cqv landing zones

8/3/2019 Cqv Landing Zones

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CQV

ELEMENTSDEFINITIONSSUCCESS CRITERIA

LANDING ZONES

GENERAL ROLES & RESPONSIBILITIES

PHASED CQV LEADERSHIP ALIGNMENT



CQV


LANDING ZONES





CQV ELEMENTS & GLIDE PATH

“The seamless and

effective transfer

of process knowledge and capability

from Project Teams to Operations

to achieve and sustain

Project Success

Criteria

Key Elements

Equipment…meets product, process,and operational criteria.

People…proficient and qualified tosustain technical and operational

criteria.

Materials…quality and availabilityassured.

Functional Systems…Landing Zone

and Support Function Plans in place

and effective.



CQV


LANDING ZONES





Equipment Installation

Static, Dynamic Checks

Safety Conformance

Complete Operational

Training

Technical Checkout

Commissioning

Support Function &

Landing Zone Plans In

Place & Active

Complete Operational

Qualification

Manufacturing

Acceptance of Equipment

and Process

Success Criteria Achieved

Ongoing Effectiveness of

Support Function and

Landing Zone Plans

Lessons Learned

Final Project Report

Release Project Team

Key Activities

CQV Success Criteria

Landing Zone Plans

StaffingTraining

Production Scheduling

Operational Systems

Facilities

Maintenance/Demoliti

on

Environmental

Safety

CQV Project Phases

Purpose

Develop the CQV Plan

and begin

implementation.

Demonstrate that the

equipment and process

conform to designspecifications, QA,

safety, and

environmental

requirements.

Demonstrate that

manufacturing

resources canproficiently operate

the process at design

specifications and

manage functional

systems.

Ensure that

manufacturing

resources, equipment,materials, and

functional systems can

be sustained at targeted

performance levels.

Toddy Quality Project-CQV

5

Preparation Commissioning Qualification

Preparation Verification



CQV


LANDING ZONES





CQV Success Criteria - Examples

Machine performance requirements (FAT, Technical Checkout)

Training plan defined, operators trained, Qualification achieved

Spare parts identified, received, verified

Documentation received, verified

Safety procedures modified, implemented

Control Screens complete, system operational, operators trained

Operational SOP’s identified, tested, effective

Punch list items identified, complete

QA protocols identified, tested, validated



CQV


LANDING ZONES





Key Preparation Activities

• Establish Landing Zone Plans• Staffing

• Training

• Production Scheduling

• Operational Systems

• Facilities

• Maintenance

• Environmental

• Safety



Landing Zone Plans• Staffing

– Plans completed for operational crewing schedules,manning requirements, etc.

• Training

– Operators, mechanics, electricians and support

resources trained and qualified.• Production Scheduling

– Plans for operating schedules, volume forecasts, rawmaterial changes, etc.

• Operational Systems – Plans to achieve operational performance targets

including daily results tracking and monitoringsystems, goal setting, process control requirements,operating SOP’s, etc.



Landing Zone Plans

• Operational Systems – Plans to achieve operational performance targets

including daily results tracking and monitoringsystems, goal setting, process control requirements,operating SOP’s, etc.

• Facilities – Plans for site preparation, utilities (air, water, power,

etc.), material handling requirements, etc.

• Maintenance

– Plans to ensure site preparation, receipt of spareparts, required documentation, and initial andpreventive maintenance requirements are complete.



Landing Zone Plans

• Environmental

– Plans to identify and manage plant environmentalissues including required waste handling, recycling,and Emergency Response plans

• Safety

– Plans to satisfy personnel safety requirements inaccordance with Toddy standards, train requiredpersonnel, etc.



Criteria Resp Criteria Resp Criteria Resp Criteria Resp

Develop QA Plan for

Commissioning, Qualification,

Verification

Validate CIP for line/tank

cleanability

Provide final approval to release

batch by QC, QA, R&D

Ongoing (4 wks) evaluation of

performnce

Develop product validation runs

schedule (what,how

much,when)

Ribofla vi n te sti ng of ta nks? Compl ete any addi tiona l la b

technician/operator training

Quality specs issued Validate all product meets specs

Identify any training for new test

method

Verification of Line Flushes

(Documentation)

Process specifications

CCP's

Product formulas delivered to

Eng

All LAMP criteria defined and in

place

Product specifications delivered

to Eng and Mfg

Complete system qualifications

criteria

Verify System Functionality

Complete P&ID's, functional

description, process definition

Complete piping and equipment

labeling

Develop listing of operating

parameters to be me asured for

Commissioning

Complete program validation

Verify equipment specifications

are met before Commissioning

Verify correct operation of CIP

skid and circuits

Provide recommended Spare

Parts list

Complete punch list

Verify Vendor Documentation

Define Remaining Construction

Schedule

Complete Mechanical &

Electrical installation

Complete passivation

Hydrostatic checks

Define Criteria for Software

Development

FAT criteria. Complete FAT

V eri fy S oftw are HMI & P LC Compl ete con tro ls, autom ati on

hands-on training

Ongoing interface betwe en

operations and vendors

Define technology HMI & Valves Veri fy standards fol lowed

Esta blish Training Docs Conduct training for PLC,

Operator, Maintenance

Electrica l insta ll ation review Ver ify controller interaction

I/O checks Verify Valve sequencing

Equipment Vendor Negotiate vendor requirements

for CQV support

Commissioning Vendor Support

provided

Qualification Vendor support

provided

On-Call Vendor support

Quality Assurance

Engineering

Installation/

Construction Mgt.

