that will need to be completed before Pall Technical Services will start plant commissioning

How Pall plans to check out and start up the system

How Pall plans to perform initial operation of the system

Each topic above is addressed in a separate section in the document.

How to Contact Pall

The key Pall contacts during installation and start-up of [ENTER PROJECT NAME] are:

Pall Technical Service Engineer:

Pall Project Manager:

Pall Systems Engineer:

Software Engineer:

Controls Engineer:

The Project Manager will handle all contract issues. The Pall Technical Service Manager handles all scheduling requirements, the Pall Technical Service Engineer coordinates day to day commissioning activities and requests for information as necessary. All questions or concerns regarding the Installation Contractor’s scope for the [ENTER PROJECT NAME] project must be directed to the [ENTER ENGINEER COMPANY NAME] awarded for this project.

The GC must complete the Equipment Installation Checklists prior to the Pall Technical Service Engineer’s arrival.

This Document contains installation checklists for individual pieces of equipment that must be completed by the project MF equipment contractor. If an individual piece of equipment will not be checked out prior to initiation of start-up activities by Pall field service engineers (these items must be identified to the Pall Project Manager and Pall Start-up Engineer prior to Pall arrival), but all pieces have to be successfully checked and signed off before wet process testing can begin. Note that we anticipate that the commissioning activities listed below will last duration of [XX ] weeks, excluding required testing and training.

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Pall Advanced Separations Systems Division of Pall Corporation

Introduction Continued

Pall Initial Commissioning Activities: Dry Testing

Below is the schedule of initial dry testing activities by Pall Technical Service Engineers and Support:

Step 1: Initial Activities Following Completion of Equipment Installation:

P&ID walk through, addressing any discovered issues with project engineer and installation contractors

Validate GC Installation checklist: power available, water and drain management plan in place, equipment installed, control panels installed

Confirm that compressed air system and compressed air piping “air flush” have been performed.

Pump verification for all centrifugal pumps in the plant: properly installed and wired per manufacturer’s recommendations, balancing, grouting, and rotation check.

PLC / HMI Network functionality checkout

Compressor start-up completed (coordinated by Pall).

I/O Checks begin. Actuate main process valve dry testing, including check and adjust limit switches / actuator speed as necessary.

Step 2: Continue Mechanical and Electrical Adjustments

Complete I/O Checks. Actuate main process valve dry testing, including check and adjust limit switches / actuator speed as necessary.

Instrument checks begin (loop checks, configuration and initial calibration).

Verify VFD and MCC configuration for Feed and RF pumps (If VFD and MCC provided by PALL)

Feed, RF Pump start-up (pump alignment, rotation and flow rate check) completed (coordinated by Pall).

Alarm testing of Main system

Pall Initial System Operation: Wet Testing

Below is the schedule of initial wet testing activities by Pall Technical Service Engineers and Support.

Wet testing begins with the flushing modules in place. The Pall Technical Service Engineer will assess the site readiness and give the go-ahead for membrane installation. A Pall representative will train the Installation Contractor’s staff in proper membrane installation procedure. The Installation Contractor’s staff will carry out the actual membrane installation work. Suitable time should be given to permit the membranes to be installed and flushed to remove their shipping preservative. All onsite handling, pumping and disposal of the Calcium Chloride preservative and flush water is the responsibility of the Installation Contractor. Further discussion of system draining is provided in Appendix B.

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Pall Advanced Separations Systems Division of Pall Corporation

Step 3: System Wet Testing Without Membrane Modules and CIP System Initiation

Flushing of interconnecting piping and filter racks.

Wet system pressure test with flushing modules installed.

Actuate CIP valves dry testing, including check and adjustment of limit switches as necessary

Alarm testing of CIP system

Step 4: Installation Membrane Modules and CIP System Adjustment

Membrane Module Installation. Oversee installation of membrane filter modules, and perform pressure testing on racks. Please refer to separate document Pall Microza Valve and Module Rack Installation Guidelines.

Flush out modules to remove remaining membrane preservative.

Adjust tank levels and filling times.

Adjust as necessary: filter rack valves , drain RF flows, air scrib, air flow, integrity test pressure, etc.

Manual run-through of process operations sequence.

Initial tuning of PID loop controls in main system

Wet process test of entire CIP system.

Initial tuning of PID loop controls in CIP system.

Step 5: System Testing and Adjustment with Modules in Service

Verify that required chemicals for CIP system operation are present.

Verify that feed water quality is as specified.

Prepare all chemicals to be used during system operation.

Check all manual valve positions in preparation for process operation.

Enter the start-up operating and alarm set points.

Start up system in automatic mode.

