Startup Planning Process Overview

Transcription

1 G S U M Startup Planning Process Overview Revision Date: Revision Number: Owner: Startup Leader: Interface with Eng/Const/PDD/Purchasing a. Preliminary C&F complete b. Final C&F complete c. EO's/Line Trials complete d. Funding approved e. Reliability Engineering input given f. Change Control process --Preliminary Review --Final Review --Walkthrough g. Finished product release criteria established h. Plant approval of design basis i. Technical feasibility --Codedates --Chemical clearance (MSDS) --Approved chemicals information j. Construction plan completed --Acid wash plan approved --Caustic wash plan approved --CCA document reviewed/approved k. Process Safety Studies complete l. Drawing list from Engineering received m. Production request received n. Project Success Criteria approved o. Project Charter established p. Project Kickoff meeting held Page 1 of 10

2 Startup Implementation Strategy a. Identify Startup Team members b. Develop first cut plan for review c. Kickoff meeting for Startup Team w/ trng on the Startup Process, if needed d. Determine need for Current Operations Assessment and Process Definition e. Document in Preliminary Startup/Capability Plan format f. Approval of Preliminary Plan Resources & Staffing Plan a. Resources roster established b. Detailed schedule laid out c. PDD/Eng/Contract support identified Roles & Responsibilities a. Documented for overall Project Team b. Documented for Startup Team members Communications Plan a. Project team communication established b. Startup team communication established --prior to construction --during downtime (daily meetings) --during PSU work c. Established with Construction organization Safety Plan a. Overall plan completed and documented b. JSA's complete c. BOS's developed and tracked d. Energy isolation procedures established e. Safe practices established (temp and ongoing) f. Construction /operation interface planned Page 2 of 10

3 Startup Success Criteria a. Input to overall project success criteria b. Develop detailed criteria for commissioning c. Develop detailed criteria for qualification d. Develop detailed criteria for verification including startup curve e. Approval by operating department of criteria System Definition Plan a. Determine need for definition plan b. Meet with construction and operations c. Develop plan and gain alignment Page 3 of 10

4 Static (IQ) and Dynamic (OQ) Test Plans a. Develop overall list of test plans with names for responsibility b. Generate static (IQ) checksheets c. Generate dynamic (OQ) checksheets d. Develop instruments calibration checks e. Detail schedule for mechanical and electrical f. IQ/OQ validation protocol signed g. Gain alignment on plan and share with Startup Team h. Fill out static (IQ) checksheets I. Fill out dynamic (OQ) ckecksheets j. IQ/OQ validation report signed Process Definition/Centerlining Plan a. Identify outside resource for process definition work and develop overall plan b. Gather initial centerline data c. Develop all equipment measurement needs and install d. Finalize documentation and centerlines e. Develop control strategies and critical checks Commissioning Demonstration Run Plan a. Develop overall detailed schedule including prep time, inspection time, and troubleshooting time b. Detail anticipated production and finalize with logistics b. Detail all supplies needed for run and inspection (i.e. scales, stamp, rulers, glue, etc.) c. Layout crew activities and decision process d. PQ validation protocol signed e. Document all outside resources needed and communicate to organization Page 4 of 10

5 Construction Completion Agreement a. Turnover walkthrough and CCA documents review scheduled b. Turnover signed off with exceptions c. Exceptions completed Shakedown Plan a. Input to engineering concerning resources, Startup Team involvement, materials, training, success criteria, and schedule TT&T Plan a. Front End Analysis b. Training schedule laid out c. Documentation complete d. Qualification criteria established e. Training plan completed Page 5 of 10

6 Materials Plan a. Detail total needs and timing for shakedown and EO's/line trials; share with logistics b. Detail total needs and timing from CQ plan and communicate to logistics c. Ensure suppliers have a startup leader and plan in place d. All specs and standards received e. Formula cards received f. Specifications sent to suppliers g. "C" #/Batch #/ Brand-Variation Code in place h. Target weights established I. Tables, RTCIS, HPI all loaded and confirmed j. Production plan in BRP k. Raw materials and packing materials ordered l. Raw materials and packing materials received m. Raw materials and packing materials released n. Total materials plan and schedule established o. Chemicals on chemicals approved list Technical/Business Systems Plan a. Identify all support systems affected by the project (safety, process safety, environmental, information systems, computer, HPI, etc.) b. Develop spare parts impact c. Develop maintenance system impact d. Develop all clean-up procedures e. Cleaning and Sanitization validations protocols signed f. Controls and Information Systems validation protocol signed g. Cleaning and Sanitization validation report signed h. Controls and Information Systems validation report signed i. Finalize and review plan with appropriate organizations for startup and on-going j. CBA's and SOP's all complete Page 6 of 10

7 Qualification (PQ) Plan a. Develop overall detailed schedule including prep time, inspection time, and troubleshooting time b. Detail anticipated production and finalize with logistics c. Detail all supplies needed for run and inspection d. Layout crew activities and decision process e. PQ validation report signed f. Document all outside resources needed and communicate to organization g. Draft Turnover document h. Sign turnover document with organization capturing any outages with follow-ups Page 7 of 10

8 Verification Plan a. Confirm success criteria and startup plan b. Establish communication plan during verification to keep all resources informed c. Monthly initiatives reviews completed d. Final Startup and Capability report signed Startup Schedule a. Develop daily schedule for each area of the Startup team b. Detail hourly schedule for downtime period Test and Sampling Plan a. Sampling requirements received from PDD and/or Tech Packing b. Analytical and Inspection Methods Verified c. Variables and Attributes defined d. Sampling tally sheets developed e. Final sampling plan detailed including resources, tests, and sample retention needs Measures and Results Plan a. Determine reporting needs and distribution throughout startup period b. Finalize format utilizing current reporting systems or documents when possible c. Complete monthly initiative review forms Startup Budget a. Develop budget per month b. Preproduction number established c. Track monthly and reconcile Other Items Page 8 of 10

9 G S U M Startup Planning Process Overview Revision Date: Revision Number: Owner: Startup Checklist 1. Identify resources needed on the Startup Team and obtain commitment for their time. Develop Startup Team staffing/resource plan 2. Organize a functioning Startup Team. Execute join-up/team building Set-up meeting logistics/agenda/frequency Set-up decision making and team communication systems Develop Startup Team objectives/success criteria Establish team expectations 3. Verify all team members are trained on the Startup Process, new equipment and systems as appropriate. 4. Determine the need for Process Definition on existing equipment/systems. 5. Ensure a Current Operations Assessment to check the status of existing equipment, systems, and skills is planned and implemented. Identify potential barriers to delivery success Develop plans to reduce, eliminate or manage risks and barriers 6. Develop a first cut criteria, measures, and strategies for each component of the Startup Plan. Startup Success Criteria Construction Completion Agreement Commissioning Plan Qualification Plan Verification Plan System Definition Plan Shakedown Plan Materials Plan Safety Plan Communications Plan Resource & Staffing Plan Sampling Plan Roles & Responsibilities Startup Budget Startup Schedule Page 9 of 10

10 7. Ensure TT&T requirements are determined, a TT&T Plan is developed, and implementation commenced. 8. Develop the first cut Startup Plan. 9. Gain hierarchy (dept., group, plant mgr., Network leadership) agreement and alignment to start-up strategy and first cut plan. 10. Arrange phone/office/computer logistics for plant visitors/team. Page 10 of 10