Project Description

Asset Care & Technical Documentation

Plan:

Morson Projects has qualified NEC3 Project Managers experienced in initiating, planning, controlling and executing projects on time, on budget and to the highest standards. Contracts and finances are closely managed, risk is identified and managed and disputes are resolved quickly.

Our Project Managers are supported by Planning Engineers using Primavera P6 and MS Project to manage estimation and planning, cost control and budget management, scheduling and resource allocation.

Configuration:

Members of our Asset Care team are proficient in asset tagging and using complete and partial data from hard and soft excel spreadsheets to create/update the Computerised Maintenance Management Systems. Master Equipment Lists are produced/updated, critical spares identified and the Material Masters raised with current lead times, prices, etc. using supplier information. Redline Drawings are used to update CAD files and to verify plant configuration.

Build:

The provision of Installation Instructions detailing quality control & acceptance procedures, safety checks, pre-installation tasks, installation procedures, post-installation/validation checks and technical tests.

Commission:

Morson Projects’ commissioning teams ensure that all commissioning related activities are undertaken in an efficient, consistent and appropriate manner and that they meet all relevant regulatory and legislative requirements. The approach we adopt allows commissioning to be split into distinct stages collectively taking the new plant/equipment into active operation.

Stage 1          Works Commissioning & Testing

Stage 2          Inactive Plant Commissioning

Stage 3          Inactive Safety Commissioning

Stage 4          Active Plant Commissioning

Stage 5          Active Safety Commissioning

As part of our capability we develop commissioning logic, robust programmes and plans to meet client requirements. We provide extensive commissioning knowledge that is aligned to Nuclear Site License arrangements, procedures, documentation and commissioning requirements in support of the Intelligent Customer role. Commissioning Documents are produced to support all stages of the commissioning process.

Reliability Centred Maintenance (RCM2) reviews follow a Failure, Mode and Effects Analysis (FMEA) approach to maintenance tasking and the determining of periodicities. The RCM process underpins all maintenance activities undertaken on the identified system. Asset management activities are also underpinned with an assessment of ageing mechanisms.

Risk Assessments highlight the significant hazards and control measures required to prevent injury or ill health whilst carrying out the task and provide details which are added to the Method Statement documents.

Health & Safety Plans are produced to record consultation, communication and incident reporting arrangements, training and induction requirements, issue resolution, risk assessment and management, workplace hazard inspections and emergency procedures.

Operate & Maintain:

Documentation includes the full suite of Operation and Maintenance (O&M) Manuals – Volumes A, B, C and D which are a legal  requirement to support implementation of the Supply of Machinery (Safety) Regulations 2008 and the Provision and Use of Work Equipment Regulations (PUWER) 1998. All documentation is produced in accordance with BS EN 82079-1:2012 and incorporates any applicable client specific O&M requirements.

The production and review of Operating Instructions for the nuclear industry comply with the requirement that the licensee shall ensure that all operations which may affect safety are carried out in accordance with written instructions.

Maintenance Instructions for the nuclear industry comply with the requirement that all applicable machinery and equipment must be supplied with instructions for its use. The instructions must provide information for the correct and safe operation of the machinery.

Morson Projects produces a full range of documentation to support nuclear plant safety cases. Typical documentation includes Engineering Schedules and Design Assessment Reports. More complex documents such as a Plant Modification Proposals are required to meet Site Licence conditions (as required by Legislation in the Nuclear Installations Act 1965). Other deliverables include:

  • Emergency Instructions
  • Proof Test Instructions
  • Operator Instructions
  • Alarm Response Instructions
  • Breakdown Instructions
  • Guidance Instructions
  • Safety Method Statements
  • Operator Rounds
  • Risk Assessments
  • Scoping Documents
  • Quality Plans
  • Lifetime Plans
  • Equipment Specifications
  • System Performance Demonstration Documents
  • Long Term Periodic Reviews