Monitor system operation and adjust set points to optimize operation.

Continue tuning PID loops.

Verify instrument accuracy.

Test effluent quality and verify it is within specifications.

Performance Test Period/Operator Training

Pall will perform in accordance with the contract and specifications of the Performance Test and Operator Training.

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I) GC Installation Checklist

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Pall Advanced Separations Systems Division of Pall Corporation

GC Installation Checklist

Please verify that the following tasks are complete before the date that the Pall Technical service Engineer is scheduled to arrive on-site and initiate the Pall Technical Service commissioning activities:

A) Overview of GC Installation Checklist

1. Process Piping: Interconnect piping between equipment is complete and of proper size, material, and routing as indicated in the Pall P&ID. Valves and instruments are correctly located. Before wet process testing can begin: all interconnecting piping must be tested for leaks in accordance with the installation contract requirements; all interconnecting piping must be flushed thoroughly to remove all debris; and all individual equipment checks must be performed successfully.

2. Valves and Instruments: All valves and instruments are properly installed per manufacturer’s instructions and accessible, either within operators reach from the ground or by means of a ladder or other safe access device made available for Pall Technical Services Engineer to use at the site.

Pneumatically actuated valves are properly connected for compressed air control. Instruments are wired and powered.

3. Filter Rack Hardware: The Pall filter racks are anchored and assembled, excluding the installation of membrane modules. Each filter rack is configured for commissioning: module ports are capped except for a limited number of “flushing modules.” Before wet testing can begin, all Pall filter racks must be tested for leaks in accordance with the installation contract requirements.

4. Electric Power: Power connections are completed and safe to energize all devices and equipment in the system including, but not limited to control panels, pump motors, air compressors, and instruments.

5. Compressed Air System: The compressors, air conditioning equipment, receiver tank, regulators system is completely installed including those items listed in the Compressed Air Equipment checklist. Compressed air piping and tubing is complete throughout the membrane system, including connections to Pall filter racks and air-driven pumps and valves. Control solenoids, both local to equipment and in solenoid banks, are properly plumbed for air and wired for power and control signal.

Manual valves for air flow control and for equipment isolation have been installed. Once machinery has been approved for operations by factory authorized support (see Compressed Air Equipment checklist) all compressed air piping must be purged of all debris that could potentially damage MF Modules, air control solenoids, or air-powered equipment.

6. Testing Water Supply and Drain: Arrangements for the proper handling of debris flushing waters, hydraulic testing and module rinsing water must be planned in advance, specific to the requirements and limitations of the project site. It is advantageous to provide a means for clean water to recycle through the feed and filtrate connections of the filter racks. Before wet testing can begin, upstream feed pumps to Pall filter racks must be tested and operational.

7. Control Signal Wiring Complete: All instruments and network connections are terminated and the HMI computer is functional in a safe, reasonable location. All control panels are installed and properly wired, grounded, labeled, and sealed.

GC Installation Checklist

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B) Membrane Filter Rack Installation Checklist

B1 All Valve and Filter Module frames installed anchored.

B2 All equipment firmly attached to frames.

B3 All piping connections internal/external to and in the rack tight and leak-free.

B4 Module ports capped and clamped except for dummy (empty) modules installed at end farthest from valve rack.

B5 Power and signal wiring landed and complete to valve rack control panel.

B6 Air connections complete from valve rack solenoid manifold to off-rack block and bleed valves.

B7 Proximity switch cable connections complete from valve rack control panel to off-rack block and bleed valves.

B8 Drains provided for on-rack instruments, on-rack vent valves, and off-rack bleed valves:

drains free-flowing and sized in accordance with P&IDs

B9 Analytical instruments (turbidimeter, particle counter as applicable) and intraconnect piping flow meter installed, wired, and plumbed as required.

B10 Air supply connected compressed air available from properly purged air supply piping.

*Check each item that applies as described above.

DEVICE

Tag

Number B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 Initial

Rack 1 XX

Rack 2 XX

Rack 3 XX

Rack 4 XX

Rack 5 XX

Rack 6 XX

Rack 7 XX

Rack 8 XX

Rack 9 XX

Rack 10 XX

Rack 11 XX

Rack 12 XX

Checklist Complete: Date:

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Pall Advanced Separations Systems

C) Centrifugal Pump Installation Checklist

C1 Pump has been leveled, installed, and anchored per manufacturer’s instructions.

C2 All fasteners on pump assembly are properly tightened.

C3 Piping connected to pump does not transmit undue load or force on the pump nozzles.

C4 Pump and motor are lubricated per manufacturer’s instructions.

