22 Hull WWTW Sludge Treatment Facility (STF) Commissioning Plan - High Level

R1434 / VS03
22 Hull WwTW Sludge Treatment Facility (STF)

Commissioning Plan - High Level
10 April 2019
R1434 / VS03
Commissioning Plan - High Level
10 April 2019
Mott MacDonald Bentley
Livingstone House
Chadw ick Street
Leeds LS10 1LJ
United Kingdom
T +44 (0)844 848 1090

mottmacbentley.co.uk
R1434 / VS03
J500 001 A
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
Mott MacDonald Bentley Limited is a joint

venture between Mott MacDonald Limited
and JN Bentley Limited. Registered in
England and Wales no: 3827321.
Registered Office: Keighley Road,
Skipton, North Yorkshire BD23 2QR.
Mott MacDonald Bentley | R1434 / VS03
22 Hull WwTW Sludge Treatment Facility (STF) Commissioning Plan - High Level
Issue and Revision Record
Revision Date Originator Checker Approver Description

A 10/04/19 R Scarrott C Glover Tom Batman Initial Draft
B 22/08/19 R Scarrott C Glover C Glover Client Comments Incorporated
Document reference: R1434-VS03-MMB-20-ZZ-DO-Y-0380
Inform ation class: Standard
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.
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Submission - Rev B.docx
Contents
1 COMMISSIONING PLAN STRUCTURE 1

1.1 Commissioning Documentation 1
1.2 Document Control & Revision History 1
1.3 Document Ownership 2
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
3 CONSTRUCTION, COMPLETION AND TESTING 6

3.1 Construction Completion 6
3.2 Testing 7
3.2.1 Factory Acceptance Testing (FAT) 7
3.2.2 Site Acceptance Testing (SAT) 7
3.2.3 PLC Software and Version Control 7
3.2.4 Dry Testing 8
3.2.5 Wet Testing 8
3.2.6 Telemetry Testing 10
3.2.7 Inspection & Testing Reports & Construction Completion Checks 10
3.2.8 Electrical Test Certification (Amtech, EaWR workbook, COMPEX) 10
3.2.9 Functionality Tests 10
3.2.10 Process Performance Tests 10
3.2.11 Aftercare / Maintenance Requirements 10
4 ORGANISATION AND CO-ORDINATION 11

4.1 The Commissioning Team 11
4.2 Core Commissioning Team Members (CCT) 11
4.3 Sub-Contractor Commissioning 11
4.4 Reporting 12
4.5 Core Commissioning Team Responsibilities 12
4.6 Environment Agency Liaison 12
4.7 Service Levels 13
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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
6 DESIGN AND PERFORMANCE 17

6.1 Design Considerations 17
6.2 Design Parameters 18
6.2.1 Site Permit Emission Limits 18
6.2.2 Site Air Quality Objectives and Limit Values Summary 18
6.2.3 Site Environmental Assessment Levels 20
6.2.4 Stack Emission Parameters 20
6.2.5 Site Discharge Consent 21
6.2.6 Sludge Treatment Facility Capacity 21
6.2.7 Imported Sludge Parameters 22
6.2.8 Digested Sludge Dewatering Parameters 23
6.3 Performance Criteria 24
6.4 Performance Tests 24
6.4.1 Digester 24
6.4.2 Sludge Dewatering 25
6.4.3 Cake Rewetting 25
6.4.4 Odour Control 26
6.4.5 System Performance 27
6.4.6 Boiler stacks 27
6.5 Reliability 27
6.6 Optimisation 28
7 COMMISSIONING RISK MANAGEMENT 30

7.1 Identification of Key Commissioning Risks 30
7.2 Health and Safety 34
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
9 TAKEOVER TESTING DEMONSTRATION 53

9.1 Completion Test Criteria 53
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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
J500 | 001 | A | 10 April 2019

Mott MacDonald Bentley | R1434 / VS03 1
1 COMMISSIONING PLAN STRUCTURE
1.1 Commissioning Documentation

The commissioning plan shall be used as the means of planning, managing and recording all
inspections, testing and commissioning activities associated with the contract works and in line
with the requirements of the commissioning and testing report
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: -
1 Commissioning Plan Structure
2 Commissioning Strategy
3 Construction, Completion & Testing
4 Organisation and Co-ordination

5 Commissioning Scope
6 Design and Performance
7 Commissioning Risk management
8 Specific Commissioning
9 Takeover Test Documentation

10 Training
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.
1.2 Document Control & Revision History

The commissioning plan should be revised when any of the following apply.
• Major change required.

• Multiple small changes / amendments.
• Immediately following commissioning hazard appraisals if changes are required.
The nature of the change shall be summarised in the issue table and the issue raised
accordingly.
J500 | 001 | A | 10 April 2019

1.3 Document Ownership

The outline commissioning plan shall be prepared during the design phase and it shall be in
place prior to site implementation. As part of the QES handover process the commissioning plan
will be handed over to the site team and a record of this handover recorded in this document.
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.
J500 | 001 | A | 10 April 2019

