C P Meloni Projects Ltd

Testing/Commissioning Plan

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 TESTING/COMMISSIONING PLAN

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 TESTING/COMMISSIONING PLAN

CONTENTS

Page No.

1.0 INTRODUCTION................................................................................................................................................................3

1.1 Preface......................................................................................................................................................................3

1.2 Definitions.................................................................................................................................................................3
1.2.1 Construction Completion Testing (Testing)...............................................................................................3
1.2.2 Take-over Tests (Commissioning).............................................................................................................3
1.2.3 Performance Tests (if required).................................................................................................................4

2.0 PLANT AND EQUIPMENT INDEX....................................................................................................................................5

3.0 COMMISSIONING PLAN..................................................................................................................................................6

3.1 Procedures and Documentation................................................................................................................................6

3.2 Sequences................................................................................................................................................................6
3.2.1 Programme Requirements.........................................................................................................................6
3.2.2 Documentation Requirements...................................................................................................................6
3.2.3 FATs .........................................................................................................................................................7
3.2.4 Special Requirements................................................................................................................................7
3.2.5 Construction Completion Report (Testing)................................................................................................7
3.2.6 Completion Certificate...............................................................................................................................7
3.2.7 Take-over Tests (Commissioning).............................................................................................................7
3.2.8 Take-over Certificate.................................................................................................................................7
3.2.9 Performance Tests (If applicable)..............................................................................................................7
3.2.10 Acceptance Certificate.............................................................................................................................8
3.2.11 Final Acceptance Certificate....................................................................................................................8

APPENDIX A............................................................................................................................................................................9

Detailed Programme to Completion................................................................................................................................9

APPENDIX B..........................................................................................................................................................................10

Method Statements.......................................................................................................................................................10

FAT Test Results..........................................................................................................................................................10

As-built Plant and Equipment Schedules......................................................................................................................10

APPENDIX C..........................................................................................................................................................................11

Construction Completion Test Record Sheets..............................................................................................................11

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Electrical Installation Completion Certificate.................................................................................................................11

APPENDIX D..........................................................................................................................................................................12

Start-up and Shutdown Procedures..............................................................................................................................12

Commissioning Record.................................................................................................................................................12

Parameter Settings........................................................................................................................................................12

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 TESTING/COMMISSIONING PLAN

1.0 INTRODUCTION

1.1 Preface

The principles are the basis for an orderly and efficient completion of the installation.

The inception to successful commissioning starts at the commencement of each contract.

Complete and accurate documentation, scheduling, programming, monitoring and control

of documentation throughout all phases of the work is essential.

1.2 Definitions

1.2.1 Construction Completion Testing (Testing)

This phase covers all the specific testing (sometimes referred to as just ‘testing’ or ‘pre-
commissioning’) of all individual items of mechanical, electrical, instrumentation
equipment and the building services installations and civil works.

This is the most important phase of site testing, which verifies that all equipment
and installation are completed and operational.

Once completed correctly this work should not have to be revisited.

1.2.2 Take-over Tests (Commissioning)

This phase covers the setting to work of functional groups of equipment, the correct
functional interaction with other areas of the plant, the starting up and shutting down of the
plant and the alarm procedures.

These tests are intended to demonstrate to the Purchaser:

• Plant functionality

• Plant operability

• Plant safety

• Plant maintainability

The introduction of raw water (effluent) to the main flow process requires that training and
O&M manuals are completed before these tests are carried out and temporary discharge
permits in place, if required.

The start-up and shutdown procedures of the plant will include the following:

• sequential start-up procedure

• process adjustments procedure

• operating procedure

• shut down procedure

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• alarm procedure

• control parameters

This phase constitutes the Commissioning of the plant.

1.2.3 Performance Tests (if required)

The performance tests are normally carried out by the Client’s operating personnel on a
routine basis over the first 121 months operation of the plant.

During the first few weeks some minor adjustment may be required to process parameters
to fine-tune the performance.

If all the preceding stages have been implemented correctly this fine-tuning should be
capable of being performed by the Client’s operating/maintenance personnel.

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Client’s Specification to be referred to for performance test period.