C5 If pump requires seal water (often, pumps selected to support Pall processes do not), seal water supply and seal water drain are functional and packing/seal is properly adjusted.

C6 Pump is properly wired to starter or VFD as required project drawings.

C7 Pump shaft turns freely, rotates in the proper direction when powered very briefly (bumped).

C8 Pump drain and vent valves are installed if called for in the P&IDs.

C9 Expansion joints are installed if called for in the P&IDs.

*Check each item that applies as described above.

DEVICE Tag Number C1 C2 C3 C4 C5 C6 C7 C8 C9 C10 Initial

Pump MFP

Pump MFP

Pump MFP

Pump MFP

Pump MFP

Pump MFP

Pump RFP

Pump RFP

Pump RFP

Pump CIPRP

Pump CIPRP

Pump CIPDP

Pump CIPDP

Pump NCP

Pump NCP

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D) Compressed Air System Installation Checklist

D1 Compressor equipment has been leveled, installed, and anchored per manufacturer’s instructions.

D2 All fasteners on compressed air equipment are properly tightened.

D3 Piping connected to equipment does not transmit undue load or force on the pump nozzles.

D4 Compressors and motors (for compressor and refrigerated dryers) are lubricated per manufacturer’s instructions.

D5 If the compressor requires cooling water, the water supply and cooling water drain are functional.

D6 Air-cooled equipment (some compressors, most refrigerated dryers) have ventilation and surrounding clearances provided as per manufacturer’s instructions.

D7 Cooling water control valves and other devices outside of the compressor enclosure are correctly plumbed, powered, and wired for control.

D8 Automated condensate drain valves are powered, properly adjusted, and discharge to a functioning drain.

D9 All required air filter elements installed

D10 Compressors are properly wired to starters as required per project drawings.

D11 Communication cabling between compressors is installed per manufacturer’s instructions.

D12 Before operation of compressed air equipment, local vendor manufacturer’s representative of compressed air equipment start-up has already been performed (Pall includes this service as part of compressed air system procurement - coordinate with Pall Project Manager to schedule).

*Check each item that applies as described above.

DEVICE

Tag

Number D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 Initial

AC XX

AC XX

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E) Blower System/Compressor Installation Checklist

E1 Blower equipment has been leveled, installed, and anchored per manufacturer’s instructions.

E2 All fasteners on blower equipment are properly tightened.

E3 Piping connected to equipment does not transmit undue load or force on the blower.

E4 Blowers and motors (for compressor and gear box) are lubricated per manufacturer’s instructions.

E5 The blowers after cooler are to be fastened properly and that the connection does not transmit undue loading to the blower.

E6 Air-cooled equipment (some blowers) has ventilation and surrounding clearances provided as per manufacturer’s instructions.

E7 All required air filter elements installed

E8 Blowers are properly wired to starters as required per project drawings.

E9 Communication cabling between blowers is installed per manufacturer’s instructions.

*Check each item that applies as described above.

DEVICE Tag Number E1 E2 E3 E4 E5 E6 E7 E8 E9 Initial

BLR XX

BLR XX

C XX

C XX

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PALL Technical Services Commissioning Checklist

To Be Completed by a PALL Technical Service Engineer

(TSE)

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Pall Advanced Separations Systems Division of Pall Corporation

Commissioning Status (This is a weekly status report. Sections do not have to be completed sequentially.)

*To be completed weekly by a PALL TSE.

Section Description Date Complete

1.0 P&ID Review and Process Verification

2.0 Mechanical and Electrical Installation Review

2.1 Valve Rack and Module Rack Installation

2.2 Feed System – Feed Pumps and Motors Installation Review

2.3 Feed System – Feed Strainers Installation Review

2.4 Reverse Filtration Pumps Installation

2.5 Compressed Air System Installation Review

2.5 Compressed Air System Installation Review

2.6 CIP System Installation

2.7 MCC/VFD Installation Review

2.8 Control System Installation Review

2.9 Preparation for Startup

3.0 Control System, HMI, PLC and Network Configuration

3.1 HMI Configuration and Software Setup

3.2 PLC Configuration

3.3 Main Control Panel Startup

3.4 Valve Rack Control Panel Startup

3.5 VFD, Starter and MCC Configuration

3.6 Motor/Pump Alignment

3.7 Compressed Air System Startup

3.8 Control System I/O Checks

4.0 System Testing – Sequence Testing and Functional Testing

5.0 System Flushing

6.0 Module Installation

7.0 Instrument Calibrations

8.0 System Functional Testing

8.1 Feed Pumps

8.2 Feed Strainers

8.3 Clean-In-Place System

8.4 Rack Fill Cycle

8.5 Forward Filtration

8.6 Flux Maintenance

8.7 Enhanced Flux Maintenance (EFM)

8.8 Rack Clean-In-Place (CIP)

8.9 System Operation

8.10 Control/Communication with Customer System

9.0 Alarm Function Testing

10.0 Calculations, Data Logging and Reporting

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Pall Advanced Separations Systems Division of Pall Corporation

Commissioning Status (This is a weekly status report. Sections do not have to be completed sequentially.)