We adopt a Systematic Approach to Training (SAT) to fully deliver an end to end training solution, which follows the ADDIE (Analysis, Design, Development, Implementation and Evaluation) process. ADDIE is undertaken by a team of training professionals to:

  • Analyse the training need, job and task
  • Design and Develop appropriate classroom, development rig/simulator and plant based training material for a variety of disciplines including plant operators, maintainers (electrical/instrument and mechanical), team leaders and Subject Matter Experts (SMEs)
  • Implement (deliver) appropriate classroom, development rig/simulator and plant based training for a variety of disciplines including plant operators, maintainers (electrical/instrument and mechanical), team leaders and Subject Matter Experts (SMEs)
  • Evaluate the training. Hand over approved Programme Files to the training department, on completion

Our training team members perform Hierarchical Task Analyses to identify O&M deliverables, chair and facilitate workshops to define training implementation plans and schedules which identify the target audience, detailed scope of work and training programme.

Asset Management (ISO55000):

Condition Assessments are performed to assess, investigate and record asset condition details and are supported by photographs, marked-up drawings and Non-Destructive Testing records as required. Recommendations are made for any system defects, shortfalls or perceived engineering standard issues. The recommendations and data are used to measure or trend/predict system failure, life expectancy & reliability.

Spares and Obsolescence issues, where identified, are resolved via existing plant processes. The raising of a Notification of an Asset Care Concern or Issue (NACCI), Technical Query (TQ) and/or attendance at Asset Management Plan (AMP) meetings using company specified policies form part of an integrated delivery process.

The Reliability Centred Maintenance (RCM) process follows a Failure, Mode and Effects Analysis (FMEA) approach to maintenance tasking and the determining of periodicities. The RCM process underpins all maintenance activities undertaken on the system. Asset management activities are also underpinned with an assessment of ageing mechanisms.

Data gathered during the RCM preparation is used to produce an asset hierarchy to sit below the functional area in a Computerised Maintenance Management System (CMMS). Morson Projects creates a Master Equipment List (MEL) to aid this process which is used to produce all necessary documentation to upload new or changed assets into CMMS. Maintenance Prompts for activities identified during the RCM process are created once the new or changed tags are available on CMMS.

Upgrade, Refurbish, Replace:

In accordance with specified configuration policies and procedures, Morson Projects produces the Configuration Management Implementation Plan (CMIP), conducts evaluation to detailed lines of enquiry and produces the Configuration Baseline Report for the bounded system.

Morson Projects has existing arrangements in place to support major projects in the production of System Analysis Reports, CAD drawing revisions and upload to drawing databases. Reviews of the Plant Modification Proposal (PMP) and CMIP are performed to determine:

  • The design documentation produced
  • The types of design documentation requiring update
  • Actual design documentation to be updated.

The Engineering Authority & Approver is informed of any other drawings or asset schedules which require updating. Job requirements, drawing update requirements and timescales are agreed with the client team, Engineering Authority & Responsible Engineer and any commissioning redline drawings are obtained from the Project Manager. The work package is added to the Morson Projects P6 programme, including:

  • Start date
  • Target return date
  • SQEP Resource
  • Plant access requirements

Where required plant surveys are organised to mark-up changes to drawings & schedules. Morson Projects engineers determine whether the Site Plan AutoCAD model and any other drawings require updates and requests are submitted to Drawing Registry. The identified drawings are modified and new drawings produced where necessary. Completed drawing packages are verified with stakeholders prior to delivery to the Drawing Updates Team for checking/approval. The package will include:

  • All modified drawings
  • Details of any updated electronic schedules
  • Original red lined mark-ups
  • Full job report

Decommission:

Method Statements are based on an initial Risk Assessment and detail the way in which a work task or process is to be completed. Although not a legal requirement they outline the hazards involved and include a step by step guide on how to do the job safely, detailing which control measures have been introduced to ensure the safety of anyone who is affected by the task or process.

For further information please contact our team.