Professional Documents
Culture Documents
22 Hull WWTW Sludge Treatment Facility (STF) Commissioning Plan - High Level
22 Hull WWTW Sludge Treatment Facility (STF) Commissioning Plan - High Level
10 April 2019
R1434 / VS03
22 Hull WwTW Sludge Treatment Facility (STF)
Commissioning Plan - High Level
10 April 2019
Mott MacDonald Bentley
Livingstone House
Chadw ick Street
Leeds LS10 1LJ
United Kingdom
R1434 / VS03
J500 001 A
22 Hull WwTW Sludge Treatment Facility (STF)
https://mottmac.sharepoint.com/teams/pj-b3923/ps-VS03/04/06 Commissioning/VS03-
MMB-20-ZZ-DO-Y-0380 STF Commissioning Plan - High Level EA Submission - Rev
B.docx
Commissioning
Mott MacDonaldPlan
Bentley - High Level
10 April 2019
This document is issued for the party which commissioned it and for specific purposes connected with the above-
captioned project only. It should not be relied upon by any other party or used for any other purpose.
We accept no responsibility for the consequences of this document being relied upon by any other party, or being
used for any other purpose, or containing any error or omission which is due to an error or omission in data suppli ed
to us by other parties.
This document contains confidential information and proprietary intellectual property. It should not be shown to other
parties without consent from us and from the party which commissioned it.
This Repor t ha
sbee
nprepa
r edsolelyf o
r usebythepartywhichcommission
edit ( the'Client') incon
nectionwitht h
ecap
t ion
edproject. It shou
ld n
ot b
e u
sedforanyo
th
er pu
rp
ose
. Nope
r so
nothert h
ant h
eClient oranyp
art ywh
ohasex
press
lyagreedtermsof relianc
ewit hus(the'Rec
ipient( s
) ') mayrelyonthec
ontent, informationor a
nyview
sexp
r es
sed intheRep
ort .ThisRep
or tiscon
f ide
nt ia
l andc
ontainspro
priet a
r yintelectualprope
r tyan
dweacc
eptnodutyofcare,r es
pon
sibilt yorliabilit y toan
yother rec
ipient o
f thisRepo
r t. Norep
r es
entation,warr a
nt y
or un
dertaking
, ex
pr e
ssorim p
lied, ismadea
ndnoresp
ons
ibilt yor liabilit yisacc
eptedb
yus toanyp
ar tyothe
r thantheClient o
r an
yRecipien
t (s), a
st otheac
cur ac
yor c
ompleten
esso
f theinf o
r ma
t ionc
ontaine
din thisRep
or t. F
or theav
oidan
ceofdou
bt thisRep
ort doe
snotin a
nywayp
urport toincludea
nylega
l, insuran
ceorf inan
cialadv
iceor op
inion.
We disclaim all a
ndanyliabilit y w
hetherarisingin tort ,con
t ractorot h
erwisewhichwemigh
t othe
r wiseh
avetoanyp
art yo
th
er thantheClientor theRe
cipient(s) ,in res
pec
t oft h
is Re
port, or a
nyinformationcon
t ain
edin it. Weac
cep
t noresp
ons
ibilt yf o
r anye
r ror o
r omiss
ionin theRe
port wh
ichis d
uetoanerr o
r or o
missionindata,inf o
r mationorstatemen
t ss
upple
i dtousbyo
th
er p
ar tiesinc
ludingtheClient (the'Data') .Weh
aveo
nt ind
epen
den
t lyve
r ifedt h
eDataor othe
r wisee
xaminedit t od
eter minethea
ccu
ra
cy,comp
let e
nes
s, s
uf icien
cyfor a
nypurpo
seorf ea
sibilt yfor a
nyparticular o
utcomeinc
ludingfinanc
ial.
For ecast spresentedinthisdocumen
t wereprepa
r edu
singtheDataan
dt h
e R
eport isde
pen
den
t or b
ase
dontheData.I ne
vitably,someoft h
eass
umptionsu
sedtodev
eloptheforeca
stswil not b
er e
alisedan
dunan
t ic
pat e
deve
ntsandc
ir cu
mstanc
esmay o
ccu
r. C
ons
eque
ntly, wed
o n
ot g
uaran
t eeo
r warrant thec
onc
lusionsc
ontaine
din theRe
port a
st he
r ea
r elikelytobedif e
r en
cesb
etweentheforec
astsan
d thea
ctualr e
sultsandthos
edif eren
cesma
ybematerial. While wec
ons
ider tha
t theinf o
r ma
t iona
ndopinion
sgive
n inthisRep
or taresou
ndall p
ar tiesmus
t relyontheir o
wnskil an
djudge
mentwhenmak
inguseo
f it .
I nf or m a
t iona
ndop
inionsarecurrentonlyaso
f thedateoft h
eRepo
rt a
ndweaccep
t noresponsibilt yf o
r up
datingsuchinf orma
t iono
r opinio.nIt sh
ould,t h
er e
fo
re
, no
t beas
sume
dt h
at a
nysu
chinfor ma
t iono
r op
inioncon
t inu
esto b
eacc
uratesub
seq
uentt othed
ateof theRep
ort . Un
dernocir c
umstan
cesma
yt h
is R
eport o
r any
extr a
ct o
r su
mmar ythe
re
of b
e u
sedinco
nne
ctionwit han
y pub
lic orprivatesec
urit iesoffer in
g inc
ludingan
yr e
lat e
dmemorand
umor pros
pec
tu
sf o
r any
sec
ur itesoff e
r ingo
r stoc
kexc
han
gelist ingo
r ann
oun
ceme
nt.