*To be completed weekly by a PALL TSE

Section Description Date Complete

11.0 Disinfection

12.0 Training

12.1 Introduction to Pall Corporation

12.2 Water Filtration using Microza Modules

12.3 System Equipment and Function Control

12.4 Operator Interface

12.5 System Setpoints and Alarms

12.6 Clean-In-Place (CIP) and Enhanced Flux Maintenance (EFM)

12.7 Maintenance Issues

12.8 Microbial Induced Corrosion (MIC)

12.9 Pall Service Offerings

13.0 Performance Testing

14.0 Project Closeout Setpoints

14.1 Control Mode

14.2 Feed System Setpoints

14.3 Rack System Setpoints

14.4 Filtrate System Setpoints

14.5 CIP System Setpoints

14.6 Utilities

15.0 System Performance

16.0 Final Checklist

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Pall Advanced Separations Systems Division of Pall Corporation

1.0 P&ID Review & Process Verification

Objectives:

The P&ID walkthrough is intended to verify that instruments, equipment, and process piping are installed properly, and to verify that design documents (P&ID) are up-to-date and correct. Any discrepancies or problems should be noted and addressed with the appropriate team.

Note parts of the overall system that are not within Pall’s scope of supply. Often feed systems, pretreatment, and post treatment systems are not in Pall’s scope but must be coordinated to work properly with Pall supplied equipment.

Review piping and flushing plan to ensure that adequate flushing of piping is possible before installing membranes. Flushing can be done with potable water if available or raw water. It is critical to flush out any construction debris (i.e. weld rod, slag, PVC shavings, etc) that remains in the piping to avoid damage to membranes.

Note any discrepancies, changes, potential process issues and address with the appropriate team.

Procedure

Review System installation and process piping, instruments, and equipment for consistency with the Pall P&ID drawings

Section Description Complete N/A

1.0-01 Process piping matches Pall P&ID. Discrepancies noted and/or marked up on P&ID.

1.0-02 All instrumentation is installed and consistent with P&ID drawings.

1.0-03. Instrument sample tubing is installed with proper valves and flow control devices to supply proper flow rate to analytical instruments.

1.0-04 Valves are installed correctly and tagged with correct labels.

1.0-05 Instrument and valve labeling – Verify that instrument and valve tags are correct and that tag material is acceptable per contract.

1.0-06 Compressed air system – Compressed air instrumentation installed correctly. Rotameter installed vertical and non-ferrous conduit fittings used. Thermal dispersion probes installed in suitable location with probes extending into air piping. Dewpoint transmitter installed correctly.

1.0-07 Compressed air flow meter – If Thermal dispersion flow transmitter (i.e. Sierra Instruments) is used, ensure that manufacturer’s instructions are followed for locating the device. This will depend on piping materials, size, location of valves, elbows, etc. For example, Sierra instruments requires 40 pipe diameters upstream and 15 downstream and varies with upstream and downstream piping and equipment.

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1.0 P&ID Review & Process Verification

Section Description Complete N/A

1.0-08 Compressed air system – For systems with dryer/filters not integral with compressor, verify that piping, valves, filters and instruments are correct per P&ID.

1.0-09 CIP piping runs will allow complete free draining to Neutralization tank. CIP piping should be arranged such that draining racks and reclaiming chemicals will be most efficient.

1.0-10 High points in process piping have adequate air release devices with check valves. Particularly critical on filtrate headers, RF headers. The air release valve must be designed such that air can be purged from the high point in the piping but can not introduce air to the system under vacuum conditions.

1.0-11 Filtrate header will allow sufficient backpressure to supply filtrate instruments. Check for potential siphon in the filtrate piping. Some backpressure will be required to allow sample flow to filtrate analytical instruments.

1.0-12 Piping configuration will allow for adequate flushing of all piping. This may include some temporary piping depending on the site.

1.0-13 Pneumatic tubing is installed between all valves and solenoid valves

1.0-14 All flowmeters are installed correctly and are correct for application.

Verify that magnetic flowmeters are installed properly and that grounding rings or grounding electrodes are included for non metallic or lined pipe.

