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Standard Procedure for the Commissioning of Plant/Mine 1
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REVISIONS
Rev’n App App App App App App App Issue Date
Rev Description
by Sud PC Thom VB LH Clyd Act YYYY/MM/DD

1 st
1 Issue RM PC Pending Pending Pending Pending Pending Pending 2013/06/21
2013/03/18 2013/03/19

Sud = Sudbury, Ontario, PC = Port Colborne, Thom = Thompson, Manitoba, VB = Voisey’s Bay, LH = Long Harbour, Act = Acton, England,
Clyd = Clydach, Wales, N/A = Not Applicable
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Standard Procedure for the Commissioning of Plant/Mine 1
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1.0 PURPOSE

This procedure describes the methodology and prerequisites for the basic commissioning
requirements of control systems and control system field devices.

2.0 APPLICATION

This procedure is applicable to Vale Ontario Division plants and mines.

3.0 REFERENCE DOCUMENTATION

The following documents were used in the development of this document or are related to it.
They shall be used in their most recent revision.

3.1 INTERNATIONAL STANDARDS

IEC 62337 Commissioning of electrical, instrumentation and control systems in the


process industry – Specific phases and milestones
ISA 105 Commissioning, Loop Checks, and Factory Acceptance/Integration
Tests for Industrial Automation Systems
ISA 62381 Automation Systems in the Process Industry – Factory Acceptance Test
(FAT), Site Acceptance Test (SAT) and Site Integration Test (SIT)
ISA 62382 Automation Systems in the Process Industry – Electrical and
Instrumentation Loop Check

3.2 VALE ENGINEERING STANDARDS (ONTARIO/UK)

SPEC-84002 Foundation Fieldbus Specification


SPEC-84006 Patch Management
SPEC-84007 Anti-Virus Management
SPEC-84008 Back-up and Recovery Management
PROC-a84009 Loop Check Sheet (excel spreadsheet)
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3.3 VALE GLOBAL STANDARDS

GU-E-622E Support Activities for Preparation of Commissioning Plan


GU-E-623E Commissioning Package Definition Activities
GU-E-624E Technical Support for Commissioning Executive Plan Detailing
GU-E-476E Process Reliability Simulation Modeling (VIP)

3.4 OTHER VALE STANDARDS

PUG -1 PI Users Group (PUG) - PI Tag Template (IT Sharepoint)


PUG-2 PI Users Group (PUG) – PI Tag Naming Convention (IT Sharepoint)

4.0 PROCESS CONTROL SYSTEM COMMISSIONING

This document refers only to the commissioning of the process control system within a facility
including the Process Control Network (PCN) and field communications. It does not include the non-
real-time networks including maintenance systems, plant historian, or connections to the plant
enterprise network.
It should be noted that the creation of Plant Historian tags is required as part of this specification.
The keys to successful commissioning begin at the start of the project and include:
 Developing accurate User Requirements, Design and Functional Specifications
 Writing and executing robust tests based on the design
 Managing change using the appropriate controls and procedures
 Completing the turnover to the End User in a manner that satisfies the contractual, code, and
regulatory requirements.
This document and associated references aim to achieve these objectives.
The IEC standards have divided the commissioning process into 6 phases as follows:

Phase Completion Milestone Milestone Definition

1. Construction Completion of erection Facility building structures


completed prior to installation of
(Start of Project)
mechanical systems.
Completion of erection
concludes the construction
phase.
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2. Precommissioning Mechanical completion Mechanical systems installed


and tested according to
applicable specifications and
project plans. Cold
commissioning can begin when
mechanically complete.

3. Cold commissioning Systems start up Process in which operational


tests of the facility systems are
completed with inert material or
water. Hot commissioning can
begin when cold commissioning
is complete.

4. Hot commissioning Production start up Process that tests the facility


with actual chemical/materials
using the commercial process.
The production phase can
begin when hot commissioning
is complete.

5. Production Performance test A test that occurs during the


production phase and marks
the facilities ability to run to
design capacity.

6. Project turnover Facility acceptance The final turnover of the facility


to the owner, which satisfies
(End of Project)
remaining contractual
requirements excluding
warranty items.