By acceptanceo
f thisRepo
r tyoua
greet ob
ebou
ndbythisdisclaim e
r .Thisdisclaim e
r anda
nyissues,dis p
ut e
sor claim sa
r isingo
ut o
f orin conne
ctionwit hit (whe
t he
r co
ntr a
ctualor no
n-con
t rac
t ua
l innaturesu
chasc
laim sintort ,f rombreac
hof s
ta
t uteorr eg
ulationor o
th
er w
ise) s
hall b
egov
er n
edby
, an
dcon
str ue
din a
cco
rd
anc
ewit h,t h
elawsof En
glanda
ndWalestot h
eexc
lusionofall co
nflict of la
wsprinciplesan
dr ule
s. All isdputeso
r claimsarisingou
t ofor relatingt othisdisc
laim e
r sh
al bes
ubjec
t tot h
eexc
lusivejurisdictionof theE
nglishan
d We
lshcou
r tstowhichthepa
r tiesir revo
cably submit.
Contents
2 COMMISSIONING STRATEGY 3
2.1 Commissioning Strategy 3
2.2 Commissioning Progress Monitoring 1
2.3 EA Permits - U6 Exemption 1
2.4 Commissioning Programme 1
2.5 Commissioning Procedures & Method Statements 1
2.6 Commissioning Hazard Identification and Risk Analysis 2
2.7 Commissioning Constraints 2
5 COMMISSIONING SCOPE 14
5.1 Brief Description of the Project 14
5.2 Key Items to be commissioned 14
5.3 Supporting Plant and Equipment 15
5.4 Interfaces 15
8 SPECIFIC COMMISSIONING 35
8.1 General 35
8.1.1 Commissioning 35
8.1.2 Commissioning Sequence 37
8.2 De-commissioning 52
8.3 Sub-Contractor Commissioning 52
10 TRAINING 54
10.1 Training Philosophy 54
10.2 Training Scope 55
10.2.1 Training Documentation 55
11 HANDOVER 56
11.1 Responsibility 56
11.2 Handover 56
11.3 Post Hand over Support 56
11.4 Post Commissioning Review 56
12 ABBREVIATIONS 57
A. P&IDs 58
This document is intended to provide sufficient information to define, plan and sequence the
commissioning activities relating to the construction of the New Hull WwTW Sludge Treatment
Facility
The commissioning plan is divided into the following sections: -
2 Commissioning Strategy
8 Specific Commissioning
11 Handover
The commissioning plan appendices will be the main area of focus for recording that the works
have been tested and commissioned in accordance with the requirements of the Contract.
This is a live document and shall continue to be developed throughout the design and
construction phases of the project.
MMB will maintain one working copy of the commissioning plan on site. This copy will contain all
details, appendices, testing records etc. The proposed format of the commissioning plan and
the associated appendices is as detailed in Section 1.1 – Commissioning Documentation.
2 COMMISSIONING STRATEGY
Emphasis shall be given to the planning and management of the high-risk commissioning
activities that have the greatest impact on the existing works and proving of the new plant and
equipment.
The MMB Commissioning ‘Lead Commissioning Engineer’ will lead the commissioning team on
site, which will contain representatives from Yorkshire Water, MMB and Sub-contractors when
and where appropriate. (All other sub-contractors will fall under the banner of “MMB” for the
purposes of the management of this document.) Contact names for commissioning liaison are to
be listed in Section 4.
The commissioning team will implement commissioning in accordance with the commissioning
plan and procedures detailed within this document as well as the associated method
statements, risk assessments and the contract management plan.
MMB Engineers will witness all tests performed by sub-contractors with the exception of
repetitive tests (e.g. cable insulation tests) where a sample of tests will be witnessed. The MMB
‘Lead Commissioning Engineer’ shall be in attendance on site at all times during testing and
commissioning activities. Attendance during construction / installation will be on an as required
basis. The MMB ‘Lead Commissioning Engineer’ will be supported by additional commissioning
engineers and sub-contractor commissioning staff when required.
Full details on the discussions, actions and programme will be included in the relevant section of
the meeting, standard agenda as below:
1. Introductions & Agenda Review
3. Discussion Items
6. H&S Review
7. YWS Issues / Callouts
8. AOB
However due to there being sufficient sludge present on site in this case, a U6 exemption will
not be required.
Details of the Commissioning Plan are shown in phased sections within the Clause 32
programme however, a separate commissioning programme may be compiled to facilitate
programme management.
• Hazards / Risks
• Process Impact Plan that also identifies contingencies
• Roles and Responsibilities
• Contact details
The commissioning team shall review and approve the commissioning procedure/method
statement prior to implementation.
Sequencing
• MMB shall ensure that the works do not interfere with YWS’s ability to maintain the
existing treatment capacity and site discharge consent at all times.
• From May to August inclusive, four No. Digesters shall be fully operational at
Operational Treatment Capacity throughout.
• From September to April inclusive, three No. Digesters shall be fully operational at
Throughput Capacity throughout.
• Time risk allowance of two weeks shall be included between re-commissioning any
digester and taking the next digester offline.
• No Digester shall be taken off-line until the required number of remaining Digesters are
Fully Operational i.e. have been re-commissioned and proven to be biologically active
and stable for mesophilic digestion following successful performance testing
Decommissioning Activities
Commissioning shall be phased, with digesters being taken from the old system and
recommissioned onto the new system to a phased program of works .
All work tasks shall have ‘approved’ Risk Assessments and Method Statements in accordance
with BIMS 02-04 Risk Identification Assessment Control and JNB Operational Safety Standards
(OSS’s).
OSS 002 - Preparation, Communication and Use of Risk Assessments and Method Statements
(RA/MS)
OSS 004 - Preparation and Issue of Permits to Work.
DSEAR /ATEX;
Access & Working within Hazardous area’s shall be controlled by a hazardous area work ing
procedures.
All operatives working in the digester compound shall be inducted fully inducted and have
attended the YWS Digester site safety Induction and carry an in-date Digester Safety induction
Card. Any electrical / mechanical works shall be carried out by COMPEX qualified Engineers.
All operatives shall wear a gas monitor and be familiar with the device when working in and
around the digester compound at all times. If a gas alarm is to sound, then site emergency
procedures shall to be followed which are detailed in the ON Site Emergency Response Plan
and covered in the MMB & YWS site induction.
Consideration is shall be drawn to the Whessoe Valves currently operating on the remaining
digesters that are in service. When the Whessoe Valves reach High Level, YWS shall to notify
ALL MMB staff to evacuate the area due to increased risk of explosive gas release.