2 COMMISSIONING STRATEGY
2.1 Commissioning Strategy

An integrated and planned approach will be adopted for installation and commissioning.
The commissioning of all M&E plant will be carried out in a thorough and logical manner
ensuring that appropriate testing has been undertaken and recorded prior to equipment
becoming operational. All commissioning tests will be recorded and inserted as part of the
appendices of either this document or one of the sub-contractor commissioning plans. Any test
equipment used will have a current calibration certificate, details of which will be recorded on
the appropriate test sheets.
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.
Where there is an element of process commissioning involved in the project, appropriate

communication shall be held with YWS via the Core Commissioning Team (CCT) meetings
and/or directly with the YWS appointed operational staff representative.
It is a fundamental pre-requisite of this commissioning plan that a Process Risk Assessment be
undertaken and agreed with YW Operations prior to any plant / MCC isolations. Further local
discussions will take place prior to and during commissioning as part of the CCT (Core
Commissioning Team) meetings and liaison with YWS operations. A five-week look-ahead
programme will also be available.
A typical commissioning activity flow sheet follows:
J500 | 001 | A | 10 April 2019

Figure 1: Commissioning Activities Flow Chart
J500 | 001 | A | 10 April 2019

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2.2 Commissioning Progress Monitoring

The progress and status of the commissioning will be reviewed and discussed at the Core
Commissioning Team (CCT) meetings. The timing of these meetings will be to suit the
commissioning works being planned or on-going.
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
2. Review of Previous Actions
3. Discussion Items
4. Programme and Progress
5. PMC, Handovers, RAMS, Process Risk Reviews
6. H&S Review
7. YWS Issues / Callouts
8. AOB
A look ahead will also be updated on an ongoing basis.
2.3 EA Permits - U6 Exemption

The critical part of the commissioning is how MMB plan to manage the environmental impact on
site. This starts with the import of seed sludge to seed the digesters.
However due to there being sufficient sludge present on site in this case, a U6 exemption will
not be required.
2.4 Commissioning Programme

MMB will provide a detailed commissioning programme incorporating all plant and equipment
M&E testing and commissioning and all process related commissioning.
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.
2.5 Commissioning Procedures & Method Statements

Each plant area will be the subject of a specific testing and commissioning procedure / RAMS,
as required.
The commissioning procedure / RAMS shall typically include the following information:
• Outline Scope of works
• Detailed commissioning procedure / method of working
• Interfaces with the existing works
J500 | 001 | A | 10 April 2019

• 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.
2.6 Commissioning Hazard Identification and Risk Analysis

Commissioning hazard identification appraisals will be undertaken as part of the review process
for commissioning procedures / method statements.
2.7 Commissioning Constraints

The following constraints must be considered on an ongoing basis:
Sequencing
The commissioning sequence has been based on the following constraints:
• Prior to Commissioning any necessary operational permits and exemptions shall be in

place for the proposed works including, as required, modified environmental permit
(waste) for sludge imports and combustion, EA stack licence, cake disposal and
highway junction permits.
• 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 .
During commissioning, elements of de-commissioning shall take place simultaneously.
J500 | 001 | A | 10 April 2019

Health & Safety
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.
OSS 103 - Work On or Connecting To Live Electrical Systems
OSS 113 - Managing and Using Hazardous Substance
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.
J500 | 001 | A | 10 April 2019

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.
Live Process Plant
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.
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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.
J500 | 001 | A | 10 April 2019

3 CONSTRUCTION, COMPLETION AND

TESTING
3.1 Construction Completion

The Construction Completion Process comprises four phases:
Phase 1: Factory Acceptance Testing

• FAT of selected plant and equipment (Off-site) if required
• PLC software testing (Off-site)
Phase 2: Self Certification
• Visual Inspections (Civils structures, Mechanical, Cabling, Switchgear & MCCs)
Phase 3: Construction Completion Tests
• Pipeline water and / or air test
• Pipework Pressure tests
• Concrete cube results
• Structure / tank water tightness tests
• Installation checks and dry testing of mechanical equipment
• Electrical Installation
• Instrumentation and Control
• All mechanical equipment installations, alignment and guarding requirements
• Confirmation of correct lubrication systems of all equipment
• Checks on serviceability and access to equipment
• Statutory testing of installed lifting equipment and pressure systems (where applicable)
• Plant and equipment lift out demonstrations completed
• Checks on cable duct seals (where applicable)
• Check that all plant signage and safety signs have been installed
• Chemical storage facility inspection by the chemical suppliers (where applicable)
Phase 4: Functionality Testing and Construction Completion Endorsement
• I/O Testing
• Functional testing
• Telemetry testing
• Equipment commissioning sheets
The Works will be constructed in accordance with the Contractor’s Works Information and the
approved construction drawings. Construction completion tests will be carried out in accordance
with the Construction Completion Testing Plan.
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
J500 | 001 | A | 10 April 2019

sheet specification. Electrical and Mechanical equipment installation and testing shall be
recorded using inspection and testing report sheets.
3.2 Testing
3.2.1 Factory Acceptance Testing (FAT)

All deliverable items associated with the project will, at the Project Managers discretion, be
subject to a Factory Acceptance Test (FAT). The aim of the FAT is to prove that the items being
delivered are ‘fit for purpose’ and perform as per the relevant specifications and FDS.
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.
3.2.2 Site Acceptance Testing (SAT)

Once delivered to site and installed, all deliverable items will be subject to a Site Acceptance
Test (SAT), irrespective of whether they had a corresponding FAT. The software Site
Acceptance Tests (SAT) shall be a repeat of the FAT functionality testing but will be undertaken,
as far as possible, using actual plant operation sequences and interlocks, and shall include any
tests that could not be properly performed during the FAT tests. As with the FAT, MMB will be
responsible for producing the SAT document which must be approved by MMB.
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.
3.2.3 PLC Software and Version Control

