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Identification
GI-18.201
October 2008

Safety Audit Guide for Refrigeration Plants using


Carbon Dioxide as primary and secondary
Refrigerant
Classification Document type: Internal Standard
Hierarchical level: Procedure
Confidentiality: Yellow Class

Copyright The content of this document is a trade secret. It may not be reproduced, distributed or disclosed to third
parties without proper authorisation. All rights belong to Nestec Ltd., CH-1800 Vevey, Switzerland.
©Nestec Ltd. 2007

Author(s) CO-Eng/Serv, Michel Pirard


Approver(s) CO-Eng/Serv, Luca Guscetti

Embedded N-CSA Package

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Table of Contents

Introduction............................................................................................................................... 3
Purpose of the Audit Guide...................................................................................................3
Objectives of the Safety Audit...............................................................................................3
Why do we need a Guide for CO2 R-Plants?.......................................................................3
Target.................................................................................................................................... 4
Auditing CO2 and NH3 R-Plants..........................................................................................4
Distribution and download.....................................................................................................4
Support and feedback........................................................................................................... 4
Audit Guidelines........................................................................................................................ 5
Coordination and follow up....................................................................................................5
Audit frequency..................................................................................................................... 5
Pre-Audits for Project Phase.................................................................................................5
Periodic Safety Checkups.....................................................................................................6
Audit preparation................................................................................................................... 6
Audit team composition......................................................................................................... 7
Audit sequence...................................................................................................................... 7
Safety Index Rating............................................................................................................... 8
Completed and planned safety audits...................................................................................8
The N-CSA Package................................................................................................................. 9
Content.................................................................................................................................. 9
N-CSA Package.................................................................................................................... 9
Package installation.............................................................................................................. 9
The N-CSA Package Workbook..............................................................................................10
Worksheets......................................................................................................................... 10
Access to Worksheets......................................................................................................... 10
Rooms & Equipment Worksheets........................................................................................10
Summary Worksheets......................................................................................................... 11
General Worksheets............................................................................................................11
Action Plan Worksheet........................................................................................................12
N-CSA Cover Sheet............................................................................................................ 12
Guidance Notes................................................................................................................... 13
Drop-down Lists.................................................................................................................. 13
Worksheets Protection........................................................................................................14
Macros................................................................................................................................ 15
How to run the N-CSA Workbook............................................................................................16
Starting the Workbook.........................................................................................................16
Filling in the Cover Sheet....................................................................................................16
Preparing the Worksheets...................................................................................................17
Adding, Deleting and Exchanging Worksheets....................................................................17
Updating a Summary Worksheet.........................................................................................18

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Introduction

Purpose of  The purpose of the Audit Guide is to ensure that all Nestlé refrigeration plants
the Audit operating with carbon dioxide (CO2) are designed, built, operated and
Guide maintained in a safe manner, minimising risks to persons, environment,
production and goods.

 The Audit Guide is a practical development of Nestlé Policy GI-18.001 "The


Nestlé Occupational Health and Safety Management System (NSMS)" and a
support to the Group's Policy encouraging the use of natural refrigerants as
per
GI-20.004-2:
"Use and phase out of Substances Depleting the Ozone layer" as well as per
"Nestlé Position on Industrial Refrigeration" paper.

Objectives of By combining the expertise of a safety audit team and a structured reviewing
the Safety tool, which also includes specific Guidance Notes, the Safety Audit will:
Audit
 Provide a means to assess and document the safety of CO2 R-Plants.
 Identify actual and potential safety hazards due to design, modifications,
operation and maintenance.
 Provide a means of defining the needs for upgrading and modification of
plants and operations.
 Provide feedback on safety issues that may be incorporated into new plant
design.
 Promote safety understanding.