Isolations points shall be determined to remove the risk of explosive atmospheres away from
the work area as far as reasonably practicable. This action shall minimise risk of exposure to
hazardous and/or combustible gas mixes as far as practicable while working on new system
plant and components being brought into service.
Electrical
As Per BIMS 02-16 Electrical Safety Rules and Code of Practice (Latest Version).
Only persons who are appropriately authorised shall undertake work on electrical systems /
installations.
Isolations shall be carried out by an MMB &/or Delegate in the presence of the Authorised
person prior to works commencing on any electrical circuit.
Energisations shall be carried out by an MMB &/or Delegate in the presence of the Authorised
person prior to works commencing on any electrical circuit or system.
Only COMPEX qualified engineers shall work on Electrical Systems within Hazardous areas
and associated circuits.
COSHH
COSHH Register & Risk Assessments shall be in place and consulted for any works where
COSHH may be required. This shall identify any exposure or additional PPE requirements
required.
Operation of the existing digestion plant will continue while a phased commissioning takes
place. During the phased commissioning, de-commissioning of redundant plant shall also take
place.
During Phased commissioning Isolation points used in the de-commissioning process shall be
present. All Isolations shall be recorded on an isolation schedule and P&ID under control of an
appointed person.
All sub-contractor isolations shall also be recorded by the appointed person.
Any minor isolations shall be carried out by MMB. Process isolation points are to be agreed with
the client prior to isolations being carried out.
PLEASE NOTE:
- Commissioned machinery may start without warning.
- Stored energy potential.
Asbestos
As phased commissioning, shall run along with de-commissioning there is a potential for items
identified during the asbestos demolition survey to be present on site.
Items such as gaskets (manufactured pre 2000) may contain asbestos. MMB will execute an
asbestos demolition survey to identify if the gaskets do contain the substance.
CDM
Handovers shall be obtained for working within the Digester Compound via the client. These
handovers shall be in place prior to commissioning and run until project completion.
During the phased commissioning the process of existing digestion shall remain responsibility of
YWS with the isolated assets being handed over in full to MMB.
The full digester compound shall ultimately be covered by ‘area handover’ to MMB when final
commissioning works is carried out.
During the phased commissioning full (True) standby capability on each system shall be
compromised due to running of the systems simultaneously, however due to the systems being
separate then both systems shall be available until standby capability is available.
Commissioning offline will always be the preferred method of commissioning. And where it
cannot, then dry testing/simulations will be carried out to confirm functionality, as far as is
practicable prior to removal from the system and system change over.
On Whessoe Valve operation, all MMB staff shall evacuate the digester area due to increased
risk of explosive gas release.
Operation of the existing digestion plant will continue while a phased commissioning takes
place.
Both systems shall work independently however areas of work may cross over during the
commissioning process.
In addition to the civil and building works, the construction completion tests cover all equipment
items. This provides a check that the equipment has been installed as specified, and that
installation is as shown on P&ID and installation drawings. Instruments will be calibrated and
ranges set as shown on the appropriate sheets such that all plant performs to the individual test
sheet specification. Electrical and Mechanical equipment installation and testing shall be
recorded using inspection and testing report sheets.
3.2 Testing
The MCC/SI framework contractor will be responsible for producing a FAT document, which
details the tests/inspections necessary to prove the operation, functionality and reliability of the
items being delivered. This document must be approved by MMB prior to the FAT being
arranged.
Upon completion the FAT document will be signed off as complete. This will provide a formal
documentary record as to the state of the equipment when supplied. The FAT document and
subsequent results will form part of this document (included within the Appendices), and
ultimately the Handover documentation.
MMB will provide the Project Manager at least 14 days’ notice in advance of each FAT to allow
the relevant parties to attend.
A FAT will typically be undertaken for the following items:
• MCC
• Local control panel
• PLC
• SCADA
FAT test documentation shall be forwarded to site for reference during the site acceptance
testing (SAT) with details of any simulations, set-points, and faults/non-tested items being
clearly identified.
The aim of this document once completed and signed off accordingly, will not only prove the
satisfactory operation of the delivered asset but also demonstrate its operating characteristics
and performance at the time of commissioning.
This document will be supplied as a formal documentary record and will form part of the
handover documentation.
Manager. In the instance of a PLC replacement, where no new software is being written the
FAT may be waived, however a full Site Acceptance Test (SAT) will need to be performed.
As the PLC FAT will be performed with the aid of simulation routines; whereby field devices are
simulated to operate as commanded.
The aim of the PLC software tests will be to prove the following:
• Start-up sequence/routine
• Shut-down sequence/routine
• Fault Routines
• Alarm Handling
• SCADA/HMI Interface
• Recovery from Power loss
• Telemetry interface
• Confirmation that the latest Yorkshire Water Standard function blocks are being used.
Version control of the plant application software shall be maintained at all times by the
nominated System Integrator.
The version control system shall record all software changes made at each stage of software
development and testing. The record shall provide a means of logging all changes, the
originator and the reason for the change.
During dry testing, care should be taken to ensure that all construc tion debris is removed prior
to progression to wet testing.
procedures / method statements. MMBs SAT specification shall form the basis of the wet testing
verification, and this shall be supplemented by other test pro-forma as required
Wet Testing may also incorporate such elements as Tank and Vessel leak testing. Where this is
applicable, the chosen media and its source and disposal methods shall be detailed in the
associated RAMS.
On completion of wet testing it shall have been demonstrated that all plant and equipment is
ready to receive flows and that the plant control systems are ready to be put into service.
There are to be four elements to the testing, and these shall be implemented to verify the
control system Functional Design Specification (FDS), while proving correct operation of
equipment:
Wet Testing of control systems shall include but not be limited to the items noted
below:
The Telemetry testing will have to be co-ordinated with Yorkshire Water ITT department, as the
Telemetry outstation is a Yorkshire Water owned asset, and the configuration is the
responsibility of Yorkshire Water ITT department.