1.0-15 Sunshades are installed to protect instruments and other devices as needed.

1.0-16 Identify any potential freeze points such as instrument sample tubing or other piping.

1.0 P&ID Review and Process Verification

SIGN OFF: I have reviewed sections 1.0-01-1.0-16 and I certify that the information contained within this section is complete and accurate.

Pall Employee Signature Date

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Customer Representative Signature Date

2.0 Mechanical and Electrical Installation Review

Objectives:

Verify correct installation of Pall-supplied equipment, piping, and connections to customer equipment..

This includes proper foundations, housekeeping pads, anchoring bolts, grouting, and other required equipment. Alignment of valve racks, integrity of piping couplings and clamps, hardware, fittings is critical. Review installation for suitable pipe supports and note if questionable.

Identify parts, equipment, and tools will be needed for the next phase. This may include chemicals for calibration, calibration tools, CIP chemicals, tools and equipment for module installation

2.1 Valve Rack and Module Rack Installation

Objectives:

Verify proper installation of valve rack assemblies and module racks, manifolds, and interconnecting piping. Inspect for proper alignment of module rack manifolds such that membrane modules can be installed without interfering with manifolds. Verify that air scrub manifold and tubing is installed and secure. To verify that piping supports and structural members are installed per the design. Verify that the installation is prepared for further commissioning activities.

2.1-01 Valve rack foundations and housekeeping pads are poured and at correct elevations so stresses are not present on piping connections between valve rack and membrane rack

2.1-02 Valve rack and module rack are securely anchored to housekeeping pads with suitable anchor bolts.

2.1-03 Valve racks and module racks are leveled. Module rack uprights are vertical and plumb

2.1-04 Grouting of anchor bolts is complete where required

2.1-05 Module rack manifolds are aligned properly and connections from filtrate header to Feed header are plumb. Manifold pulls are vertical for correct connections with module ends

2.1-06 Air scrub manifold is installed, supported and clamped properly.

Manifold is straight and no bowing or distortion is visible.

2.1-07 Air scrub tubing is installed for all locations that will have a module installed. Unused air scrub fittings on air scrub manifold and feed manifold are securely capped

2.1-08 Rack hardware including manifold caps, air scrub tubing and fittings has been installed. Victaulic style pipe clamps are installed and tightened completely

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2.1-10 Pipe supports and clamps are installed and securely tightened

2.1 Valve Rack & Module Rack Installation

2.1-09 Dummy modules are installed for flushing and testing. Dummy modules should be installed at the farthest end of the module rack to allow flushing through entire length of module racks.

2.1-10 Pipe supports and clamps are installed and securely tightened

2.1-11 Field installed valves are in place with limit switch cables attached to valve rack panel

2.1-12 Limit switch assemblies are tightened so that limit switch is held firmly in position

2.1-13 Sample drains for turbidmeters installed

2.1-14 Process bleed valves installed, if applicable, and routed to suitable drain or pipe trench

Exceptions or Clarifications

2.1 Valve Rack and Module Rack Installation

SIGN OFF: I have reviewed sections 2.1-01-2.1-14 and I certify that the information contained

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2.2 Feed System – Feed Pumps and Motors Installation Review

Objectives:

Verify that Feed pumps and associated equipment have been installed per manufacturer’s requirements and per design. Feed pump configurations and equipment varies with each system. It is important to make sure that pumps are installed per the manufacturer’s instructions. Typically, feed pumps will be commissioned by a pump manufacturer’s representative (refer to pump startup section) so verify that equipment is installed properly and is ready to proceed with alignment and commissioning.

Section Description Complete N/A

2.2-01 Pumps are installed in correct orientation with proper foundation and anchoring

2.2-02 Pump base is grouted per manufacturer’s specifications

2.2-03 Associated equipment is installed where applicable

2.2-04 Check valve orientation is correct if check valves are installed

2.2-05 Motor wiring/VFD – Wiring has been terminated properly at motor junction box and VFD terminals

2.2-06 Motor is uncoupled. Motor shaft and pump shaft turn freely. Not applicable for close-coupled pump assemblies

2.2-07 Motor/Pump couplings are available with all hardware on site for installation during pump alignment and startup.

2.2-08 Verify motor and pump ratings and compare to P&ID drawings and design documents.

2.2-09 Seal flush water supply is installed correctly if applicable

2.2-10 Design documents including P&ID are correct. Markup drawings as required

2.2 Feed System – Feed Pumps and Motors Installation Review

SIGN OFF: I have reviewed sections 2.2-01-2.2-10 and I certify that the information contained

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2.3 Feed System – Feed Strainers Installation Review

Objectives:

Feed strainer equipment and options will vary with each system. It is critical to become familiar with each piece of equipment, included options, control methods, and manufacturer’s instructions.