Why do we  CO2 refrigerant has been reintroduced in industrial refrigeration systems


need a Guide because it presents various advantages, among others no toxicity, smaller
for CO2 components (compressors, piping) and increased efficiency when used as
R-Plants? primary refrigerant in low temperature (<-25°C) systems.
 However, not toxic does not mean harmless: CO2 systems operate at higher
pressures compared to NH3 and CO2 can become dangerous to health when
present in high concentrations in the ambience. To be stressed is that CO2 is
colourless and odourless which makes it pernicious.
 Typically carbon dioxide is used as:
- Primary refrigerant in a compression cascade
- Secondary refrigerant or two-phase brine in a network operating with
pumps.
 In both cases, CO2 is combined with a cycle operating with another refrigerant,
usually ammonia (NH3), which means that the safety of the whole system
must be audited.
 To be noted is that here is basically no difference in the safety level needed
for systems operating with CO2 either as primary refrigerant or as secondary
refrigerant.
 This Audit Guide is a complement to GI-18.200: "Safety Audit Guide for
ammonia refrigeration plants".
Continued on next page

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Introduction, Continued

Target Carbon dioxide refrigeration plants serving Nestlé operations and operated by
third parties must be audited to make sure that:

 They guarantee a safe plant operation, guarantee a reliable supply and


comply with local regulations.
 Any legal actions resulting from incidents, accidents or violation to local laws
will not affect the Nestlé image or interests.

Auditing CO2  Systems operating with distributed CO2, as primary or secondary refrigerant,
and NH3 usually operate with NH3 confined in a plant room. However in some cases,
R-Plants CO2 and NH3 might be found in production areas e.g. after a partial existing
NH3 to CO2 system conversion; for example, in an ice cream facility we might
find continuous IC freezers still operating with NH3 and hardening tunnels
operating with CO2.
 The auditors shall make sure that the safety audit is performed according to
the GI appropriate for each type of refrigerant (for NH3: GI-18.200).
 Obviously, and typically for a refrigeration plant room, a certain number of
questions might repeat. Auditors shall use their judgment to simplify the
auditing procedure whenever possible.

Distribution  The Audit Guide and its embedded N-CSA Package (page 9) will be
and download distributed to:

 Chief Engineers in Markets and PTCs

 The Audit Guide can be downloaded from Nestec Intranet site "Technical
Instructions" based at the "Technical & Production" site.

Support and  Nestec CO-Eng/Serv will provide support for the use of the N-CSA Guide.
feedback
Please contact:
 Michel Pirard (e-mail: Michel.Pirard@nestle.com)
or
Any member of CO-ENG/Serv team:
http://intranet.nestle.com/EngServ/

 Feedback on the Guide use and content as well as improvement suggestions


will be appreciated and will make it possible to improve continuously the tool.

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Audit Guidelines

Coordination Market corporate engineering will coordinate and follow up the safety audits. The
and follow up coordinator has the responsibility to ensure that audits are carried out effectively
and efficiently and must:

 Schedule audits in consultation with the factory management


 Ensure that the preparation for the audit is completed and the necessary
documentation is available in advance for the audit team review.
 Ensure that the recommended corrective actions are taken.
 Keep the team members informed about the main progress of the required
actions.

Audit As a minimum CO2 R-plants safety audits shall be conducted every 5 years or
frequency less.

 The actual audit frequency shall primarily be risk based in function of local
conditions such as factory location, plant age and condition, climate, e.g.
increased risk of corrosion in warm/humid areas, availability of external
support, action plan and Safety Index Ratings (SIR) from previous audits.

Safety Index Rating Audit frequency Remark


from previous audit
At least one E Every year Or more frequently as
At least one U Every 3 years per risk analysis
Only Is Every 5 years And no major system
changes

 New plants shall be audited within 12 months from full commissioning.


 Major plant extensions and modifications shall be audited within 6 months
from full commissioning.