The Telemetry testing sheet shall be submitted as a record within the Commissioning and
Testing Report on completion.
4.4 Reporting
The MMB M & E Commissioning Engineer’s report directly to the MMB Lead MEP
Commissioning Engineer, who in turn reports to the Operations Manager. MMB are responsible
for managing the commissioning programme.
YW’s Lead Environmental Advisor and Senior Compliance Analyst - Sludge are responsible to
providing a copy of this commissioning plan to the local EA either by email or within local EA
liaison meetings.
YW’s Senior Compliance Analyst – Sludge shall be responsible for liaising with local EA
Environment Officers regarding;
• Site audits conducted by the EA during and post commissioning
• Compliance issues during and post commissioning
MMB’s Lead Commissioning Engineer shall be responsible for reporting issues with the CHP’s /
boilers leading to non-compliant emissions, flare operation (hours run) or any pollution to the
EA’s pollution hotline and YW’s Senior Compliance Analyst – Sludge (the Technically
Competent Manager for the site).
MMB’s Lead Commissioning Engineer is responsible for ensuring the full suite of emissions
tests are carried out in line with the new environmental permit.
Criteria Detail
Water Quality To ensure commissioning activities have as little as
possible negative impact on current water quality.
Effluent Quality Specific consent requirements for water quality are as
follows - See Section 6.4
Process Requirements Specific consent requirements for water quality are as
follows - See Section 6.4
Flow Requirements Specific consent requirements for water quality are as
follows - See Section 6.4
Works Shutdowns and Intrusive All work shall be carried out under normal flow
Works conditions as far as practicable, interactions with
existing processes shall be managed in accordance
with site handover restrictions.
Control Systems Downtime All new control systems will be Factory Acceptance
Tested FAT, Site Acceptance Tested (SAT) powered
up in advance and connections made under process-
controlled conditions. Downtime will be kept at a
minimum with periods identified approved by the
commissioning team for each element of work.
Response Time to Failures The works will continue to be operated, during the
construction work, as it is currently.
The response time to works failures will be to the
current operating system. Any temporary works left
unattended shall fail-safe.
Consider out of hour’s support and standby response
personnel training and abilities.
Availability of Operations Staff Any requirement for Operational Staff during
construction & commissioning will be discussed in
advance and agreed with the commissioning team, It
is not envisaged that any operational procedures by
the client will be required outside normal operations
already taking place
5 COMMISSIONING SCOPE
As part of this works 6 No. conventional anaerobic mesophilic digesters require upgrade. Two
of the digesters 1 and 2 are currently off service. It is required to refurbish digesters 1 to 4 only
to take full duty of the new sludge throughput. Digesters 5 and 6 shall be decommissioned.
Temporary works designs required for managed processes will be listed in the temporary works
schedule.
5.4 Interfaces
The following interfaces have been identified and will need the appropriate management during
the commissioning phase:
The New permit emission limits of the site are detailed below: in Table 3.
Table 3 - Hull STW Site Permit Emission Limits
Source:YW and communication with Chris Gaughan (Regulatory Officer at the Environment
Agency) (a) Reference conditions (unless specified) = 0oC, 1 atm, dry air @ 3% O2
(b) Reference conditions = 0oC, 1 atm, dry air @ 15% O2
The New air quality objective & limit values of the site are detailed below: in Table 4.
Table 4 - Hull STW Summary of relevant air quality objectives and limit values
Averaging Objectives should apply at: Objectives should not apply at:
period
Annual All locations where members of Building façades of offices or other
the public might be regularly places of work where members of the
exposed. Building façades of public do not have regular access.
residential properties, schools, Hotels, unless people live there as their
hospitals, care homes etc. permanent residence. Gardens of
residential properties. Kerbside sites (as
opposed to locations at the building
façade), or any other location where
public exposure is expected to be short
term.
24 hour All locations where the annual Kerbside sites (as opposed to locations
mean objective would apply, at the building façade), or any other
together with hotels. Gardens of location where public exposure is
residential properties. expected to be short term.
1 hour All locations where the annual Kerbside sites where the public would
mean and 24 and 8-hour mean not be expected to have regular access.
objectives apply. Kerbside sites
(for example, pavements of busy
shopping streets). Those parts of
car parks, bus stations and railway
stations etc which are not fully
enclosed, where members of the
public might reasonably be
expected to spend one hour or
more. Any outdoor locations
where members of the public
might reasonably be expected to
spend one hour or longer.
The New Site environmental assessment levels for the site are detailed below: in Table 6.
Table 6 - Summary of relevant Environmental Assessment Levels (EAL)
The existing Stack Emission Parameters of the site is detailed below: in Table X.
Table X- Hull STW discharge consent
Boiler
Parameter Units CHP 1 CHP 2 CHP 3 Flare stack
(multiflue)
Stack x,y 516457.5, 516455.5, 516456.5, 516439.5, 516412.5,
location 429164.9 429155.5 429160.0 429164.2 429023.5
Stack height m 5.2 5.2 5.2 14(a) 21.9(b)
Exit diameter m 0.2 0.2 0.2 0.45 2.46(c)
Exit 478 478 478 210 1000
°C
temperature
Efflux 55.7 55.7 55.7 12.1 10.3
velocity m/s
(actual)
Volumetric 1.75 (d) 1.75 (d) 1.75 (d) 1.93 (e) 54.79 (f)
flow rate Am3/s
(actual)
Volumetric 0.51 0.51 0.51 0.89 10.04
flow rate Nm3/s
(normalised*)
mg/Nm³ 500 500 500 200 150
NOx
emission g/s 0.26 0.26 0.26 0.36 1.51
S in fuel 200 200 200 200 500
SO2 (ppmv)
emission
g/s 0.04 0.04 0.04 0.168 1.07
CO emission mg/Nm³ 1400 1400 1400 1400 (g) 50
g/s 0.71 0.71 0.71 2.5 0.50
VOC mg/Nm³ 75 75 75 75 (g) 10
(benzene) 0.038 0.038 0.038 0.134 0.1
emission g/s
All sampling and monitoring required for the consent shall be maintained throughout the works.