This standard will refer only to steps 2 and 3 of the IEC standard while the ISA standard shall be
used for the actual commissioning procedure of the instrument loops.
Loop
FAT SAT SIT Checks Acceptance of Plant

Construction Precommissioning Commissioning Production


PHASES
COLD HOT

MILESTONES Completion of erection Mechanical completion Start-up Start of Production Performance Test

NOTE: Construction and precommissioning activities coild be overlapping From IEC 2057/06

Figure 1 – Definition of phases and milestones (see page 17 ISA-62382)


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The IEC and ISA standards are available for use by Vale on the Ontario/UK Specialty Engineering
Process Automation website. The license for the documents only allows for their use from within
Vale.

4.1 PRECOMMISSIONING

A risk assessment should be conducted to determine the level of detail in the verification tests. In
addition, a Quality Assurance unit should approve all verification plans, tests, and acceptance criteria
related to Critical Quality Attributes and Critical Process Parameters. No such additional quality
function assessment is required for non-regulated applications. If there is no Quality Assurance Unit,
that role will be assumed by a designated Vale Subject Matter Expert.
Vendor documentation gathered in turnover packages or vendor supplied testing requires additional
levels of scrutiny by the quality unit. Verification tests should be independently reviewed and
approved by Subject Matter Experts (SME) who did not execute the test. The SME also reviews and
approves deviations from the verification test plan or failed tests and approves corrective actions.
In addition to the definitions in Section 3 of IEC 62237, the following sections of IEC 62237 are
relevant for the instrumentation and control pre-commissioning process, and shall be considered
incorporated in this document.

Section(s) Description

4a–c General preparations before acceptance of plant

5.2 Procedure

6 Precommissioning (except Annex B references


for which sections listed below are to be used
only)

Annex B; 1.1, 1.2, 1.3, 1.10, 1.11, 1.12, 1.19, Description of precommissioning activities
2.8, 2.9, 2.10

Annex D; 9 Description of Commissioning activities


(Instrumentation)

As part of pre-commissioning, a list of variables required for the plant/mine historian (PI) is to be
established. Data from the plant historian may be used in the commissioning process. The historian
standard tag naming convention will be used.
If required, commissioning of the historian data collector node on the PCN or PIN is to be included as
part of the automation system. The Vale representative is to be contacted to determine this
requirement.
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The portions of the historian sitting outside the PCN or PIN are not included. The Vale representative
is responsible to ensure PI trends or reports are developed at this stage though a request to the Vale
IT department process.

4.2 COMMISSIONING

The ISA105 committee has adapted the IEC document IEC 62382 (Automation Systems in the
Process Industry - Electrical and Instrumentation Loop Check) for North American practices as ISA-
62382 which documents the requirements for loop and functional testing of field instruments. This
document and its associated appendices which document the requirements for the different types of
I/O loops shall be used for all field device commissioning procedures.

4.3 PERFORMANCE AND ACCEPTANCE TEST

Performance and acceptance testing criteria shall be developed in conjunction with the project team
to properly capture the requirements of the control system used on the project. For example some
control systems support I/O simulation without requiring physical hardware or signal simulators on all
inputs while others and certainly safety system tests should include as a minimum simulated signals
for all analog and discrete signals.

5.0 APPENDICES

Appendix A: Revision and Transition Notes

Appendix B: Keywords

Appendix A: Revision and Transition Notes

(Revisions are listed in reverse chronological order with most recent revision at the top.
Revision notes describe: what was changed, why it was changed, and the plan to implement
the change, including whether changes are retroactive)

Revision 1
1st Issue
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Appendix B: Keywords and Acronyms

Acronym Definition
BPCS Basic Process Control System
DMZ Demilitarized Zone – Network Zone between PIN/PCN and
Business
E&I Electrical and Instrumentation
LRV Lower Range Value
FAT Factory Acceptance Test
FDS Functional Design Specification
FPS Functional Program Specification
I/O Control system Inputs/Outputs
PIN Process Information Network (part of PCN)
PCN Process Control Network
PCT Process Control Technology
SAT Site Acceptance Test
SIS Safety Instrumented System
SIT Site Integration Test
SME Subject Matter Expert
URV Upper Range Value

Commissioning, Process Control Commissioning, Automation Commissioning, Loop Check,


Loop Check Sheet