TRANSNET PIPELINES
TPL 25
Tarlton Commissioning Plan
Issue Date: 03/07/2015 Revision No.: A Project No.: 11992
Date: 03/07/2015
Document Title: TPL25 – Tarlton Commissioning Plan
Author: Edward Standen
Revision Number: A
Checked by: Trevor Albertyn
Approved by: Didier Regnaud
For: SiVEST Project Management Division
Signature:
Approved by: Charl Bothma (TPL Project Manager)
For: Transnet Pipelines
Signature:
TRANSNET PIPELINES prepared by: SiVEST TPL25 – Commissioning Plan
Revision No. A
03 July 2015 Page 1 of 9
TRANSNET PIPELINES 11992 - TPL 25
Commissioning Plan Contents Page 1. Introduction: ...................................................................................................................... 2
2. Extent of Work: ................................................................................................................. 2
3. Organisation: ..................................................................................................................... 2
3.1. Stages to Construction and Commissioning. ........................................................... 2
3.1.1. C1 - Pre-Commissioning ...................................................................................... 3
3.1.2. C2 - “Cold” Commissioning .................................................................................. 4
3.1.3. C3 - “Hot” Commissioning ................................................................................... 4
3.2. Roles and responsibilities ........................................................................................ 5
3.3. Division of Works into sub-systems for Commissioning .......................................... 6
3.4. Commissioning activity sequencing ......................................................................... 7
4. Schedule: .......................................................................................................................... 7
5. Individual Equipment Testing Procedures: ....................................................................... 9
6. Facility Testing Procedures:.............................................................................................. 9
7. Safety: ............................................................................................................................... 9
8. Check / Data Forms: ......................................................................................................... 9
9. Hand-over Procedures: ..................................................................................................... 9
Annexure A ................................................................................................................................ 1
Annexure B ................................................................................................................................ 2
Annexure C ................................................................................................................................ 3
Annexure D ................................................................................................................................ 4
Annexure E ................................................................................................................................ 5
Annexure F ................................................................................................................................ 6
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Revision No. A
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1. Introduction:
This document is a commissioning plan developed for the Tarlton Fire Protection
upgrade and is to be used to inform the Contractor of the commissioning requirements
for inclusion in the offer as well as to guide the construction and commissioning process
during implementation.
This document will require revision and updating by the Project Manager and Contractor
during implementation. Areas requiring updated are indicated and updates may be in
the form of revisions to the document or addition of Annexures and addendums.
The intention of this document is to indicate the parties involved in commissioning and
define the roles and responsibilities as well as reporting and approval requirements.
2. Extent of Work:
The commissioning shall consider the full extent of the Works and shall encompass
monitoring and approval of civil, structural and building works in addition to monitoring,
approval, installation verification and performance testing of the piping, electrical, control
and mechanical equipment installations.
Commissioning shall be an ongoing process and shall commence during construction
both in order to reduce the overall timeline as well as due to necessity as some
commissioning activities need to be completed before other construction activities can
commence; an example of this is the bottom layer of piping in trenches must be
hydrostatically tested before the pipe can be backfilled and the piping layer above that
layer can be installed.
3. Organisation:
The organisation of the works will facilitate the efficient management and completion of
the commissioning by defining responsibilities, defining the division of works into
manageable and separate sub-systems and indicating a preliminary sequencing of the
commissioning activities.
These factors will inform the scheduling of commissioning activities as well as the
interfaces between the Employer, Project Manager and Contractor.
3.1. Stages to Construction and Commissioning.
The development from existing site to completed installation will develop through a
number of stages broadly comprising construction and commissioning.
There are a number of interfaces and at multiple points during construction and
commissioning the Contractor shall be required to gain permission from the Project
Manager to progress to the following stage.
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The construction will primarily be controlled by the utilisation of Work Permits. Work
Permits shall be completed for each area of work for each day and shall indicate any
work to be completed which will require further permissions. Approval of a work permit
will not constitute approval of that work requiring further permission and the relevant
forms shall be completed for all such works.
Works which require additional permission include:
Excavation
Work within bunds
Work on Tanks
Backfilling over pipelines
Pouring Concrete
The Contractor shall develop standard forms for management of all works requiring
additional approval. These shall indicate the following as a minimum:
Date
Area of works (indicating extents)
Node (i.e. pipe number)
Permission Required
Contractors Name, Position and Signature
Once an area of works is complete the Construction team shall complete pre-
commissioning.
Once pre-commissioning has been completed and signed off, the commissioning team
can complete cold-commissioning then hot-commissioning.