The following STF design data shall be used for the following sections:
Digester refurbishment,
Hull STF is defined as a Yorkshire Water regional sludge treatment facility and is designed for
the capacity provided in Table 8.
All items to be refurbished or replaced shall be done on the basis that the plant will need to
operate at the Throughput Capacity based on the following parameters:
The design and control shall also allow the works to operate at the Operational Treatment
Capacity as per the requirements of the Asset Standard, namely;
The facility shall be capable of handling and treating sludge at the concentrations indicated in
Table 7 at any proportion (as defined in Table 10 and Table 11 below) in accordance with the
defined minimum and maximum indigenous and imported sludge production levels:
Imported cake 18 25 30 % DS
Primary % Secondary/Humus %
Sludge Type
Min Max Min Max
Load %
Sludge Type Comment
Min Max
The dewatering system shall be designed based on Throughput Capacity and the relevant
Asset Standard volatile solid loading rates and destruction rates. This gives a design throughput
of 51.1tDS/d to be processed by the new dewatering system within 16 hours/day.
The dewatering facility shall be capable of achieving a turndown of at least 50% Throughput
Capacity.
Samples shall be tested in accordance with the current version of “Methods for the Examination
of Water and Associated Materials” published by the Environment Agency.
A daily summary of the results of tests carried out during take over or performance testing and
submitted to YWS. If YWS disagrees with any of the results, they shall inform the Project
Manager in writing within 14 days of receiving the results stating the reasons for the
disagreement. In the event of a disagreement with the test results the back-up sample will be
analysed by an independent third party.
The 14-day performance tests shall include the following and any other testing requirements
specified within the relevant asset standards.
6.4.1 Digester
Performance test requirements shall be as per Asset Standards with the following exception:
Lithium Tracer tests are to be carried out but are not considered a performance test, rather
these are required for YWS’s information and risk evaluation.
Testing of the mixing system on a single digester shall be carried out to determine if the
following conditions are met under normal operation.
• An active volume of greater than 90% of the liquid volume of the tank
Not achieving these conditions shall not be considered a failure of the performance tests
provided that the ancillary equipment is functioning correctly.
Tracer testing shall be carried out and interpreted by a suitably competent person.
If the feed characteristics for any sample are outside the values detailed in
Section 6.4 then this sample shall be discounted, and the remaining samples shall be used to
assess the pass criteria. The performance of the assets shall be evaluated at the design loading
rate per unit in operation as per the Accepted Design. For the avoidance of doubt this may lead
to reduced operating hours on any individual day. As a minimum during performance testing the
following parameters shall be monitored.
Dewatering cake dry solids – cake dry solids average to be equal or greater than 25%. The
average volatile solids measurement shall be compared to the average dry solids measurement
to assess if the test has passed.
The above centrifuge performance and polymer consumption figures are subject to confirmation
by test work on the actual sludge to be treated.
In order to allow the pumped sludge to reach the instrument and the instrument to start stable
readings, an agreed period at the start of the test, shall be discounted.
A set point dry solids shall be fixed for the truck load and the re-wetting control system shall
control the re-wetted cake to this set point.
Pass criteria – Average value of a minimum of four samples collected downstream of the re-
wetting cake transfer pump at equal time intervals over 1 hour (minus the agreed discounted
period) to be ± 0.7% w/w DS of the set point (with allowance for the accuracy of the solids
monitor).
Measurements:
The testing / sampling regime shall verify the online solids instrumentation and its accuracy in
accordance with the manufactures O&M. The total run hours for any one day and the
associated performance shall be evaluated from online PLC/SCADA trending, as verified by the
manual sampling regime.
Sample analysis
Pass values:
No sample deviates by more than ± 10% (in addition to the stated accuracy of the instrument)
from mean sample data.
No sample from the Primary or Secondary Sludge Storage tank deviates by more than ± 20%
(in addition to the stated accuracy of the instrument) from mean sample data.
The new inlet works odour control facility and related new covered and air extracted assets shall
be subject to full performance testing as detailed in the Asset Standard with the addition of the
following clauses:
• Mercaptans, DMS and TVOC shall be monitored through 1 spot sample per day for 10
days at both the inlet and outlet of each bio-trickling filter and each dry absorption unit, as well
as at the OCU stack.
• Total VOCs shall be measured using a photo ionization detector (PID) which shall be
equipped with a lamp that does not register H2S. Results shall be provided as isobutylene
equivalents.
• Olfactometry shall be sampled for 10 days (2 samples per day- not duplicates) at both
the inlet and outlet of each bio-trickling filter and each dry absorption unit, as well as at the OCU
stack.
Modified OCU2
The existing OCU2 with modifications (as agreed with YWS) shall be subject to full performance
testing as specified in the Asset Standard with the addition of the following clauses:
• Mercaptans, DMS and TVOC shall be monitored through 1 spot sample per day for 10
days at both the inlet and outlet of each BTF and each dry absorption unit, as well as at the
OCU stack.
• Total VOCs shall be measured using a photo ionization detector (PID) which shall be
equipped with a lamp that does not register H2S. Results shall be provided as isobutylene
equivalents.
• Olfactometry shall be sampled for 10 days (2 samples per day- not duplicates) at both
the inlet and outlet of each BTF and each dry absorption unit, as well as at the OCU stack.
MMB shall not be responsible for the odour removal achieved by OCU2.
Existing suitable sampling points at the inlet and outlet of each bio-trickling filter and dry
absorption unit on OCU2 to allow for performance testing to occur.
CO 50 mg/Nm3
Each boiler stack shall be tested 4 times over the 14 days period to demonstrate compliance
with Table 10 in line with EA Guidance (LFTGN05 and 08).
6.5 Reliability
All installed plant items shall be tested to demonstrate reliability in operation and control under
the specified conditions. The plant shall be run for a period of 21 days over which time the
reliability shall be monitored. Prior to commencement of reliability tests, MMB shall ensure that
the plant is operating as designed. The time to be allowed for the plant to reach operational
standard shall be determined by YWS.