The following is intended to be a general installation review for the feed strainer system.

Scope: Pall Corp. Contractor Owner Other

Strainer Type: Amiad Hayward Other Mfr:

Strainer Control method:

Standalone (MFR supplied controls) Pall PLC Control

Other

2.3-01 Strainers are installed properly with correct orientation and piping sizes match design documents. Adequate space is allowed around strainers to allow servicing and removal of strainer baskets

2.3-02 Backwash drain piping is of sufficient size and with minimal restriction per manufacturers requirements

2.3-03 Associated controls and instruments are installed and wired.

2.3 Feed System – Feed Strainers Installation Review

SIGN OFF: I have reviewed sections 2.3-.1-2.3-03 and I certify that the information contained

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2.4 Reverse Filtration Pumps Installation

Objectives:

Verify that mechanical installation of reverse filtration pumps is correct and electrical connections have been made. Review operation of RF pumps and note potential problems such as potential piping high points.

2.4-01 Pumps are installed in correct orientation with proper foundation and anchoring

2.4-02 Pump base is grouted per manufacturer’s specifications

2.4-03 Ancillary equipment installed where applicable. Installed equipment matches P&ID.

2.4-04 Check valve orientation is correct if check valves are installed.

2.4-05 Motor wiring/VFD – Wiring has been terminated properly at motor junction box and VFD terminals

2.4-06 Motor is uncoupled. Motor shaft and pump shaft turn freely

2.4-07 Motor/Pump couplings are available with all hardware on site for future installation during pump startup.

2.4-08 Air release valve or other means to bleed air from header high points is installed.

2.4-09 Verify motor and pump ratings and compare to P&ID drawings and design documents.

2.4 Reverse Filtration Pumps Installation

SIGN OFF: I have reviewed sections 2.4-01-2.4-09 and I certify that the information contained

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2.5 Compressed Air System Installation Review

Objectives:

Compressed air systems will vary with system design and may include air compressors, blowers, or both. The purpose of this section is to verify that air compressors and/or blowers are properly installed and ancillary equipment is installed, identified, and ready for commissioning.

Equipment Type:

Compressors # of Units:

Blowers # of Units:

Customer supplied Equipment Description:

Existing Plant Air System Description:

Control Method: Standalone (MFR supplied controls) Pall PLC Control Other

2.5-01 Units are installed per manufacturer’s instructions, anchored and level

2.5-02 Discharge piping from units is suitable size for application

2.5-03 Cooling water connections, valves, and equipment installed if required

2.5-04 Particulate filters and coalescing filters installed if required

2.5-05 Compressor oil type is correct (Food Grade oil for drinking water)

2.5-06 Compressor power connections have been made

2.5-07 Control/Feedback signal connections made to control system if applicable

2.5-08 Compressed air receiver is installed and anchored securely to foundation

2.5-09 Compressed air piping is of proper size and matches design documents

2.5-10 Air flow transmitter – Rotameter installed vertical and using non-ferrous piping and conduit fittings. Thermal dispersion type installed with probes extending into compressed air piping.

2.5-11 Compressed air dewpoint instrumentation is installed in proper location upstream of air receiver vessel.

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2.5 Compressed Air System Installation Review

2.5 Compressed Air System Installation Review

SIGN OFF: I have reviewed sections 2.5-01-2.5-11 and I certify that the information contained

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2.6 CIP System Installation

Review the CIP system installation and piping for correct piping sizes, instruments, valves, and equipment. The CIP system is typically a part of the system with the most variation so particular attention should be paid to make sure that the CIP system is installed properly and that all CIP processes will function properly with maximum efficiency

2.6-01 CIP tanks are installed, level, and properly anchored to foundations as required. Seismic control cables are installed if required.

2.6-02 CIP tank instruments are installed in the proper tank penetrations according to tank drawings or design documents

2.6-03 Immersion heaters installed and wired correctly. Titanium heater materials in Caustic/Chlorine tank and Stainless Steel materials in acid tank. Orientation is correct so that high limit temp sensor is at top of heater bundle (flange is marked on outside for proper orientation).

2.6-04 pH Instruments or other sensitive instruments installed with caps to keep probes wet.

2.6-05 Tank overflows and vents are installed correctly and piped so that they will not drain on instruments or equipment.

2.6-06 Tank outlets are at elevation that will allow sufficient draining of tanks Tank outlet can be installed at the bottom of the tank or an internal downcomer may be installed inside the tank to allow the CIP circ pump to draw down the tank as much as possible

2.6-07 Tank mixer if supplied is installed and anchored securely to tank or mounting frame as required.