The FAT/SAT for the PLC software is to demonstrate the sequence, functionality and interface
of the PLC software. The level of testing at the FAT will be at the discretion of the Project
J500 | 001 | A | 10 April 2019

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.
3.2.4 Dry Testing

A series of functional tests will be undertaken as part of the commissioning procedure. The first
of these tests will be the dry tests whereby the Commissioning Engineers shall undertake initial
tests of the equipment prior to undertaking “Wet” testing and Site Acceptance Testing. Typical
tests would include:
• Installation checks (against P&IDs and GA drawings)
• Wiring checks
• Rotation checks
• Safety system checks (E Stops, overload setting, interlocks)
• Instrument set up (Loop checks, ranges, analogue range testing, parameter recording)
• Valve / actuators set up (stroking, limits, position feedback)
• MCC – Plant status indications, I/O checks, Alarm indications
• LOI/SCADA – Plant status indications, I/O checks, Alarm indications
• Telemetry testing
• PLC and SCADA Comms testing
(The above list is indicative only and not exhaustive).
During dry testing, care should be taken to ensure that all construc tion debris is removed prior
to progression to wet testing.
3.2.5 Wet Testing

Wet testing will be undertaken by MMB to verify correct operation of all plant and equipment.
Wet testing will be carried out in accordance with an approved test schedule and approved test
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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:
• Manual mode operation

• Automatic mode operation
• Fault/failure shut down of main elements of the plant including PLC failure
• Simulation of power failure with all systems in normal operation, and subsequent restart
in auto mode (to demonstrate equipment re-start/availability, alarms and resets
required).
Wet Testing of control systems shall include but not be limited to the items noted
below:
• Demonstration of Manual control facilities

• The performance of instruments and their calibration throughout their operating range
• Check that all level monitoring and probes are installed at the correct levels. Correct
operation of the level control system shall be demonstrated throughout its proposed
operating range
• Operation of all pumps, inverters and instruments associated with each sub-system
shall be proved to conform to the Functional Design Specification
• All alarms and trips shall be tested by operation of the primary initiating device
• Demonstration of interlocking systems shall be by simulating each condition and
checking the correct operation of each circuit
• Verification that the plant control system operates correctly and provides the correct
information on operator’s display equipment
• Verification of LOI/SCADA and telemetry alarms and status signals in accordance with
the Specification
Demonstration of fully automatic operation of all equipment associated with the works
Demonstration of failure modes (inconsistent conditions, fail safe shutdown, etc.) and plant
recovery (re-sets, auto re-start, etc) in accordance with the FDS to include site power failure,
individual drive failures and instrument failures
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3.2.6 Telemetry Testing

A full Telemetry list will be provided with an associated check/tick box to prove that each
Telemetry I/O point has been tested and proven from source through to ROCC in accordance
with YWS Engineering Specification guideline documents. This includes both hardware and
software derived alarms.
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.
3.2.7 Inspection & Testing Reports & Construction Completion Checks

Throughout the construction phase and throughout commissioning phase, Inspection & Testing
Report sheets (ITR’s) and Construction Completion checks shall be completed recording all test
results, operational parameters and settings. These sheets shall be referred to in operational
training and form part of the O&M on final completion / handover.
3.2.8 Electrical Test Certification (Amtech, EaWR workbook, COMPEX)

All electrical test results shall be recorded and submitted to the Main Contractor’s
commissioning team on completion of the electrical works and prior to energisation.
These test results shall be recorded in form of the YWS EaWR Workbook which shall form part
of the Inspection and Testing Report Section of the O&M.
3.2.9 Functionality Tests

Functional Testing shall be carried out and results recorded within the ITR’s, functional tests
shall be carried out throughout commissioning and energisation of plant.
3.2.10 Process Performance Tests

For Process performance test criteria see section 6 of this document .
3.2.11 Aftercare / Maintenance Requirements

During commissioning ongoing maintenance shall be carried out and recorded as per the
manufacturer’s instructions. Maintenance files and schedules shall form part of the final
completion documentation and O&M.
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4 ORGANISATION AND CO-ORDINATION
4.1 The Commissioning Team

All commissioning activities to be co-ordinated by the commissioning team, this includes
commissioning engineers and commissioning management with the support of members of the
CCT.
4.2 Core Commissioning Team Members (CCT)

The Core Commissioning Team (CCT) for the project will be selected from the following list and
identified below: -
Table 1: Commissioning Team

Role Nam e Contact No.
YWS Project Manager Maggie Whiteford
YWS Network Asset Engineer
YWS Site Operative Roger Blount 07790 616 995
YWS Solutions Engineer Gary Black 07791 817 073
YWS Environmental Lead Advisor Adele Burns 07790 616 733
YW’s Senior Compliance Analyst - TBC TBC
Sludge
MMB Operations Manager Chris Wilcock 07896 445 899
MMB Design Manager Paul Luxton 07974 813 878
MMB Project Leader Rebecca Dresser 0783 560 5524
MMB Process Engineer Peter Stott 0113 212 2435
MMB MEP Lead Design Engineer Tom Batman 07985 363 592
MMB M&E Design Engineer Hagen Stewart 0757 627 5013
MMB Contracts Manager Andrew Tindall 07792 249 410
MMB MEP Lead Commissioning Roy Scarrott 07805 594 170
Engineer
MMB MEP Commissioning TBC
Engineer
MMB Site Delivery Manager Zak Moore 07498 502 038
4.3 Sub-Contractor Commissioning