These activities are defined as follows:
3.1.1. C1 - Pre-Commissioning - Contractor and/or Suppliers & Construction
Team
Pre-commissioning consists of Punch Listing of discrete parts of equipment or
systems by Contractors and/or Suppliers before handing over to the Commissioning
Team.
The Construction Engineer will sign off this stage of commissioning when the
following have been achieved:
Punch Listing by the Contractor and Project Construction Team
Rectification of Cat 1 & 2 Punch List Items by the Contractor
Cleaning of the area intended for hand-over
Completion of test sheets such as for Megger, alignment and pressure tests
The equipment or module shall have all hardwired interlocks and protective
systems checked and tested by the Contractor or Supplier
The Construction Engineers shall complete the Certificate once they have
satisfied themselves that all the remaining items on the Punch List can be carried
forward to run testing without endangering life or the safety of the works. They
shall clear any uncertainties with the Construction Manager
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The Construction Team, Commissioning Team and Client Commissioning Team
shall sign the C1 Acceptance Certificate
C1 – “Pre” Commissioning shall be considered complete when all the above items
have been addressed and all documentation submitted to the Document Controller.
C1 - Document Package consists of:
C1 - Acceptance Certificate
QC Data Packs for all disciplines, which include:
- All pre-commissioning checklists and test certificates.
- Punch or Defect Lists
The C1 – Pre-Commissioning Acceptance Certificate must be signed off before
proceeding to the next stage of commissioning.
3.1.2. C2 - “Cold” Commissioning - Contractors and/or Suppliers,
Construction Team and Commissioning Team
This involves running the equipment or module dry to test or perform relevant checks
on the equipment or system. After all safety checks have been completed, all
equipment such as conveyors, motors etc. are run for short periods under the
supervision of the Contractors and/or Suppliers, Construction Engineer and
Commissioning Engineers in accordance with the running tests and procedures
provided by the Design Engineer, Contractor and/or Suppliers.
The following shall be done during these tests:
Equipment or module PLC sequence interlocks shall be checked
Checking, calibration and rectification of all instrumentation such as level, flow,
pressure, density, power meters etc.to ensure correct functionality
Leaks, splashing and any other adverse operating feature shall be eliminated
Unacceptable structural vibrations shall be identified and eliminated
Warranty repairs shall be identified and the installation Contractor and/or
Supplier will provide a programme for rectification
All equipment that forms a zone or stream shall be run simultaneously where
possible, to allow balancing and to check all interlocks and process control
C2 - Document Package consists of:
C2 - Acceptance Certificate
Additions to QC Data Packs:
- Dry run test certificates
- Cold Commissioning Checklists
- Master Punch or Defect Lists
The C2 - “Cold” Commissioning Acceptance Certificate must be signed off before
proceeding to the next stage of commissioning.
3.1.3. C3 - “Hot” Commissioning” - Client Commissioning Team
This involves operating systems to test or perform relevant checks in order to balance
the operation and prove the performance of the system. After all “cold”
commissioning has been completed, whole systems are operated under the
supervision of the Contractors and/or Suppliers, Construction Engineer and
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Commissioning Engineers in accordance with the running tests and procedures
provided by the Design Engineer, Contractor and/or Suppliers.
The following shall be done during these tests:
Discharge flow rates are verified or balanced
Pipelines, valves and systems are tested with full product flow.
Pump flow tests are conducted to prove performance
Foam dosing performance is tested to prove range of operation and correct foam
premix generation
Leaks, splashing and any other adverse operating feature shall be eliminated
Unacceptable structural vibrations shall be identified and eliminated
Warranty repairs shall be identified and the installation Contractor and/or
Supplier will provide a programme for rectification
C3 - Document Package consists of:
C3 - Acceptance Certificate
Additions to QC Data Packs:
- Run test certificates
- Hot Commissioning Checklists
- Final / Master Punch or Defect Lists
- Final Hand Over Certificates
The C3 - “Hot” Commissioning Acceptance Certificate must be signed off in order to
certify completion.
Defect Classification:
Cat 1 These deviations, defects or outstanding items may affect health
and/or safety of personnel and operability and must therefore be
rectified immediately.
Cat 2 These deviations, defects or outstanding items may affect
operability and must therefore be rectified before commencement
of “cold” commissioning.
Cat 3 These deviations, defects or outstanding items do not affect
operability and therefore may rectified during operation but will be
subject to access permits.
3.2. Roles and responsibilities
There are three primary parties involved in the commissioning; these are the Employer,
Project Manager and Contractor.