Pre-Audits for Project Engineers should use the N-CSA Package, especially the embedded
Project Phase Guidance Notes:

 To ensure completeness of basic concepts, specifications and offers at a


pre-contract stage.
 To assist in the review and approval of CO2 flow sheets, piping and
instrumentation diagrams prior construction start.
 To assist in the preparation of documentation and safety standards.
 To assist in the preparation of the safety concept that should be part of the
control and monitoring system.
Continued on next page

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Audit Guidelines, Continued

Periodic In addition to the Safety Audit, Periodic Safety Checkups shall be performed,
Safety preferably on an annual basis, and include, among others, the following items:
Checkups
 Review of the progress made on the actions required during the last safety
audit.
Whenever needed the action plan shall be updated with new deadlines and
with the findings made during the safety checkups.
 Inspection of calibration, function test records for the safety cut-outs, CO2 leak
detectors and other instruments related to the plant safety.
 Inspection of the refrigeration plant: plant room, production, storage areas
 Testing of the CO2 refrigeration plant room ventilation.
This should be done in manual and automatic mode.
 Testing of the local, remote visual and audible alarms
 Inspection of the protective equipment used for interventions in the system.

Periodic Safety Checkup reports shall be part of the documentation that should
be reviewed by the auditors during the safety audit.

Audit Following actions shall be taken to ensure the effectiveness of the audit:
preparation
 The N-CSA Guide Package will be sent well in advance to the factory by the
market coordinator for the audit preparation.
Failure to do the audit preparation will result in delays in the completion of the
audit and waste the time of both the audit team and the factory staff.
 Following information shall be prepared and made available to the audit team
during the audit. The factory shall ensure that the required documentation is
available and gathered in a single location to simplify reference.
- As-built CO2 Piping & Instrumentation Diagrams (PIDs)
- As-built electrical diagrams + detailed and updated functional description
- Operating and Maintenance manuals
- Certification documents for compressors, pressure vessels and heat
exchangers
- Updated action plan (from last audit) and periodic safety checkup reports.
- Other documents relevant for the assessment of the R-plant safety in the
factory and its environment
 The as-built CO2 PIDs shall be sent to the audit team for familiarisation at
least 2 weeks prior the audit start.
This will also be a confirmation that the preparation has been completed.
 The factory shall allocate their representatives for the audit team and ensure
that sufficient technical support will be available for the whole duration of the
audit.
Continued on next page

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Audit Guidelines, Continued

Audit team It is recommended that the audit team be composed of a minimum of 2


composition members, one from the audited factory and one refrigeration/safety audit
"Expert".
The "Expert" shall have CO2 (and NH3) refrigeration system design experience
and full knowledge of the audit purpose, N-CSA Package content, especially the
Guidance Notes, and be aware that safety matters are not negotiable.
The "Expert" could be either from the market, the region or be a refrigeration
expert nominated by Nestec.
Team member from the factory: may include:
 The factory engineer
 The safety officer
A trainee from another factory or market should participate for either training or
"cross fertilisation" of experience.
Consultants must be approved / trained by Nestec or a Nestlé expert. They
must have clearly defined roles.

Audit The suggested schedule for the safety audit is:


sequence

Stage Description
1 Review the factory layout, rooms, areas and R-Plant PIDs
2 Perform a brief inspection to gain an overview of the main areas and
R-Plant components.
3
Audit in detail the R-Plant components such as compressors, vessels, heat
exchangers, pipe work.
It is recommended to audit, i.e. inspect, answer the questionnaire and assign
SIRs for each type of equipment, e.g. compressors, after performing a visual
inspection of all similar units.
In some cases the audit team may be divided in groups to perform the detailed
inspection of a given type of equipment.
4 Audit the various areas such as plant rooms, production areas,
and cold rooms.
In some cases the audit team may be divided in groups to perform the detailed
inspection of a given area
5 Audit of the organisational aspects like documentation, staff competence,
training etc. Recommended after the detailed hardware inspection to allow
the audit team to first become familiar with the plant.
6 Consolidate the Action Plan and add the name(s) of the responsible in charge
of the action and expected completion dates.
7 Based on the content of the Action Plan, recommend a schedule for the next
audit and periodic safety checkups.
8 Present and discuss the audit results and required actions to the factory
management, including whenever possible a cost estimate for the main
required actions.
Note Sufficient resources and time should be allocated to perform safety audits!
For instance, 3 to 4 weeks could be needed to complete the first safety audit
(ammonia + carbon dioxide systems) for a very large plant.