2.6-08 CIP Circ skid is installed and anchored.

2.6-09 CIP Circ Pump – Pump orientation and level is correct

2.6-10 CIP Circ Pump – Pump base is grouted per manufacturers specifications

2.6-11 CIP Circ Pump – Related valves, check valves, expansion joints, and instrumentation are correct per P&ID

2.6-12 CIP Circ Pump – Motor wiring to VFD or starter is correct

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2.6-13 CIP Circ Pump – Motor is uncoupled and turns freely (unless close coupled pump is used)

2.6-14 CIP Circ Pump – Motor/pump ratings and specifications match design documents

2.6-15 CIP Circ Pump – Electrical connections have been completed

2.6-16 CIP drain pump is installed properly and anchored. Piping connections have been completed

2.6-17 CIP rinse water connection is adequate to achieve sufficient flow rate to rinse membranes

2.6-18 Chemical transfer skid is installed and anchored. Piping connections have been made.

2.6-19 Instrument air is connected to solenoid valves as required.

2.6-20 Air tubing is installed between solenoid bank and each process valve as required.

2.6-21 CIP circulation strainer is installed with correct orientation

2.6-22 CIP circulation strainer basket is installed in basket strainer or available on site.

2.6-23 CIP piping is sloped per design to drain toward CIP drain pump.

2.6-24 Instruments are installed and tagged appropriately. Tag numbers match P&ID

2.6-25 CIP Chemicals on site, if not on site, note expected delivery date:

2.6-26 Instrument sample pumps are installed correctly if supplied

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SIGN OFF: I have reviewed sections 2.6-01-2.6-26 and I certify that the information contained

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2.7 MCC/VFD Installation Review

Objectives:

Motor control centers may be supplied Pall or others and configuration and equipment supplied will vary. The purpose of this section is to verify that equipment is supplied per design and scope, that the equipment is installed, and that the equipment is prepared for commissioning

2.7-01 MCC mains are connected

2.7-02 MCC load wiring is completed as required

2.7-03 MCC buckets match design documents and are marked properly with nameplates

2.7-04 Communication wiring and connections to MCC have been made

2.7 MCC/VFD Installation Review

SIGN OFF: I have reviewed sections 2.7-01-2.7-04 and I certify that the information contained

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2.8 Control System Installation Review

Objectives:

The control system for a custom microfiltration system typically includes a main PLC with remote IO or slave PLCs to control equipment and monitor the system. Data acquisition and operator interface is usually a PC based system with HMI software installed. It is critical to understand what is included with each system and the basic control scheme. The purpose of this section is to verify installation of control panels and ensure that the control system is prepared for further commissioning.

Section Description Complete N/A

2.8-01 Control Panels are installed per design and anchored securely to floor or equipment frame

2.8-02 Locations of control panels are in a suitable environment (i.e.

shielded from sun, adequate cooling, etc).

2.8-03 Interiors of control enclosures are clean, dry, and free of construction debris from enclosure penetrations

2.8-04 Penetrations to control panels are in appropriate locations and suitable conduit fittings or cable glands are used and installed properly.

2.8-05 Unused conduit penetrations are sealed properly

2.8.06 Door mounted operator interface or computers are installed and wired properly (enclosure mounted HMI equipment is often shipped separately for safer shipping).

2.8-07 Network cabling is complete and correct cable is used for each type of network.

2.8-08 Cables and connectors are securely fastened with screws tightened when applicable

2.8-09 Electrical drawings are located in each control panel door pocket

2.8 Control System Installation Review

SIGN OFF: I have reviewed sections 2.8-01-2.8-09 and I certify that the information contained

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2.9 Preparation for Startup

Objectives:

Preparations for startup should be discussed with contractors and customer as needed to make sure that needs during the next phase are understood and that parts and materials are available. Any outstanding items should be discussed with the customer so that a schedule can be developed.