The primary responsibility for the planning and completion of the commissioning
including the development of all test procedures for equipment and facilities shall rest
with the Contractor. The Contractor may develop these procedures or commission
equipment or system suppliers to develop and complete these procedures however the
responsibility shall at all times remain with the Contractor and the Employer or Project
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Manager may at any time interact directly with the Contractor should problems arise in
interaction with the Contractors appointed sub-consultants.
The Contractor shall complete the following in addition to all commissioning tests:
Develop Commissioning Schedule (may form part of master construction
schedule)
Develop Commissioning Control Document
o This document shall indicate all commissioning activities and interfaces
and shall be a live document, updated and signed off as activities are
completed in order to indicate what following activities can occur.
Develop a Safety Lock out Procedure
Develop Individual Equipment Commissioning Procedures.
Develop Facility Commissioning Procedures.
Arrange for the attendance of the Employer and / or Project Manager at all
activities they are required to witness (this includes planning of activities and
liaison regarding the availability of necessary persons but does not included
provision for travel, accommodation or other similar requirements for persons
other than the Contractor or their suppliers or representatives)
Maintain the records of all commissioning completed and all approved
documents.
The Employer and Project Manager shall be required to witness and approve all final
facility testing. The Employer Project Manager shall also be required to approve the
Commissioning Plan, the Contractors Commissioning Schedule and the Contractors
Commissioning Control Document
The Project Manager shall also be required to approve the Safety Lock-out Procedure
and all Individual Equipment and Facility Commissioning Procedures and shall witness
and approve all tests conducted during cold and hot commissioning.
Particular activities which the Project Manager must approve are:
All back filling must be approved prior to commencement.
Connection to any power supply must be approved
Filling or pressurising of any systems
Starting of any drives (other than valve actuators)
Particular tests which may not form part of cold or hot commissioning but that the Project
Manager must witness and approve are:
Alignment of the fire pump unit
Piping connection to fixed / separately supported equipment
3.3. Division of Works into sub-systems for Commissioning
The commissioning activities of each phase consider different scales of systems.
Pre-commissioning activities consider individual pieces of equipment, lines or sections of
lines and other small installations which form part of a larger system. The division of
systems into separate elements for the pre-commissioning phase means that there are
numerous interfaces which could be neglected and thus the pre-commissioning phase
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must include consideration of interfaces; for instance the connection of pipework to a
pump must be considered and this could form part of the pump or pipework pre-
commissioning or a separate element. For the purpose of this project, all equipment will
be pre-commissioned prior to the installation of pipework connections and the connection
of pipework will form part of the pre-commissioning check for the pipework. This
includes tanks, pumps and any separately supported valves.
Further commissioning including cold and hot commissioning tests are performed on
systems not elements and as such the scope for division is limited. Broadly there are
storage, pumping, foam dosing, distribution, detection and control systems. Each of
these can be cold-commissioned separately with further division possible. There are
elements which will require sequencing such that one two aspects are commissioned
together or for instance the piping can only be commissioned once the storage and
pumping have been commissioned.
Hot-commissioning requires that all systems related to the hot-commissioning activity
have been cold-commissioned. Hot-commissioning will involve the operation of multiple
systems concurrently to both ensure their operational functionality as well as to allow
performance testing of the systems.
3.4. Commissioning activity sequencing
The sequencing of the stages of commissioning is most critical at the interface with
construction and particularly with regards to the installation of piping in trenches and to
operational facilities.
For the installation of piping in trenches, each level of piping needs to be backfilled
before the level above it may be installed; in order to prevent significant rework, all
pipework must be pre-commissioned before it may be backfilled as this verifies the
pipework is free from leaks and suitable for service.
For the installation of piping to tanks, gantries and other working areas, pre-
commissioning shall be completed immediately after completion of the works in an area
in order to prevent the need to grant further access for remedial work after the area has
been returned to operation.
Further to these sequencing considerations, as noted previously, piping may only be
installed to equipment after the equipment has been installed and pre-commissioned.
The Contractor therefore needs to consider this in the scheduling and management of
the construction.
4. Schedule:
The Contractor is to include the commissioning activities in the construction schedule.
Commissioning activities are to take place from an early stage of construction and the
necessary provision for time and resources shall be evident on the programme.
The following is a draft breakdown of the activities during the various project stages:
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Stage Activities
Pre
-
con
stru
ctio
n
Ensure the commissioning costs are considered in the estimate
Make sure that the requirements of the commissioning process are clearly defined
in the tender documentation that is issued to the specialist trade contractors C
on
stru
ctio
n
Prepare the commissioning specification
Produce a detailed commissioning programme
Produce first draft O&M manuals, commissioning method statements and an off-
site commissioning strategy before the start of installation work
Co-ordinate third party involvement in the commissioning process
Conduct pre-commissioning works, involving verification of installation works and
static tests.