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2.0 PLANT AND EQUIPMENT INDEX

The plant and equipment index will consist of a number of schedules containing the most
significant details of all the M&E equipment. These are:

• Pump Schedule

• Valves Schedule

• Tank Schedule

• Drives Schedule (including actuators)

• Instruments Schedule

• Penstock Schedule

• Pipe Schedule

The unique TAG identifies each item No. as shown on the P & I Diagram.

These are the minimal requirements of most projects.

Schedules will be prepared as early as possible in conjunction with the P&I Diagram as
they form the basis of the project scheduling, project engineering, requisitioning,
procurement, inspection, testing and commissioning control procedures later in the
project.

The schedules listed above for M&E equipment is contained in Appendix B.

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3.0 COMMISSIONING PLAN

3.1 Procedures and Documentation

The procedural requirements and documentation for completion will be followed as

detailed in the client’s specifications and Conditions of Contract.

3.2 Sequences

The sequence for completion is given below:

3.2.1 Programme Requirements

The programme for completion, testing and commissioning will be prepared in outline at
the commencement of the project and detailed towards the completion of the detailed
design phase.

3.2.2 Documentation Requirements

Prior to the start of Construction Completion testing the following documents will be
prepared and/or completed and attached in their relevant Appendices.

Appendix A

• Detailed Programme to Completion

Appendix B

• Disinfection Method Statements (potable water projects only)

• FAT Test Results

• As-built Plant and Equipment Schedules

Appendix C

• Construction Completion Test Record Sheets

• Electrical Installation Completion Certificate BS7671: (IEE Wiring Regulations

seventeenth Edition)

Appendix D

• Start-up and Shutdown Procedures

• Commissioning Record

• Parameter Settings

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3.2.3 FATs

The installations/plant will be inspected, tested and recorded on the suppliers/sub-

contractors standard test sheets The FDS will be used as the basis for the test document
for any control panels and/or software testing.

The testing may be completed in phases / plant areas as agreed beforehand with the
Engineer. All test records will be inserted in Appendix B with a copy sent to the Engineer

3.2.4 Special Requirements

Method statements will be prepared and record test data recorded. These documents will
be inserted in Appendix B

3.2.5 Construction Completion Report (Testing)

When the plant has been completely tested, the Construction Completion Report will be in
the form of a copy of all documents listed in Appendix B & C, together with a record of the
programme of demonstrated tests. This will be submitted to the Engineer.

In practice, the demonstration tests required by the Engineer will be agreed at an early
stage and carried out progressively when completed plant systems have been checked
and tested.

3.2.6 Completion Certificate

After satisfactory completion of testing and demonstration tests, the Engineer will issue a
Certificate of Completion, together with a list of minor items requiring completion before
the issue of a Taking-over Certificate.

3.2.7 Take-over Tests (Commissioning)

The following items will be completed before/during this stage of the project:

• draft O&M manuals and as-build drawings

• Training

• safety related minor items advised with the Completion Certificate

• a programme agreed with the Engineer

Completion of take-over tests will be reported / transmitted to the Engineer.

3.2.8 Take-over Certificate

On satisfactory completion of the take-over tests, the Engineer prepares the Taking-over
Certificate for signing by the Purchaser.

At this stage the responsibility for the plant is transferred to the Purchaser.

3.2.9 Performance Tests (If applicable)

If required, Performance tests will be carried out by the Purchaser to check the plant in
respect of final water (final effluent) quality, flow range, specific plant section performance
and operating costs.

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3.2.10 Acceptance Certificate

The Engineer issues an Acceptance Certificate on satisfactory completion of performance

tests.

• quality tests are usually conducted over agreed periods of operation decided by the
Engineer

• performance over the range of design

• performance of plant sections

• operating costs

Performance records will normally comprise the plant archived records from the SCADA
system, supplemented by sampling records, maintenance records and operating cost
records.

3.2.11 Final Acceptance Certificate

Subject to satisfactory performance and completion / rectification of any defects, the

Engineer will issue a Final Acceptance Certificate.

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APPENDIX A

Detailed Programme to Completion

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APPENDIX B

Method Statements

FAT Test Results

As-built Plant and Equipment Schedules

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APPENDIX C

Construction Completion Test Record Sheets

Electrical Installation Completion Certificate

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APPENDIX D

Start-up and Shutdown Procedures

Commissioning Record

Parameter Settings