All instrumentation shall be calibrated in accordance with the requirements of the supplier prior
to commencement of reliability testing. For sludge solids concentration instrument ation
(measured as %DS or mg/l) twice daily samples will be collected (AM and PM) throughout the
21-day reliability period for analysis to confirm instrument accuracy. If instrument accuracy falls
outside the accuracy specified by the supplier, then intervention is required to calibrate the
instrument.
Reliability tests may be carried out for individually defined areas of the works, subject to the
agreement of the Project Manager.
Following completion of all other tests, the complete plant shall be operated with all unit
processes installed and linked to each other with only the levels of intervention as specified in
the Operation and Maintenance Manuals. These tests shall not confine themselves to individual
items of plant but shall detail sequences that clearly demonstrate the ability of the whole plant.
During this period, the specified harmonics study shall be undertaken to prove compliance for
the works with Engineering Recommendation G5/4.
The failure of plant to operate correctly shall be deemed a failure of the reliability test.
If additional maintenance or operational input is required, above the levels stated in the
Operation and Maintenance manuals, this shall be deemed a failure of the reliability test.
If the first malfunction of duty plant and equipment brings into use standby plant and equipment
this shall not be deemed a failure. However, a repeat malfunction shall be deemed a failure of
the reliability test.
In the case of a failure of the reliability test, plant shall be fully adjusted or repaired to the
satisfaction of the Project Manager before the test is restarted. On restart the test shall run for
the full test period specified above.
6.6 Optimisation
The Optimisation Period commences from the date of the Take Over certificate and has a term
with a maximum duration of twelve months.
MMB shall work with YWS to optimise the performance of the works. The focus of optimisation
will be highly dependent upon the blend and volume of sludge arriving at the works. Focussed
optimisation effort shall be in the areas of:
• Screening
• Digestion
• Power Generation
• Dewatering
• Cake Handling
An optimised works shall be one that delivers the lowest whole life cost across the full range of
sludge loads and ratios whilst maintaining compliance and providing a safe working
environment at all times.
YWS shall set out in the Optimisation Scope the requirements for the 12 month Optimisation
Period with particular focus on the first three months [month one to three].
By the end of month two of the Optimisation Period YWS sets out their requirements for months
four to six.
By the end of month five of the Optimisation Period YWS sets out their requirements for months
seven to nine.
By the end of month eight of the Optimisation Period YWS sets out their requirements for the
remainder of the term.
The Optimisation Plan shall clearly set out how MMB will address the Optimisation Scope set
out by YWS. The Optimisation Plan shall include as a minimum:
e. measures of success
f. risks
i. a detailed programme
MMB does not proceed with the tasks set out within the Optimisation Plan until it has been
accepted by YWS.
MMB shall fully document each optimisation process they have developed / followed for each of
the key assets in the focus areas. Where necessary MMB shall update / add to the current
version of the Operation & Maintenance Manuals and YWS’s electronic Asset Inventory
Databases to reflect the optimisation work undertaken.
Within 21 days of completion of the works set out within each Optimisation Plan MMB shall
prepare an Optimisation Plan Completion Report. Each Optimisation Plan Completion Report
shall summarise the work undertaken, the findings and also make recommendations regarding
any further opportunities for optimisation of the works.
Digester 1,2,3 Initial commissioning Explosive Atmosphere Mix Nitrogen Purging to reduce
&4 within Digester Head Space methane / explosive mixture
(Mixing of air with methane) levels
Gas Plant, Gas Initial commissioning Explosive Atmosphere Mix Nitrogen Purging to reduce
Holders & within Digester Head Space methane / explosive mixture
pipework (Mixing of air with methane) levels
Digester Temperature - Transfer of Kill digestion Process Minimum & Maximum
1,2,3,4 Sludge from Digester Temperatures to be
3,4,5,6 to Digester 1,2,3,4 maintained & Monitored on
Transfer of sludge & Initial
Commissioning
burner to be available
throughout.
Actual / Expected biogas
pressures and
concentrations to be
monitored throughout
commissioning.
All relief valves and pressure
instruments to be in service
and monitored throughout
the duration of
commissioning.
Digester 1 to 4 Over production of biogas Biogas Emission to air during During biogas production,
/ System Over Pressure commissioning pressure via Gas Commissioning Plan to
relief valves. Accumulation of be consulted, and waste gas
explosive gas’s local to relief burner to be available
valves throughout.
Actual / Expected biogas
pressures and
concentrations to be
monitored throughout
commissioning.
All relief valves and pressure
instruments to be in service
and monitored throughout
the duration of
commissioning.
Digester 1 to 4 Local release of low levels Emissions to air during Monitoring via gas detection
of gas via bleed off valves. commissioning pressure via to be carried out to ensure
relief valves. explosive atmospheres are
Zoned area biogas release not created. Any release to
Accumulation of explosive be confirmed dispersed
gas’s In Zoned areas before continuation of further
bleed off. Any opened valves
should be logged open and
logged closed on completion
of any bleed off / purging
works.
Digester 1 to 4 H2s & Odour created on Emissions of low levels of Digesters shall be
commissioning, released H2S from poor digester commissioned under
via relief venting / commissioning. competent process engineer
commissioning purging. consultation, and in
compliance with fully detailed
process commissioning
RAMS.
During biogas production,
Gas Commissioning Plan to
be consulted, and waste gas
burner to be available
throughout.
Actual / Expected biogas
pressures and
concentrations to be
monitored throughout
commissioning.
On detection of higher than
expected H2s levels,
samples shall be taken, and
adjustment shall be made to
the digester commissioning
process to reduce H2s and
increase biogas production.
All relief valves and pressure
instruments to be in service
and monitored throughout
the duration of
commissioning.
All Gas Plant Nitrogen Purging of air Over pressurisation of plant All works under suitable
Pipework and from pipework / plant and relief of (Non-Toxic / RAMS. Nitrogen Purging to
Gas Holders Non-Explosive) nitrogen to be completed by specialist
atmosphere. Damage to subcontractor. All purge
plant. points confirmed and
recorded closed before
purging of the system.