Verify and document that the required performance outcomes have been achieved
Collate the pre-commissioning checklists and test sheets in the format agreed
Monitor progress of commissioning activities and construction works
Ensure that continual progress is made with the development of the O&M manuals
Co
mm
issi
on
ing
Perform the setting to work of systems.
Verify and document that the required performance outcomes have been achieved
Carry out regulation of systems. Verify and document that the required
performance outcomes have been achieved.
Undertake performance testing of the works.
Verify and document that the required performance outcomes have been achieved.
Involve facilities management personnel in the commissioning works
Collate the commissioning checklists and test sheets in the format agreed by the
commissioning team
Finish the production of the O&M manuals and integrate the required
commissioning information.
Monitor progress of commissioning process activities and construction works
Pre
-han
do
ver
Verify the quality of the documentary evidence from commissioning process works
Ensure that all required statutory documentation has been produced
Conduct training of users and operators
Update the commissioning plan. Changes made and knowledge gained during site-
based works should be reflected in post-handover works
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5. Individual Equipment Testing Procedures:
The Contractor shall be responsible for the development of commissioning procedures
and test forms for each piece of equipment and element of the works and each stage of
commissioning.
These shall correlate with the Commissioning Control Document.
6. Facility Testing Procedures:
The Contractor shall be responsible for the development of the cold and hot-
commissioning procedures and test forms for each system.
These shall correlate with the Commissioning Control Document.
7. Safety:
Safety is of the utmost importance during construction and no work shall be conducted in
the vicinity of pressurised or running equipment. Commissioning work shall require the
completion of work permits.
8. Check / Data Forms:
In addition to the test forms and procedures for the various phases of commissioning,
there shall be final approval forms. Draft forms have been included in the appendices.
The forms required include:
Pre-commissioning Acceptance Certificate
Cold-commissioning Acceptance Certificate
Hot-commissioning Acceptance Certificate
Design Acceptance
Change Control Notice
Commissioning Dossier Checklist
9. Hand-over Procedures:
The Contractor shall be responsible for the completion of all commissioning including
hot-commissioning.
Hand-over shall be achieved once all commissioning work has been completed with all
tests, verifications and settings approved by the Engineer and the Employer. Hand-over
shall also require that all documentation including all Manuals, Quality Control Files, as-
built and red-lined drawings and operating spares have been supplied by the Contractor.
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Annexure A C1 – PRE-COMMISSIONING ACCEPTANCE CERTIFICATE
AREA / SUB - AREA :
MECHANICAL EQUIPMENT LIST ATTACHED
ELECTRICAL EQUIPMENT LIST ATTACHED
C & I EQUIPMENT LIST ATTACHED
This is to certify that the Equipment / System (as per attached lists) has been tested
and punch listed and “cold” commissioning may commence.
It is the responsibility of the Contractor/Supplier to address the Punch Lists as per a
program agreed with the Construction Manager.
RESPONSIBLE PERSONS:
DISCIPLINE NAME SIGNATURE DATE
MECHANICAL:
AREA ENGINEER
COMMISSIONING ENGINEER
ELECTRICAL:
AREA ENGINEER
COMMISSIONING ENGINEER
C & I:
AREA ENGINEER / COW
DESIGN / COMM. ENGINEER
OTHER:
CONSTRUCTION MANAGER
AREA TEAM LEADER
CLIENT ELEC. ENGINEER
CLIENT C & I ENGINEER
CLIENT COMM. ENGINEER
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Annexure B
C2 – “COLD” COMMISSIONING ACCEPTANCE CERTIFICATE
AREA / SUB - AREA :
MECHANICAL EQUIPMENT LIST ATTACHED
ELECTRICAL EQUIPMENT LIST ATTACHED
C & I EQUIPMENT LIST ATTACHED
This is to certify that the Equipment / System (as per attached lists) has been tested
and “hot” commissioning may commence.
It is the responsibility of the Contractor/Supplier to address the Final / Master Punch
Lists as per a program agreed with the Construction Manager.
Final Hand Over / Release Certificates have been issued to the Contractor.
Client has taken over the responsibility for the care, custody and control of the
system/plant.