Section Description Complete N/A

2.9-01 Power is available to energize all panels, MCC, instruments, compressors, and other equipment

2.9-02 CIP Chemical are available on site of will be available

2.9-03 Potable water is available for flushing, testing, and rinsing

2.9-04 Raw water is available and intake structure is available for raw water delivery

2.9-05 Pre-treatment equipment and chemicals are available

2.9-06 Suitable means to discharge water from rinsing, flushing, and testing is available

2.9-07 Equipment and reagents for instrument calibrations are available on site. pH standards, turbidity standards, turbidimeters calibration base

Filtertrak 660 nepholometer standards: Hach p/n 2788453 – StablCal 800mNTU

Hach 1720E Low Range Turbidimeter: Hach p/n 2660153 – StablCal 20.0 NTU

2.9-08 Startup activities have been discussed with customer and contractors. Resources needed from contractors have been identified

Exceptions or Clarifications:

2.9 Preparation For Startup

SIGN OFF: I have reviewed sections 2.9-01-2.9-08 and I certify that the information contained

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3.1 Control System, HMI, PLC, and Network Configuration

Commission communication networks, PLCs, HMI computers as required by Pall design. Be sure that all network configuration files are backed up to the project database. Record basic computer configurations with Windows passwords; programs installed, network settings, PCAnywhere configuration and other critical computer information.

3.1 HMI Configuration and Software Setup

Multiple HMI computers may be included with a project. Each included HMI must be configured per the contract requirements. Installed software, versions, and serial numbers must be recorded for each computer supplied. Security information must be recorded along with remote access information if applicable and other critical information.

Section Description HMI-1 HMI-2 HMI-3

3.1-01 Function

3.1-02 Location

3.1-03 IP Address

3.1-04 Subnet Mask

3.1-05 Admin Username

3.1-06 Admin Password

3.1-07 Operator Username

3.1-08 Operator Password

3.1-09 Other Username

3.1-10 Other Password

3.1-11 HMI Software

3.1-12 HMI Software version

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Section Description HMI-1 HMI-2 HMI-3

3.1-13 HMI Software S/N

3.1-14 PLC Software

3.1-15 PLC Software version

3.1-16 PLC Software S/N

3.1-17 Remote Access Software

3.1-18 Dial Up access #

3.1-19 Internet Access IP

3.1-20 Remote access username

3.1-21 Remote access password

SIGN OFF: I have reviewed sections 3.1-01-3.1-18 and I certify that the information contained

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3.2 PLC Configuration

The PLC configuration and network topology will vary. Use the design documents and network diagram to verify correct configuration of the PLC. Make sure that network addresses match those shown on the network diagram. If there are none on the network diagram, mark up the drawing with the proper information. If multiple PLCs are included with the system, check the following on each unit.

Procedure:

Section Description Complete N/A

3.2-01 Design documents and network diagram is correct with correct network address for each PLC as required

3.2.02 PLC Battery is installed. PLC Battery LED indicates battery is charged. Replace if necessary

3.2-03 Compact flash or other non volatile memory card is present where applicable

3.2 PLC Configuration

SIGN OFF: I have reviewed sections 3.2-01-3.2-03 and I certify that the information contained

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3.3 Main Control Panel Startup

Objectives:

Verify that incoming power to the main control panel is correct. Verify that circuits and devices powered from the main panel are correct and per design. Identify problems or errors in wiring or 38labeling

Procedure:

Once wiring to main panel has been complete and power is available to the system, energize the main control panel according to the following sequence.

1. Inspect main control panel and internals for wiring and mechanical problems. Rectify any problems before proceeding

2. Open all circuit breakers or fuse blocks in the main panel

3. Turn on power to main panel at power source and measure voltage at main panel incoming power terminal blocks and verify proper voltage. Verify that voltage is within 10% of rated voltage

4. Turn on main control panel and ensure that power is present.

5. Using the main panel electrical drawing, energize each circuit and verify that the circuit matches the electrical drawings.

Section Description Complete N/A

3.3-01 Incoming power to main control panel is of correct voltage and within specifications

3.3-02 All circuits powered from the main panel have been energized and verified. Circuit breaker numbers, fuse numbers, and wire numbers match the electrical design drawings

3.3-03 Electrical Drawings have been updated with changes or modifications

3.3-04 UPS, if installed, is functional. UPS has been commissioned per manufacturer’s instructions.

3.3-05 All panel pilot light bulbs are OK. Replace bulbs if necessary

3.3 Main Control Panel Startup

SIGN OFF: I have reviewed sections 3.3-01-3.3-05 and I certify that the information contained

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3.4 Valve Rack Control Panel Startup

Objectives:

The objective is to prepare the valves and instruments on the valve rack assemblies for operation and further commissioning. When this section is complete, the racks should be prepared for I/O checks.

Procedure:

Power up each valve rack using the following sequence

1. Turn off power to each panel by switching off circuit breaker, pulling fuse, or other method as needed to isolate incoming power from valve rack panel internal circuits.

2. Energize valve rack panel circuit.

3. Measure voltage at valve rack panel incoming power terminal blocks and verify proper voltage.

4. Turn on valve rack panel and ensure that power is present on valve rack instruments and devices.

Section Description Complete N/A

3.4-01 On racks with…