In our previous blog we discussed the upfront design tasks associated with a typical Instrumentation Project. The project clock is ticking, and it is time to procure the instrumentation & valves!
As discussed previously, before we purchase and begin processing any instruments, it is essential that there is a mechanism in place to easily track and report on the (work-in-progress) status of any given instrument and valve. For small projects a spreadsheet can be used but, in many cases, projects consist of thousands of devices. Hallam-ICS prefers to use, and has developed, a custom database application for managing and tracking the instrumentation through the project life-cycle. The information maintained for each device in our database includes:
Using this application, we have the ability to query, filter and generate standard and custom reports to plan for, and track, key project milestones. Our standard reports include:
A peak at our database application and a few reports:
Once received, a few quality checks should be employed to ensure each instrument is ready for installation and commissioning / validation. Specifically, a Material Receipt Verification and a Bench Test should be performed. At last, the excitement can begin!
First, upon receipt of a new instrument, it should be visually inspected and verified that the construction / model matches, exactly, the device specification and purchase order. Specifically, the Material Receipt process should verify the following:
In establishing our Material Receipt process, we used the ASME Bioprocessing Equipment (BPE) Standard as a guide. All material inspection results should be recorded and submitted as part of the Turnover Package to the client. To download a template of the Material Receipt Form we use please click here
For any given project, there is almost always a component that is delivered with a quality issue. Examples of things that we have found during the material receipt process:
An important secondary step is to perform a basic functional test of each instrument / valve before it is delivered to the field for installation. Tests do not need to be exhaustive but should be extensive enough to ensure that instruments / valves are in good working order and have not been damaged in shipment. Valves should be stroked open and close. Instruments and gauges should be exercised through (or at least a portion of) the calibration range. A NIST traceable calibration does not need to be performed at this point. The objective is to find failures early in the project so that devices can be replaced easily and in a timely manner. Instruments found to be faulty after installation or during testing can cost you precious time and money, when you have little of either! Moreover, if devices are exposed to process conditions they are not easily returned.
All test data should be recorded and submitted as part of the Turnover Package to the client. For an example of a Bench Test Form click here.
Upon the successful completion of these tasks, you can feel confident that the devices are ready for installation! In our next blog we will discuss what needs to occur next in the field. In the meantime, if you have any questions regarding our MIV services, please feel free to call Hallam-ICS.
About the author
Pete is a graduate of the University of Vermont, with a B.S. in Electrical Engineering and a Masters of Business Administration. He originally joined Hallam-ICS in 1995 (leaving in 2001 and returning again in 2005) as Controls Engineer. Currently, he serves as a Project Manager and Team Leader for the Control Systems Integration group. Outside of work Pete enjoys skiing, golfing, music, and coaching his kid’s baseball / softball teams.
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About Hallam-ICS
Hallam-ICS is an engineering and automation company that designs MEP systems for facilities and plants, engineers control and automation solutions, and ensures safety and regulatory compliance through arc flash studies, commissioning, and validation. Our offices are located in Massachusetts, Connecticut, New York, Vermont and North Carolina and our projects take us world-wide.