Representatives from each of the sub-contractors will carry out commissioning activities
associated with their equipment supplied. All commissioning works will be the responsibility of
the sub-contractor under the supervision of the commissioning engineer and with the CCT
review and approve commissioning documentation prior to any site commissioning activities.
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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.
4.5 Core Commissioning Team Responsibilities

The Commissioning Team will be responsible for the following activities: -
• Attendance & Contribution with Process Safety Stages 3,4,5 & 6

• Attendance at QES3b project handover.
• Development of the Commissioning Plan, Programme and ITR’s
• Agreement of the Service Levels required between YWS Operations and YWS Project
Manager
• Agreement of the requirements for Performance Testing
• Identification of the interfaces between individual contractors and the client
• Provide site-based information for the Operating and Maintenance manual requirements
• Input to the development of training plans and facilitate client training
• Hazard identification of risk and safety issues during commissioning completion
requirements for hand over
4.6 Environment Agency Liaison

YW’s Lead Environmental Advisor shall be responsible for communication with the EA during
the pre-application and permit determination phase of the project. This includes providing the
EA (National Permitting Service) with this commissioning plan as part of the permit application.
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.
MMB’s Lead Commissioning Engineer is responsible for accompanying local EA Environment

Officers and the site TCM during any site audits during commissioning.
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4.7 Service Levels

Proposed service levels are as follows:
Table 2: Project Criteria
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
Flow Requirements Specific consent requirements for water quality are as
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
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5 COMMISSIONING SCOPE
5.1 Brief Description of the Project

Hull Wastewater Treatment Plant (WwTW) comprises the Sewage Treatment Works (STW)
which treats wastewater arising from the Hull catchment and the Sludge Treatment Facility
(STF). Indigenous primary and secondary sludge produced in the STW is thickened and
digested along with liquid sludge and cake imported from the surrounding region.
This project shall provide improvements to Hull STW and STF.
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.
Areas to be Improved are:
• Wastewater Inlet Works - (Under Separate Commissioning Plan)

• Anaerobic Digestion Facility Refurbishment,
• Liquid Sludge Import Facility,
• Sludge Cake Import Facility,
• Digested Sludge Dewatering and Lime Sanitisation,
• Optimisation of the new STF Works
5.2 Key Items to be commissioned

Due to the nature of this project and the depth of detail required around each phase we will
produce four separate commissioning plans to cover the different stages required to complete
commissioning
These commissioning plans shall be split by area’s follows:
• Digester Plant Area
• Gas System
• Sludge Import & Screening Plant
• Import & Dewatering Plant
Key items that shall be commissioned under these improvements shall be:
• Anaerobic Digestion Facility
- Digester Feed System
- Digesters & Mixing Pumps
- Biogas Holders
- Excess Biogas Flare
- Biogas Boosters
- Dual Fuel Hot Water Boilers
- Digesting Sludge Recirculation System (including the sludge pumps)
• Liquid Sludge Import Facility,
• Sludge Cake Import Facility,
• Digested Sludge Dewatering and Lime Sanitisation,
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5.3 Supporting Plant and Equipment

To enable the above equipment to be commissioned it is required to provide the following
services and temporary works……….
• GTS Sludge Screening & Sludge Transfer Systems

(Installed in parallel – For transfer of digester 4 & 3 sludge to digester’s 2 & 1)
• GTS Nitrogen – Nitrogen Purging
• Tanker – Standby Requirement During Sludge Transfer
• Sludge Sampling/Verification – Requirement During Sludge Transfer
• Gas Sampling – Instrumentation Commissioning & Verification Post Sludge Transfer
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:
Interfaces shall include but shall not be limited to:
• Existing Lamella De-Sludge System

o Existing Sludge Pumps shall deliver sludge into the new screened sludge
pumping station.
• Existing Sludge Storage Tanks

o New Screened Sludge Pumping Station shall transfer screened sludge received
from both screened sludge holding tank and lamella de-sludge pumps to the
Existing Sludge Storage Tank.
o Sludge Storage Tanks shall remain in service on completion of the project
serving the 4 no. newly refurbished digesters.
• Existing Ferric Chloride Dosing System & Chemical Storage Tanks

o Chemical deliveries shall continue as per YWS procedures however frequency
of deliveries will increase due to additional dosing points being introduced into
the digester sludge feed pipework.
• Existing Sludge Thickeners Polymer Dosing & GBT’s

o Existing Sludge Thickener plant shall not directly interface with new and
refurbished plant items however running of the plant is key to the start-up and
commissioning of the newly refurbished digester systems.
• Existing Thickened Sludge Storage Tanks

o Sludge from the Existing Thickened Sludge Storage Tanks shall feed the
digesters on both old and new systems during the commissioning phase, up
until final changeover of the system from old to new.
• Existing Digesters & Biogas Systems

o Existing digester and STF plant shall work simultaneously with the new system
and shall interface on sludge draw off from the thickened sludge storage tanks
via the digester feed pumps from both systems.
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• Existing Natural Gas Incoming Supply

o Usage should not increase however flow requirements should be monitored
during commissioning on natural gas.
o Running/Commissioning of plant shall be co-ordinated as such to avoid draw off
from the natural gas supply at the same time to avoid effects of pressure loss in
the supply pipework.
• Existing Gas Boosters, Scrubber plant & CHP’s

o Existing Gas Boosters, Scrubber plant & CHP’s should not directly interface
with the new plant until CHP’s are transferred onto the new system, however,
shall be operated with the existing digester plant by YWS during commissioning
and form part of the plant removed on decommissioning.
• Existing Site Odour Control Systems

o New plant shall be connected onto and utilise the existing OCU plants spare
capacity, mechanical commissioning of dampers shall take place on this system
only.
• Existing Site Water Services.