Continued on next page

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Audit Guidelines, Continued

Safety Index Specifying deficiencies in the questionnaire


Rating  The audit questionnaire has been structured to assist in the determination of
the R-plant safety. Most of the questions directly related to plant safety require
only a Yes/No answer. The sense of the questions is generally such that a
"no" answer may indicate some degree of deficiency. The audit team must
judge the degree of the deficiencies and assign a Safety Index Rating (SIR),
which reflects the severity of the defect and the potential impact on the safety
of the refrigeration plant.
 The following SIRs are defined:

SIR Definition
"E" = Emergency The defect is so severe that there is immediate danger to
the plant e.g. extended corrosion or organisational defects
that will lead to rapid deterioration of the plant. Or the
inability to safely deal with an incident e.g. lack of
competent staff, inadequate safety equipment etc.
The audit team should ensure that an action is
committed to rectify the defect before leaving the site.
"U" = Urgent The deficiency represents a serious hazard, which may not
be immediately dangerous to life or property and would not
expose the company to any immediate legal action.
A firm deadline should be set to correct the deficiency.
"I" = Improvement Improvement is required, and can be achieved by the factory
through regular channels of maintenance and capital
investment.
Improvements should not be underestimated. It is good
practice to undertake the required corrective actions
latest till the end of the calendar year following the safety
audit.
"N" = Normal No action considered necessary. Where appropriate, the
audit team should include notes explaining why no action is
considered necessary.
No action is required. The audited section is of
acceptable or above normal standard.

Completed The following information shall be distributed:


and planned
safety audits CO2 Safety Audit Cover Sheet and Action Plan:
 Factory Management and Market Corporate Engineering
 Nestec CO-ENG/Serv

Periodic Safety Checkup Reports:
 As defined by the Market Corporate Engineering
 Nestec CO-ENG/Serv: On request

Time Schedule for the coming safety audits at all sites:
 Factory Management and Market Corporate Engineering
 Nestec CO-ENG/Serv

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The N-CSA Package

Content The original N-CSA Package (Nestlé-CO2 Safety Audit) comes as a zipped file
and includes:

 1 Excel 2003 (SP3) Workbook "N-CSA V1.0-2008"


 9 Guidance Notes (Word 2003 SP3)

N-CSA
Package N-CSA Package
(V1.0-2008) .zip

Package The Package should be unzipped in a common folder, e.g. "C:\Data\CSA\...".


installation This will keep the links between the Excel Worksheets and the Guidance Notes
intact.

Guidelines for naming the files:

 The original name of the Excel Workbook, "N-CSA V1.0-2008", can be


changed to any preferred name, including the factory name etc.
 The name of the Guidance Notes should not be modified unless the hyperlink
in the corresponding Worksheet is also updated.

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The N-CSA Package Workbook

Worksheets The Package Workbook is composed of the following Worksheets:

Type of Worksheet Description


Rooms & Equipment A1 Rooms
(Annexes A1...A5) A2 Cold Rooms
A3 Compressors
A4 Vessels (Pumps)
A5 Heat Exchangers
General A6 System Components
(Annexes A6...A11) A7 Work Procedures
A8 Inspections
A9 Documentation
A10 CO2 Training
A11 Emergency Response
Summary For Annexes A1 to A5 and Relief Safety Valves
Action Plan Consolidates all required actions.
N-ASA Cover Sheet Summarises audit participants, annual safety check-
ups, incidents summary, plant charge & losses and
major plant modifications.