RESPONSIBLE PERSONS:
DISCIPLINE NAME SIGNATURE DATE
MECHANICAL:
COMMISSIONING ENGINEER
DESIGN ENGINEER
ELECTRICAL:
COMMISSIONING ENGINEER
DESIGN ENGINEER
C & I:
COMM / DESIGN ENGINEER
AREA TEAM LEADER
CLIENT ELEC. ENGINEER
CLIENT C & I ENGINEER
CLIENT COMM. ENGINEER
CLIENT PROJECT MANAGER
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Annexure C
C3 – “HOT” COMMISSIONING ACCEPTANCE CERTIFICATE
AREA / SUB - AREA :
MECHANICAL EQUIPMENT LIST ATTACHED
ELECTRICAL EQUIPMENT LIST ATTACHED
C & I EQUIPMENT LIST ATTACHED
This is to certify that the Equipment / System (as per attached lists) has been tested
and “hot” commissioned.
It is the responsibility of the Contractor/Supplier to address the Final / Master Punch
Lists as per a program agreed with the Construction Manager.
Client has taken over the responsibility for the care, custody and control of the
system/plant.
RESPONSIBLE PERSONS:
DISCIPLINE NAME SIGNATURE DATE
MECHANICAL:
COMMISSIONING ENGINEER
DESIGN ENGINEER
ELECTRICAL:
COMMISSIONING ENGINEER
DESIGN ENGINEER
C & I:
COMM / DESIGN ENGINEER
AREA TEAM LEADER
CLIENT ELEC. ENGINEER
CLIENT C & I ENGINEER
CLIENT COMM. ENGINEER
CLIENT PROJECT MANAGER
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Annexure D
DESIGN ACCEPTANCE
AREA / SUB - AREA :
MECHANICAL EQUIPMENT LIST ATTACHED
ELECTRICAL EQUIPMENT LIST / CABLE SCHEDULE ATTACHED
C & I EQUIPMENT LIST / CABLE SCHEDULE ATTACHED
DESIGNERS / SUPPLIERS;
COMPANY DOCUMENT RECEIVED
COMMENT
The above mentioned installation / system has been constructed according to
approved design and thus is “fit for purpose”.
Alterations / Amendments / Additions / Exclusions / Restrictions
Name_____________________ Signature_________________ Date______________ Design Engineer
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Annexure E
CHANGE CONTROL NOTICE
Contractor /Vendor:: Area:
Attached : SI Nº CVCO Nº CN Nº:
Originator : Date : Sign : Revision :
Description :
Name Signature Date
Requested by:
Schedule checked
Hazop completed
Disciplines Design Cost Equip. cost Estimated by Total
Mechanical
Elect/Instr/Contr
Civil/Structural
Other
Cost :
TICK IN APPROPRIATE BLOCK
PROCEED WITH WORK
PROCEED WITH CHANGE WHILE COST & SCHEDULE IMPACT IS BEING
EVALUATED (EVALUATION TO BE COMPLETED WITHIN 2 WEEKS)
HOLD UNTIL DETAILED EVALUATION OF COST & SCHEDULE IMPACT IS APPROVED
SIGNING AUTHORITY
FOR EMPLOYER
Name :…………………....
Title ………………………
Signed …….………………
Date ……..…………..……..
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Annexure F
COMMISSIONING DOSSIER CHECKLIST
AREA / SUB - AREA :
MECHANICAL EQUIPMENT LIST ATTACHED
ELECTRICAL EQUIPMENT LIST / CABLE SCHEDULE ATTACHED
C & I EQUIPMENT LIST / CABLE SCHEDULE ATTACHED
Checklist:
Yes No Comment
1. Mechanical QC Packs
As - Built Drawings
O & M Manuals (Spare Parts List)
2. C & I (Install) QC Packs
Loop Drawings
As - Built Cable Schedules
3. C & I (Supply) Certificates Of Compliance
Calibration Certificates
Delivery Acceptance
Data Sheets
4. Electrical QC Packs
As Built Drawings
5. Equipment: Data Sheets
Certificates Of Compliance
6. Pre- Commission Acceptance Certificate
7. Cold commissioning Acceptance Certificate
8. Final Hand Over Certificates to Contractors
9. P & ID’s (Redlined or As Built)
10. Other Drawings
11. Design Acceptance
12. READY FOR TRANSMITTAL TO CLIENT
SiVEST Project Management Division 4 Pencarrow Crescent, La Lucia Ridge Office Estate, Umhlanga Rocks. 4320 PO Box 1899, Umhlanga Rocks. 4320 South Africa Tel + 27 31 581 1500 Fax +27 31 566 2375 Email [email protected] www.sivest.co.za Contact Person: Didier Regnaud Cell No.: 082 818 4965 Email: [email protected]