Qualification

BCD’s systematic qualification process spans the life cycle of each project, assuring the quality of the process system, and its conformance with User Requirement Specifications.
The project-specific quality plan ensures that the design, fabrication, installation, testing, and commissioning is carried out in accordance with all relevant standards and specifications. The high standard of drawings and documentation generated during the project builds up to deliver the highest standards of documentation hand-over pack allowing for the efficient and timely validation of our systems.

F.A.T.

Every effort is made to make the FAT as complete as possible to fully challenge the process systems and vessels prior to delivery. Our dedicated testing bays are fully serviced with utilities such as Clean Steam, Hot and Cold DI Water, CIP, Plant Steam, Compressed Air, Nitrogen etc. There is also a full suite of instrumentation and testing equipment available to mimic the conditions in the clients facility. Our tests are comprehensively executed and documented allowing them to be leveraged against further testing on site if the client requires.

Documentation review and verification
Review construction documentation; Welder Quals, Material Certs, NDT reports etc.
Review of certification: hydrotest, PED certification, surface finish certification, calibration certification, etc.

GA and P&ID walkdown
Heating and Cooling Performance
Slope Checks & Drain-ability
Site Built Tanks
Sprayball Performance Testing – Riboflavin
Electrical checks – Continuity, Earthing
Documentation review and verification
I/O Testing – Valve stroking, Instrument Checks
Review of certification: hydrotest, PED certification, surface finish certification, calibration certification, etc.
Test Scada/PLC Communications
Dynamic check on Pumps & Mixers (low and high speeds and loads)
Run phases/operations
Sprayball Performance Testing – Riboflavin
Mixing performance
CIP performance
Heating and Cooling Performance

S.A.T. & Commissioning

With a comprehensive FAT completed we can leverage this testing and reduce the time on site for SAT and commissioning. The main thrust of the testing at this stage is focused on testing the integration of the system with the clients utilities, automation systems and connected process equipment.

Pressure-test and passivate system
Calibrate all instrumentation

Re-execute some/all of FAT
Verify communications with Utilities, BMS and other process systems.
Run all control modules and phases within the skid boundar.
Hydraulically balance the system.
P&ID’s
Simulate failures
Execute the Batch testing with the other process systems.
Verify all deviations are closed out before change control.

IQ/OQ/PQ

Validation is the collection and evaluation of data, beginning at the process development stage and continuing through the production phase, which ensure that the manufacturing processes- including equipment, buildings, personnel and materials – are capable of achieving the intended results on a consistent and continuous basis.
Installation Qualification (IQ) verifies that the equipment, and its ancillary systems or sub-systems have been installed in accordance with installation drawings and or specifications.
Operational Qualification (OQ) verifies that the process system operates in accordance with the Process and Automation Specifications and the user’s Standard Operating Procedures (SOPs).
Performance Qualification (PQ) verifies that the overall user requirements have been met.

Equipment design features
Installation conditions
Ergonomics
Calibration, cleaning schedules, preventative maintenance
Supplier documentation, drawings and manuals
Spare parts list and labels
Testing of control indicators and alarms
Functional testing
Challenge testing
Process control limits
Software parameters