o Final Effluent – Interfaces as per System Design
o Potable Water – Interfaces as per System Design
• Existing Site Drainage
• Existing Return Liquor Pumping Station
• Site Telemetry System

o The site telemetry system during commissioning will have both new and old
telemetry signals/alarms until final decommissioning of the old digester plant,
when the old signals/alarms shall be removed.
o New alarms shall be handled in ‘contractors’ group’ until final changeover of
systems.
• Site SCADA System

o The SCADA system during commissioning will have both new and old system
pages remaining until final decommissioning of the old digester plant, when the
old pages shall be removed
• Site wide fibre networks

o The site wide fibre ring will be extended to the new MCC fibre patch panel
within the new MCC ICA.
• Site Wide Fire & Security Systems
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6 DESIGN AND PERFORMANCE
6.1 Design Considerations

Specifications used to design this project are stated in the in the Contractor’s Works
Information. The following documents are relevant to this scheme:
• Digester Asset Standard Version 12

• Sludge Treatment Facility Asset Standard Version 11
• Conditioning Asset Standard Version 1
• Screens & Screenings Handling Version 5
• Pumping Sewage Asset Standard Version 5
• Control & Automation AS Version 4
• Liquor Balancing Version 1
• Odour Abatement Asset Standard Version 2
• Lime Amendment Asset Standard Version 1
• Wastewater Polymer Version 9
• Thickening and Dewatering Asset Standard Version 3
• Decking Asset Standard Version 4
• Roads Pathways and Landscaping Version 2
• Civil Engineering Specification for the Water Industry with YW amendments (The
Engineering Specification Rev 17)
• Procedure for Temporary Pumping and Flow Restriction Activities v2 (Oct 2010)
• Pollution Procedure for Capital Contract Partners (April 2004)
• Regulation 31 Section of Policies, Procedures, and Regulatory Data
• WIMES 1.07: Ram Pump Units
• WIMES 2.01: Rotating Half-Bridge Scrapers
• WIMES 3.01: Low Voltage Switchgear and Control Gear Assemblies for Use in The Water
Industry
• WIMES 3.02: Low Voltage Electrical Installations
• WIMES 3.03: Low Voltage AC Electric Motors for Use in The Water Industry
• WIMES 3.05: Components for LV assemblies
• WIMES 4.01: Paints and polymeric coatings for corrosion protection
• WIMES 8.03: Mechanical Installation
• WIMES 8.04: Mechanical Installation
• Asset Standard Generic Automation and Control for Digestion, Biogas Handling and
Combined Heat & Power System
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6.2 Design Parameters
6.2.1 Site Permit Emission Limits
The New permit emission limits of the site are detailed below: in Table 3.
Table 3 - Hull STW Site Permit Emission Limits
Site Emission Limits Emission Relevant Legislation/Guidance

Component Compliance Limit Values
Date (mg/m3)(a)
CHP Before 1 NOx = 500 Existing permit
January 2030 SO2 = 350
H2S = 5 The Environmental Permitting
CO = 1400 (England and Wales) (Amendment)
NMVOCs = Regulations 2013, SI 2013/390
75
After 1 January NOx = 190 This date and emission limits are
2030 (b) for tranche A specified generators
SO2 = 60 (b) between 1 and 5 MWth input in
accordance with the Environmental
Permitting (England and Wales)
(Amendment) Regulations 2018
No.110
New boilers From date of NOx = 200 The Environmental Permitting
first operation SO2 = 100 (England and Wales) (Amendment)
Regulations 2018 No.110
New flaring From date of NOx = 150 LFTGN 05 (Guidance for
stacks (not first operation CO = 50 monitoring enclosed landfill gas
classified VOCs = 10 flares)
as an MCP)
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
6.2.2 Site Air Quality Objectives and Limit Values Summary
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
Pollutant Averaging period Objective / limit Allowance

value (µg/m³)
For the protection of human health
Nitrogen dioxide 1-hour 200 18 times pcy
(NO2) Annual 40 –
Sulphur dioxide 15-minute 266 35 times pcy
(SO2) 1-hour 350 24 times pcy
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Pollutant Averaging period Objective / limit Allowance

value (µg/m³)
24-hour 125 3 times pcy
Carbon monoxide 8-hour 10,000 -
(CO)
Benzene (C6H6) Annual 5 -
For the protection of vegetation and ecosystems
Nitrogen oxides Annual 30 –
(NOX) Daily 75 –
Sulphur dioxide Annual 20 –
(SO2)
Notes: pcy = per calendar year
Table 5 - Locations where air quality objectives apply
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.
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6.2.3 Site Environmental Assessment Levels
The New Site environmental assessment levels for the site are detailed below: in Table 6.
Table 6 - Summary of relevant Environmental Assessment Levels (EAL)
Pollutant Averaging period EAL (µg/m³)

Carbon Monoxide 1-hour 30,000
(CO)
VOCs (as benzene) 1-hour 195
6.2.4 Stack Emission Parameters
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
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Notes: *Normalised conditions = 3% O2, 0oC, 1 atm, dry air

(a) A stack height of 14m has been chosen based on the findings from the stack
height determination, presented in Appendix B.
(b) Physical flare height is 16m AoD + height increase due to net heat release.
(c) Physical flare diameter is 2.6m at release. Effective diameter is 2.46m based on
exit parameters
(d) @ 9.2% O2, 16% H2O
(e) @ 3% O2, 15.5% H2O
(f) @ 3% O2, 12.5% H2O
(g) CO and VOC emissions from the new boiler are expected to be less than this
but emission limits from the existing permit for the CHPs used as a worst-case
6.2.5 Site Discharge Consent
The existing discharge consent of the site is detailed below: in Table 7.