Access to Each Worksheet can be accessed by clicking on the bottom tab in the Workbook.
Worksheets

Rooms & Recommendation for filling in the Worksheets


Equipment Rooms & Equipment Worksheets have to be partly filled in during the preparation
Worksheets phase and completed with safety Index Ratings and required actions.
Denomination of Worksheets
The Rooms & Equipment Worksheets are annexes to the corresponding
Summary Worksheet. The Rooms and Equipment Worksheets can be multiplied
according to the number of items that are apart of the system. When adding a
new Worksheet, the "Tab root name" + a sequential "Index Number" is
automatically inserted.
Example:
 The original Worksheet "Cold Rooms & Cold Process Spaces" has the tab name
"A2 Cold Rooms 1"
 When adding a second worksheet from the "Cold Rooms Summary" worksheet,
the name of the new worksheet will be "A2 Cold Rooms 2", as shown below:

For more details see "How to start the Audit Guide ==> Adding and Deleting
Worksheets".
Continued on next page

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The N-CSA Package Workbook, Continued

Summary Content
Worksheets The Summary Worksheets shows key data that may be helpful to the factory.
The illustrations below show the total number of "I", "U", "E" SIRs assigned to a
given plant item.

The corresponding Summary Worksheet can be updated as often as required.

Number of Worksheets
The macros for the Summary Worksheets allow for the consolidation of a
predefined number of Worksheets as listed below.

Annex Item Max. Number


A1 Rooms 30
A2 Cold Rooms 30
A3 Compressors 25
A4 Vessels 30
A5 Heat Exchangers 30

General General Worksheets refer mainly those that do not need to be multiplied as a
Worksheets function of the number of plant items, like rooms and equipment.

For example, General Worksheets like "A7 Work Procedures" have no


Summary Worksheet.
Continued on next page

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The N-CSA Package Workbook, Continued

Action Plan Content


Worksheet When using the button "Consolidate the Action Plan", the worksheet
consolidates the following data:

 Total number of "I", "U" and "E" SIRs


 "SIRs" and "Actions Required" defined by the auditors for each item in the
corresponding Annex Worksheet.
 The corresponding "Plant Reference" and the "Question" related to the SIR.

If a SIR different than "N" has been assigned, the Plant Reference, Question
and SIR will be shown even if no specific action has been required; sometimes
the action required can be obvious without the need for additional comments.

Responsibilities and timing


The Action Plan should be filled in with the name(s) of the person(s) who will be
in charge of the completion of the actions and with the expected completion
dates.

N-CSA Cover The Audit Cover Sheet provides an overview of key data such as:
Sheet  Factory reference
 Audit number and date
 Audit Team
 Periodic Safety Checkups summary
 Safety Index Ratings for the current audit and the previous one.
 Incidents summary
 Refrigerant charge modifications and average losses % calculation
 System alterations such as major plant extensions, plant items replacement etc.

Continued on next page

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The N-CSA Package Workbook, Continued

Guidance Guidance Notes have been developed to help the auditors answering the
Notes questionnaires. In many cases recommendations, suggestions or examples,
often based on EU Regulations, are provided.
CSA GNs can be modified or updated to reflect the local Regulations, Codes
and best practices, but the essence of the GNs must be maintained.
The relevant GN can be open through a "blue link" in the Worksheet:

Drop-down Many questions can be answered with the help of a drop-down list.
Lists To display the drop-down list, click on the grey button that appears after having
selected the light blue coloured cell.
Example:
Annex 3: Question A3.1.5: Compressor type?
A list of the most of the most commonly used compressor types, such as "Open
reciprocating" will appear.

Safety Index Ratings (SIRs) and YES/NO answers are selected the same way.

Continued on next page

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The N-CSA Package Workbook, Continued

Worksheets Unprotecting Worksheets


Protection Worksheet forms are protected against accidental modifications of text, format,
cell references, etc. The N-CSA Package comes without password that would
be needed to unprotect the Worksheets.
To add a password in a Worksheet or to unprotect it go to:
"Tools" ==> "Protection" ==> "Protect Sheet" (optional password) or "Unprotect
Sheet".

Unlocking individual cells


Only cells that are "locked" are protected when the Worksheet has been
protected.
To lock or unlock a cell or a group of cells select the cell(s) with the mouse and
right click; then select "Format Cells" ==> "Protection"

Formatting of cells
Cells where text can be written (=not locked) have a light yellow background.