All relief valves and pressure
instruments to be in service
and monitored throughout
the duration of
commissioning.
All Gas Plant Low quality Biogas / Low Quality Biogas and / or Gas Holder inner bag to be
Pipework and Nitrogen (Mix) Purging on Nitrogen / Biogas (Mix), deflated, minimising nitrogen
Gas Holders start-up of waste gas release to atmosphere within content (after purging) prior
burner waste gas burner area. to biogas filling.
During biogas production,
Gas Commissioning Plan to
be consulted, and waste gas
burner to be available
throughout.
Actual / Expected biogas
pressures and
concentrations to be
monitored throughout
commissioning.
All relief valves and pressure
instruments to be in service
and monitored throughout
the duration of
commissioning.
All Gas Plant Over production of biogas Biogas Emission to air during During biogas production,
Pipework and / System Over Pressure commissioning pressure via Gas Commissioning Plan to
Gas Holders relief valves. Accumulation of be consulted, and waste gas
explosive gas’s local to relief burner to be available
valves throughout.
Actual / Expected biogas
pressures and
concentrations to be
monitored throughout
commissioning.
All relief valves and pressure
instruments to be in service
and monitored throughout
the duration of
commissioning.
All Gas Plant Local release of low levels Emissions to air during Monitoring via gas detection
Pipework and of gas via bleed off valves. commissioning pressure via to be carried out to ensure
Gas Holders relief valves. explosive atmospheres are
Zoned area biogas release not created. Any release to
Accumulation of explosive be confirmed dispersed
gas’s In Zoned areas before continuation of further
bleed off. Any opened valves
should be logged open and
logged closed on completion
of any bleed off / purging
works.
All Gas Plant H2s & Odour created on Emissions of low levels of All gas plant, pipework and
Pipework and commissioning, released H2S from poor digester holders, shall be
Gas Holders via relief venting / commissioning. commissioned under
commissioning purging. competent process engineer
consultation, and in
compliance with fully detailed
process commissioning
RAMS.
All Gas Plant Emissions to water/land Condensate level high / Instrumentation indicating
Pipework and Condensate accumulating overflow high level operation alarms to
Gas Holders in condensate catch pots / telemetry.
drains Drain & Overflow are
considered normal operation
and shall drain to site
drainage pumping station to
the head of the works.
Centrifuge/RL Emissions to water - Over flow of RLPS, on failure RLPS operates as duty
PS Centrifuge Operation – of pumps standby pump arrangement.
centrate return With instrumentation as per
asset standard.
HAZOP Completed, with
risks mitigated during design.
Anti Foam Emissions to land - Anti Spillage to land Bunded bulk storage and
Plant foam dosing secondary containment with
instrumentation as per asset
standard.
HAZOP Completed, with
risks mitigated during design.
Ferric Chloride Emissions to land - Ferric Spillage to land Bunded ‘existing’ bulk
Plant Chloride dosing storage and secondary
containment with
instrumentation as per asset
standard.
HAZOP Completed, with
risks mitigated during design.
Actions are taken forward to section 8 for the development of the specific commissioning
strategies. Any review of this commissioning hazard appraisal is carried out in parallel with a
All test certificates, CE compliance certificates, performance test results, drawings and manuals
shall be amended where necessary, before being submitted for entry into the 'Project Health and
Safety File'.
8 SPECIFIC COMMISSIONING
8.1 General
The commissioning plan is a live document, to be reviewed / updated / modified as necessary
during the construction phase up to Hazard Study 4, by the commissioning team, until such time
that the assets are handed over to the client at Hazard Study 5. Overall responsibility of the
document lies with the Commissioning Engineer.
Commissioning logic is based on the provision of any new assets described in section 5.1 of this
document and in line with the sequencing of construction as detailed in the latest contract
programme.
8.1.1 Commissioning
During the phased commissioning the process of existing digestion shall remain responsibility of
YWS with the isolated assets being handed over in full to MMB, therefore a commissioning
sequence has been developed to indicate the key milestones for the phased changeover of
systems throughout this process.
Constraints
The commissioning sequence has been based on the following constraints:
• MMB shall ensure that the works do not interfere with YWS’s ability to maintain the
existing treatment capacity and site discharge consent and STF permit emission limit
values to air at all times.
• From May to August inclusive, four No. Digesters shall be fully operational at
Operational Treatment Capacity throughout.
• From September to April inclusive, three No. Digesters shall be fully operational at
Throughput Capacity throughout.
• Time risk allowance of two weeks shall be included between re-commissioning any
digester and taking the next digester offline.
• No Digester shall be taken off-line until the required number of remaining Digesters are
Fully Operational i.e. have been re-commissioned and proven to be biologically active
and stable for mesophilic digestion following successful performance testing.
Table 15:
Outline
• NEW Gas Holder 1, Flare Stack, Boilers & Digester Plant Items installed / constructed
offline.
• NEW system shall be brought into service independent of the existing system.
• Both Systems shall run together at various points through the commissioning sequence.
• Digesters 1 & 2 shall be taken offline from the OLD system & refurbished.
• Refurbished, Digesters 1 & 2 shall be transferred onto the new system.
• Digesters 1 & 2 shall be filled/seeded & nitrogen purged .
• Refurbished, Digesters 1 & 2 shall be commissioned & brought into service, supplying
the NEW system.
• The New System shall be commissioned & optimised as required.
• The New system shall complete ‘partial’ reliability using digesters 1 & 2.
NOTE: The project shall always have 4 digesters available throughout the phased construction
and commissioning periods.
• Digesters 2 & 3 shall be taken offline from the OLD system & refurbished leaving
digesters 5 & 6 serving the OLD system.
• OLD Gas Holder 2 shall be taken offline leaving OLD Gas Holder 1 in service.
• OLD Gas Holder 2 shall be decommissioned & removed.
• NEW Gas Holder 2 shall be constructed in place of OLD Gas Holder 2.
• NEW Gas Holder 2 Shall be commissioned and brought into service on the NEW
system.