Table 7- Hull STW discharge consent
Parameter Units Existing Consent
Consented dry weather flow (DWF) m3/day 91,620
Consent flow to full treatment (FFT) m3/day 172,800
Biochemical oxygen demand (BOD), 95%ile mg/l 25 or 70% reduction
Chemical oxygen demand (COD), 95%ile mg/l 125 or 75% reduction
All discharge consents will remain unchanged under this scheme.

MMB shall agree the phasing of the works with the Project Manager to minimise the risk to
compliance during construction and commissioning. MMB shall not undertake any activities
which will compromise the compliance of the STW. MMB shall not be responsible for the
implications of any activities undertaken, or the failure to undertake necessary maintenance or
similar activities, by YWS which affect the performance of the STW.
All sampling and monitoring required for the consent shall be maintained throughout the works.
6.2.6 Sludge Treatment Facility Capacity
The following STF design data shall be used for the following sections:
Liquid sludge imports,
Sludge cake imports,
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Digester refurbishment,
Dewatering and lime sanitisation facility.
Hull STF is defined as a Yorkshire Water regional sludge treatment facility and is designed for
the capacity provided in Table 8.
Table 8 – STF Capacity
Annual Capacity Daily Capacity
Operational treatment Capacity 19,300tDS/a 53tDS/d
Throughput Capacity 28,141tDS/a 77.1tDS/d
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:
Existing digester vessels sized at 4,282m3 each
Digester retention time of 12 days
Digester feed solids concentration of 6% w/w DS
Maximum digester active volume of 90%
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;
Digester retention time of 16 days
Digester feed solids concentration of 5.5% w/w DS
6.2.7 Imported Sludge Parameters
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:
Maximum indigenous sludge and minimum imported sludge
Minimum indigenous sludge and maximum imported sludge
Table 9 - Imported Sludge Design Point Concentrations
Parameter Min Typical Max Units
SAS 0.45 0.6 1.0 % DS
Co-settled Primary sludge 2.2 3.0 6.0 % DS
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Imported un-thickened sludge 2.0 3.0 6.0 % DS
Imported thickened sludge 3.2 5.5 8.0 % DS
Imported cake 18 25 30 % DS
Table 10 – Imported Sludge Ratios
Primary % Secondary/Humus %
Sludge Type
Min Max Min Max
Primary Settled Sludge N/A 100% 0% 0%
Co-settled Humus Sludge 50% 80% 20% 50%
Co-settled or mixed 40% 60% 40% 60%

Secondary Activated Sludge
Secondary Activated Sludge 0% 0% N/A 100%
Table 11 – Solids load variations
Load %
Sludge Type Comment
Min Max
Primary Settled Sludge 0% 50%
Co-settled Humus Sludge 0% 60%

Of the total imported daily
Co-settled or mixed Secondary 0% 100% load on any one day
Activated Sludge
Secondary Activated Sludge 0% 20%
6.2.8 Digested Sludge Dewatering Parameters
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.
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The dewatering facility shall be capable of achieving a turndown of at least 50% Throughput
Capacity.
6.3 Performance Criteria

The performance of any existing plant shall not be impaired by testing.
For each test where sampling is required, three No. samples shall be collected. One sample will
be provided to YWS, one will be held by MMB as a back-up sample and the third will be tested
by MMB.
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 Performance Tests
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
• Less than 5% by-pass

• Dispersion of the feed throughput the tank to 10% or less of theoretical mean
concentration within 120 minutes
Not achieving these conditions shall not be considered a failure of the performance tests
provided that the ancillary equipment is functioning correctly.
Mixing testing shall be carried out using:

• Lithium chloride tracer testing to demonstrate the active digester volume, the blend time
and by-pass rate. A suitable location for feeding lithium chloride into feed sludge for the
purposes of tracer testing shall be provided.
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Tracer testing shall be carried out and interpreted by a suitably competent person.
6.4.2 Sludge Dewatering

The following parameters shall be tested based on sludge feed characteristics listed in Table
12.
• Digested sludge feed dry solids
• Dewatered sludge cake dry solids
• De-waterer sludge feed flow rate

• De-waterer polymer usage
• Centrate quality (mg/l suspended solids)

• Lime dose rate
Table 12 - Sludge feed parameters for performance testing
Parameter Average Max units
Digested Sludge Production 27.1 51.1 tDS/day
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.
6.4.3 Cake Rewetting

The Cake re-wetting system shall be tested over a 14-day period. Tests will be carried out daily
on a single cake delivery over a 1-hour period where imported cake is available. All solids
monitors shall be calibrated as per the O&M manuals.
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.
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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.
6.4.4 Odour Control