These cells are formatted for "wrap text". This means that at the end of a line the
text will continue on the next line, and the row height will automatically be
adjusted to make the whole text visible.
If this should not work, Unprotect the Worksheet, select the whole Worksheet
and go to: Format ==> Row ==> AutoFit
After that Protect again the Worksheet.

Important:
 Do not modify row heights manually in unprotected mode. This may lock the
automatic row height adjustment!
 In all Worksheets write information in cells with a light yellow background only!
Continued on next page

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The N-CSA Package Workbook, Continued

Macros Constraints on the use of the Workbook


Macros have been integrated to perform automated tasks like "Summary
Sheets" update and "Action Plan" consolidation.
Unless the macros are also adjusted, this imposes the following constraints on
the use of the Workbook and:
 Do not modify the name of the Worksheets
 Do not modify cells reference in the Worksheets
This may happen for example when lines or columns are added in the
Worksheets. Normally the Worksheet protection should restrain users from
doing this.
 Do not change the cell reference for data entered in Worksheets and used
elsewhere in the Workbook e.g. in a Summary Worksheet.
Worksheets should not be exchanged between Workbooks unless the correct
link to the macros is restored.

Error message when adding Worksheets


In some cases, the addition of up to 10...25 Worksheets from the "Add plant
item Worksheet" button (Summary Worksheet) without saving and closing the
Workbook in between may lead to the following error message:

When this message appears proceed as follows:


1.Click on "End" button to cancel the message.
2."Save" and "Close" the Workbook (Excel File).
3.Re-open the same Workbook.
The addition of Worksheets can now be resumed.

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How to run the N-CSA Workbook

Starting the Open the Excel N-CSA Workbook and "Enable Macros" from the message:
Workbook

To be able to choose whether or not to run macros while starting the Workbook,
change the Security level from High to Medium as follows:
Go to: Tools ==> Macro ==> Security ==> Security Level = Medium

Filling in the Fill in the information required in the N-CSA Cover Sheet such as participants,
Cover Sheet refrigerant charge, SIRs from previous audits etc.

Besides the total number of Is and Us assigned to the system, auditors can
define (optionally) a number of typical findings affected to identical components
(items) for the same reason(s).

Example:
Missing "Auto-Start" at 05 compressors might be defined as 01 typical finding.

Some cells, marked with a red triangle in the corner, have built-in comments:

Continued on next page

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How to run the N-CSA Workbook, Continued

Preparing the As mentioned previously the preparation work is a very important step for the
Worksheets successful completion of a safety audit.

The tables in the Worksheet are filled in as follows:


 The questions that need to be answered during the audit preparation are
marked with an orange background.
 Data are entered manually only in yellow marked fields. (To go to the line
in a cell field type: "Alt"+"Enter")
 YES/NO answers are picked from blue marked drop down lists.

Adding, Adding Worksheets


Deleting and Additional Worksheets are needed when more then one plant item is present in
Exchanging the factory. They will be generated from the button "Add plant item Worksheet"
Worksheets in the "Plant Items Summary" Worksheet.

When a Worksheet is added, the tab name will automatically have the next
Index Number. This Index Number is a mere sequence number! It is not the
"Plant Reference", which is an information added in the Worksheet
(As explained in the "Guidance Notes" linked to the Workbook)

Deleting Worksheets
Worksheets should be deleted starting with the one with the last Index Number. If
this is not respected, the Index Number given automatically to Worksheets added
subsequently will not follow the sequence anymore and will have to be corrected
manually. (Also the Index Number in Cell B2 of each Worksheet)

Exchange of Worksheets
Worksheets should not be exchanged between Workbooks unless the correct
link to the macros is restored.
Example: Copy "A3 Compressor 1" or "Compressors Summary" from Workbook
"Factory A" to Workbook "Factory B".
Continued on next page

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How to run the N-CSA Workbook, Continued

Updating a Once all Worksheets for a given Annex, have been completed with the required
Summary data, the Summary Worksheets is updated using the button "Update Plant
Worksheet items Summary" in the corresponding "Plant Items Summary" Worksheet.

Example: A3 Compressors 1, 2, 3...,

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