• Refurbished, Digesters 2 & 3 shall be transferred onto the NEW system.
• Digesters 2 & 3 shall be seeded & nitrogen purged .
• Refurbished, Digesters 2 & 3 shall be commissioned & brought into service, supplying
the NEW system.
• The NEW System shall be commissioned & optimised as required.
• The NEW system shall complete reliability using digesters 2 & 3.
• Digesters 5 & 6 & flare stack shall be decommissioned
• OLD Gas Holder 1 shall be decommissioned & removed.
• CHP’s 1, 2 & 3 shall be transferred onto the NEW system.
• CHP’s 1, 2 & 3 shall be commissioned onto the NEW system and brought into service 1
at a time.
• Full system optimisation shall commence
• Full system reliability shall commence.
Table 16:
• 2 No. Systems working independently will require co-ordination with YWS site
Operations.
• New flare needs 18mbarg pressure at inlet
• Plant will be limited to lower throughput until all digesters connected to NEW system
• VS03-STA-00-ZZ-RP-Z-0375
Phase 1
During this phase only the current system shall be in operation, existing flare, CHPs & boilers.
This phase will continue until construction of the new plant required for Phase 2 has been
completed.
Key
Key
Phase 2
During this phase the current system shall be in operation - existing flare, gas storage, CHPs &
boilers.
The new system will be brought online utilising the new boilers, gas storage and flare.
This phase will continue for approximately a duration of 12 weeks until digesters 1 & 2 are
established on the new system and digester 3 & 4 can be taken offline of the current system.
Key
Key
Phase 3
During this phase new gas holder No.2 is constructed and digesters 3&4 are emptied, cleaned,
structurally inspected and mechanically & electrically refurbished. These are then brought online
onto the new system. This phase lasts approximately 26 weeks. The two systems operate in
parallel during this phase with all plant in operation.
Key
Key
Key
Key
Phase 4
During this phase the CHP’s shall be taken off line from the old system and put onto the new
system. The old boilers shall be decommissioned, and the old flare run in parallel with the new
system to aid old system purging.
This phase will continue for approximately 12 weeks until digesters 5 & 6, the remaining old gas
holder, the old flare & boilers have been decommissioned. (6 of the 12 weeks will facilitate
changing over the CHP)
Key
Key
Key
Key
Phase 5
During this phase the All Old system plant items are out of service and the new system is
running on all plant items. This phase will continue to run throughout its asset life.
Key
Key
8.2 De-commissioning
Any redundant mechanical and electrical equipment shall be removed off site to a licensed
waste disposal centre/recycler or reused as appropriate. The following items of major equipment
will be removed, made safe and identified for recycling, re-use or general waste.
10 TRAINING
Draft O & M manuals will be issued for acceptance prior to training commencing and will form
the basis of information for the training sessions.
Site progress and commissioning meetings will identify, future interfaces with YWS Operations
and training requirements that will be agreed by the core team.
When training is identified YWS will be requested to forward names of the appropriate level of
staff to be in attendance. A training champion may need to be identified by YWS to pass on
information to any non-attendees.
Records of those personnel that have attended training shall be kept and personnel will be
required to comment on the appropriateness and adequacy of training. Any further training
requirements identified by training delegates will be arranged where necessary.
There will/may be a number of sessions of training required to cover all the personnel who will
be involved with the plant, including:
• Operations/Management staff
• M&E Maintenance staff
• CA staff
On completion of training, trainees will be issued with certificates of attendance. A record of the
training attendance will be included as part of the scheme completion documents.
It is envisaged that two training sessions per ‘discipline will be available to accommodate
operator/engineer shift patterns.
A minimum of 4 weeks’ notice will be given for all training sessions with all training notes and
programmes issued at the same time for comment and approval.
The degree of detail and emphasis of the training will be different in all cases and training will be
structured to meet the various needs.
The identified recipients of the training will be given a general overview of the plant together with
instruction on fault diagnosis, alarms and control system interrogation, breakdown maintenance
and routine maintenance. The training will enable a detailed understanding to be gained of how
the process operates and the engineering involved.
The electrical maintenance staff will require a detailed description of the new cabling and a
review of the electrical drawings. “Hands on” identification of site cable routes, switchboards,
distribution boards and their components shall be provided.
Mechanical maintenance staff will require a detailed explanation of the main process elements
with emphasis on mechanical maintenance of their components.
ICA staff will be shown the composition of each control loop/system together with details of all
instrumentation installed. The way in which individual systems interact with each other and their
relationship to the central data acquisition system shall be explained, together with fault finding
and correction techniques.
In each training course a portion of the time will be dedicated to issues of health and safety .
Each training session will last not more than four hours and will be run at least twice, to make
due allowance for availability of YW operations personnel.
The training planned will be developed into the Training Plan and this will be included in the
Appendices.
11 HANDOVER
11.1 Responsibility
The MMB Site Delivery Manager is responsible for hand over/hand back to the Client and a
specific list of requirements is defined.
11.2 Handover
Specific input from the Commissioning Team is required on the following items which must be
completed for handover: -
• All systems functioning in accordance with the control philosophy
• Draft O&M Manuals are available
• Asset Registration completed
• Training is complete, sufficient for handover to proceed
• All critical safety and maintenance equipment is in place and certified
Wherever possible the output of the review should be quantified in terms of time and cost and
be reported to Project and Operational Managers. Lessons learnt from the post commissioning
review will be broadcast and implemented in future specific commissioning plans.
12 ABBREVIATIONS
L/S Litres/Second
PS Particular Specification
RAM Random Access Memory
A. P&IDs
Table 18
Revision Description Date Nam e Signed
S4 P02 VS03-MMB-00-ZZ-DR-P-200 05-04-19 MMB
mottmacbentley.co.uk
J500 | 001 | A | 10 April 2019
https://mottmac.sharepoint.com/teams/pj-b3923/ps-VS03/04/06 Commissioning/VS03-MMB-20-ZZ-DO-Y-0380 STF Commissioning Plan - High Level EA
Submission - Rev B.docx