The Asset Standard shall be referenced for odour control testing requirements.
Inlet Works OCU
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.
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• 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.
6.4.5 System Performance

Performance testing shall be performed during the STW peak season (June to August
inclusive). It would be acceptable to conduct this test during the Optimisation Period, i.e. after
Section Completion if necessary.
6.4.6 Boiler stacks

The performance requirements for the hot water boilers are as stated in Table13 for both biogas
and natural gas operation.
Table 13 – Boiler Stack Emission Limits
Parameter Boiler (3% O2) Units
NOx 200 mg/Nm3
SO2 100 mg/Nm3
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.
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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:
• Liquid and Cake Imports
• 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.
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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:
a. the task to be undertaken by MMB

b. impacts / interfaces with the existing process / design
c. items to be provided by YWS
d. any testing / certification requirements
e. measures of success
f. risks
g. resources – [plant, labour, materials]

h. the defined cost
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.
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7 COMMISSIONING RISK MANAGEMENT
7.1 Identification of Key Commissioning Risks

Below is a summary of the main activities that result in risk to complete commissioning:
<NB: The information w ould be provided from Hazard Study 1-3 and for complex projects, a schedule of
commissioning risks may provide more detail in a supporting document e.g. PMC>
Table 14: Key Commissioning Risks

Item of plant Com m issioning Possible Consequences Action to be taken
Activity / Interruption
Digester Feed Initial Digester feed to Explosive Atmosphere Mix Nitrogen Purging to reduce
pumps Digesters 1 & 2 from 3 & 4 within Digester Head Space methane / explosive mixture
(Mixing of air with methane) levels
Digester Initial Transfer of Sludge Explosive Atmosphere Mix Nitrogen Purging to reduce
transfer pumps from Digester 3,4,5,6 to within Digester Head Space methane / explosive mixture
(temp works) Digester 1,2,3,4 (Air from displacement) levels
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
Table 14a: Environmental Risks During Commissioning

Digester 1 to 4 Nitrogen Purging of air Over pressurisation of plant All works under suitable
from pipework / plant and relief of (Non-Toxic / RAMS. Nitrogen Purging to
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.
Air within Digester to be
released via relief valves
during purging of the
digester.
All relief valves and pressure
instruments to be in service
and monitored throughout
the duration of purging /
commissioning.
Digester 1 to 4 Low quality Biogas / Low Quality Biogas and / or Nitrogen within Digester to
Nitrogen (Mix) Purging on Nitrogen / Biogas (Mix), be released via relief valves
start-up of waste gas release to atmosphere within during filling /seeding of the
burner waste gas burner area. digester, minimising nitrogen
content (after purging) prior
to biogas production.
During biogas production,
Gas Commissioning Plan to
be consulted, and waste gas
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burner to be available
throughout.
Actual / Expected biogas
pressures and
concentrations to be
monitored throughout
commissioning.
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.
pressures and
commissioning.
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.
throughout.
pressures and
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.
the duration of
commissioning.
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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.
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.
throughout.
pressures and
commissioning.
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.
pressures and
commissioning.
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.
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throughout.
pressures and
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.
the duration of
commissioning.
Digester 1 to 4 Transfer pumping of Failure of temporary Task to be completed by
sludge from and to pipework, discharge of specialist subcontractor,
digesters. sludge around digesters. under task specific RAMS.
Spill kits shall be provided
throughout the process
duration.
Double isolation valves shall
be installed on temporary
transfer pipework.
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.
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.
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
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review of the strategy and procedures outlined in section 5.
7.2 Health and Safety

• The Principal Contractor shall prepare a Construction Management Plan prior to the
commencement of works. The QES summary includes potential hazards to be
encountered in commissioning activities.
• YWS and HSE guidance notes and code of practices (COP) are to be followed.
• Safe handling of materials under the COSHH Regulations shall be applied.
• CDM Regulations will apply during all phases
• Any process testing should be conducted in an approved safe manner.
Any lifting gear including chains, shackles and davit sockets shall be 'proof load' tested in
accordance with lifting regulations prior to being used either during or after commissioning.
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'.
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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:
• Prior to Commissioning any necessary operational permits and exemptions shall be in

place for the proposed work s including, as required, modified environmental permit
(waste) for sludge imports and combustion, EA stack licence, cake disposal and
highway junction permits.
• 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.
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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.
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• 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.
Gas Handling for Commissioning.
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
8.1.2 Commissioning Sequence

Emissions Data
For Emissions data please refer to Hull STF Dispersion Modelling Report:
• VS03-STA-00-ZZ-RP-Z-0375
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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.
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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
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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.
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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
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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
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Key
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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.
8.3 Sub-Contractor Commissioning

For Specific Process Area Subcontractor Commissioning Activities, Subcontractor
commissioning documentation shall be used.
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9 TAKEOVER TESTING DEMONSTRATION
9.1 Completion Test Criteria

Table 17 includes agreed test documents to meet the client’s completion criteria.
Table 17
Nam e of Test Test Method / Conditions Pass criteria

Telemetry End to Activate monitoring signals. Ensure signals are received at the ROCC.
End Testing
EaWR Electrical testing Ensure all electrical testing results are within acceptable
Workbook criteria
Pressure As per Eng Spec section 1, As per Eng Spec section 1, section 7.9
pipework section 7.9
pressure testing
Gravity pipework As per Eng Spec section 1, As per Eng Spec section 1, section 7.6
air testing section 7.6
General CCTCs Various – refer to appendix O Various – refer to appendix O
Performance Various See Section 6.2
Testing
Reliability Various See Section 6.4
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10 TRAINING
10.1 Training Philosophy

Appropriate detailed training will be given to ensure that YWS’s personnel are fully conversant
with the new plant for the purposes of safe operation, fault finding, maintenance, repair and
overhaul.
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.
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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.
10.2 Training Scope

As a minimum, personnel shall be trained in the following aspects of plant operation, care and
maintenance.
• Process Safety Awareness.