IM/Controls/

Automation

Preparation Phase Commissioning Phase Qualification Phase Verification Phase

CQV Criteria - Support Function PlansDate:______ Date:______ Date:______ Date:______




Define training goals,

objectives, strategy

Develop operator on-the-job

training criteria

Update training materials

based on Commissioning

learnings

Complete any follow-up

training, documentation and

proceduresDevelop training

framework/template

Create job safety documents

for all new

equipment/processes

Schedule follow-up training

after startup

Identify capability gap.

Develop plan to address

gaps

Operators, mechanics,

electricians, instrument

techs, automation team fully

trained and qualified

Update SOP's/MI's based on

Qualifications learnings

Training Materials complete Train employees on proper

use of any personal

protective equipment

Changes to new

SOP's/Doc's/MI's

Identify who will be trained -

get alignment from various

groups

Complete 5S documentation

and installation

Identify additional

resource(s) required for

development of training

manuals

Identify operator training

required to support the

Maitnenance PM plan

Establish training timeline Develop operating SOP's

Receive vendor training

manuals/information.

Transmit to overall

document writer

Initiate training to all groups

Operations, Electricans,

Mechanics, Automation,

SOP's

Determine current

capabilities of individuals

within each group

Training

CQV Template - Training Landing Zone PlansPreparation Phase Commissioning Phase Qualification Phase Verification Phase




Staffing Develop staffing schedule

for CQV support

Receive product testing

schedule forCommissioning

All training completed-

Operators Qualified

Define startup production

volumes, inventory

Identify Changeover and

CIP requirements

Staffing requirements

complete

Provide product testing

schedule for

Commissioning

Funding requirements

complete

Schedule production

testing

Production reports/formats

complete

Develop Production Report

Formats

Make updates to

documentation

Develop listing of SOP's to

be createdSOP for recipe update

Determine changes created

in current operational

systems by the project

Vendor technical

documentation complete

All spare parts are on-site. Adjust Spare Parts and PM

requirements

Technical documentation

complete

Finalize spare parts All training documents

ready and training

schedule set

All mechanics trained and

qualified

PM and Spare Parts system

support requirements

Identi fy PM requirements PM requirements and

Maint. procedures in place

As-built drawings complete

Determine training needs Receive Eng. defined

operating parameters

ID all new equipment and

create list of safety

requirements

Complete Pre-Startup

Safety Review

Complete all safety punch

lsit items

Identify 5S requirements

Identify changes required

for existing safety manuals

Audit installa tion for

completeness

Complete Design Safety

Review

Safety Review Complete

Environmental

Safety/Process

Safety

Production

Scheduling

Operational

Systems

Facilities

Maintenance

CQV Template - Landing Zone PlansPreparation Phase Commissioning Phase Qualification Phase Verification Phase



CQV


LANDING ZONES





CQV General Roles and Responsibilities

Although all entities have the same objective to reach the ProjectSuccess Criteria, roles will change during phases of the startupprocess as defined below:

Construction Manager – Renato Palmeira - has the ultimateresponsibility that the objective of completing the installation is met

Engineering Startup Manager – Rodrigo Staibani - Will organizeand conduct the daily meetings through Commissioning and haveresponsibility for technical aspects of the mechanical, electrical,and process systems after installation.

Qualification Manager - ??????? - Will have responsibility for thequalification process and be the operational interface betweenOperations and Engineering.



Draft- Production Management’s CQV “R”esponsibilities

• interacts as plant single point contact during CQV

• Is responsible for the acquisition and delivery of necessary materials for trials• Communicates CQV activities, status, and schedule to other operational

groups• Provides inputs to all checklists and work lists• Conducts construction complete inspection with Engineering team• Signs off on all CQV completion documents• Participates in development of detailed performance criteria and test protocol• Coordinate plant schedule and participation in Commissioning, Qualification,

and Verification activities• Provides staffing and management of performer work force during trials and

through operational qualification activities• Responsible for supporting testing, data collection and reporting during trials• Responsible for development of all SOPs and operational data collection

requirements

• Documents and certifies performer competency• Communicates training progress to Operations Management



Draft- Maintenance CQV “R”esponsibilities

• Active participation and support during CQV implementation• Communicates CQV activities, status, and schedule to other

operational groups• Sign off on Step completion documents• Provides inputs to all checklists and work lists• Assist and support in the development of Commissioning,

Qualification, and verification work plan and activity matrix• Participate and contribute to development of detailed performance

criteria and test protocol• Communicates training progress to CQV leader• Responsible for transition of all project information to operating plant

systems for maintenance

• Supports Construction manager in delivery and adequacy of allvendor required documentation• Work with vendors to facilitate information transfer compatibility



CQV


LANDING ZONES

GENERAL ROLES & RESPONSIBILITIESPHASED CQV LEADERSHIP ALIGNMENT



Phased CQV Leadership Alignment

• Commissioning - During this phase the EngineeringStartup Manager will control the startup process, conductthe daily meetings, and schedule tasks for best use ofresources

• Qualification - During this phase the Operationscontrols the operation process and run the dailymeetings as needed, with support from Engineering,Edelstahl,….

• Training - Training will be occurring during theCommissioning phase. It will be the responsibility of the

Training Leader to coordinate with the EngineeringStartup manager or the Construction manager to ensurethat the training needs are met.