• H&S (CoSHH, Required PPE as appropriate).
• Site location.
• Overview of works undertaken
• Plant control functions
• Plant monitoring and action on alarms
• Operation of safety systems
• Operation of set-point adjustment and controls
• Fault or failure shutdown of main elements of plant whilst in automatic mode
• Restarting of plant following shutdown
• Operational function from SCADA/LOI’s
• Access to, and removal (as necessary) of equipment
• Routine maintenance tasks
• Lifting arrangements
10.2.1 Training Documentation

• Training Plan
• DVD/ Documentation
• Training certificate
• Operation & Maintenance schedule.
• Training Manual / Handouts
• Telemetry Mimics
• P&IDs
• Maintenance schedules
• Training attendance sign off sheet
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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
11.3 Post Hand over Support

The Commissioning Team will consider the need for post hand over support and list those areas
where they consider the Operational Team will need assistance or where there are outstanding
tests to be completed.
11.4 Post Commissioning Review

The Commissioning Team will carry out a Post Commissioning Review in terms of the
commissioning management, planning and physical commissioning processes as applied to the
project.
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.
J500 | 001 | A | 10 April 2019

12 ABBREVIATIONS
The following abbreviations have been used throughout this document.

CFAT Client’s Factory Acceptance Test
DOL Direct Online

E2E End to (2) End Testing
FAT Factory Acceptance Tests
FDS Functional Design Specification

H-O-A Hand-Off-Automatic
I/O Input / Output

ITR’s Inspection and Test Report’s
LOI Local Operator Interface
L/S Litres/Second
MCC Motor Control Centre

O&M Operator and Maintenance
P&ID Process and Instrument Drawings
PID Proportional Integral and Derivative
PLC Programmable Logic Controller
PS Particular Specification
RAM Random Access Memory
ROCC Regional Operation Control Centre
RTS Regional Telemetry System
SAT Site Acceptance Test
SCADA Supervisory Control and Data Acquisition

TCM Thousand Cubic Metres
TCMD Thousand Cubic Metres/Day
UPS UN-interruptible Power Supply
URS User Requirement Specification
YWS Yorkshire Water Services
J500 | 001 | A | 10 April 2019

A. P&IDs
Table 18
Revision Description Date Nam e Signed
S4 P02 VS03-MMB-00-ZZ-DR-P-200 05-04-19 MMB
J500 | 001 | A | 10 April 2019

J500 | 001 | A | 10 April 2019

mottmacbentley.co.uk
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Issue and Revision Record

Revision Date Originator Checker Approver Description

Document reference: R1434-VS03-MMB-20-ZZ-DO-Y-0380

Inform ation class: Standard

J500 | 001 | A | 10 April 2019

1 COMMISSIONING PLAN STRUCTURE 1

3 CONSTRUCTION, COMPLETION AND TESTING 6

4 ORGANISATION AND CO-ORDINATION 11

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6 DESIGN AND PERFORMANCE 17

7 COMMISSIONING RISK MANAGEMENT 30

9 TAKEOVER TESTING DEMONSTRATION 53

J500 | 001 | A | 10 April 2019

J500 | 001 | A | 10 April 2019

1 COMMISSIONING PLAN STRUCTURE

1.1 Commissioning Documentation

1 Commissioning Plan Structure

3 Construction, Completion & Testing

4 Organisation and Co-ordination

6 Design and Performance

7 Commissioning Risk management

9 Takeover Test Documentation

1.2 Document Control & Revision History

• Major change required.

J500 | 001 | A | 10 April 2019

1.3 Document Ownership

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2.1 Commissioning Strategy

Where there is an element of process commissioning involved in the project, appropriate

J500 | 001 | A | 10 April 2019

Figure 1: Commissioning Activities Flow Chart

J500 | 001 | A | 10 April 2019

2.2 Commissioning Progress Monitoring

2. Review of Previous Actions

4. Programme and Progress

5. PMC, Handovers, RAMS, Process Risk Reviews

A look ahead will also be updated on an ongoing basis.

2.3 EA Permits - U6 Exemption

2.4 Commissioning Programme

2.5 Commissioning Procedures & Method Statements

J500 | 001 | A | 10 April 2019

2.6 Commissioning Hazard Identification and Risk Analysis

2.7 Commissioning Constraints

The commissioning sequence has been based on the following constraints:

• Prior to Commissioning any necessary operational permits and exemptions shall be in

During commissioning, elements of de-commissioning shall take place simultaneously.

J500 | 001 | A | 10 April 2019

Health & Safety

OSS 103 - Work On or Connecting To Live Electrical Systems

OSS 113 - Managing and Using Hazardous Substance

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Live Process Plant

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J500 | 001 | A | 10 April 2019

3 CONSTRUCTION, COMPLETION AND

3.1 Construction Completion

Phase 1: Factory Acceptance Testing

J500 | 001 | A | 10 April 2019