Professional Documents
Culture Documents
Testing/Commissioning Plan
Date
TESTING/COMMISSIONING PLAN
Distribution
Name
Initials
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
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
APPENDIX B..........................................................................................................................................................................10
Method Statements.......................................................................................................................................................10
APPENDIX C..........................................................................................................................................................................11
1
TESTING/COMMISSIONING PLAN
APPENDIX D..........................................................................................................................................................................12
Commissioning Record.................................................................................................................................................12
Parameter Settings........................................................................................................................................................12
2
TESTING/COMMISSIONING PLAN
1.0 INTRODUCTION
1.1 Preface
The principles are the basis for an orderly and efficient completion of the installation.
1.2 Definitions
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.
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.
• 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:
• operating procedure
3
TESTING/COMMISSIONING PLAN
• alarm procedure
• control parameters
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.
1
Client’s Specification to be referred to for performance test period.
4
TESTING/COMMISSIONING PLAN
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
• Instruments Schedule
• Penstock Schedule
• Pipe Schedule
The unique TAG identifies each item No. as shown on the P & I Diagram.
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.
5
TESTING/COMMISSIONING PLAN
3.2 Sequences
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.
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
Appendix B
Appendix C
Appendix D
• Commissioning Record
• Parameter Settings
6
TESTING/COMMISSIONING PLAN
3.2.3 FATs
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
Method statements will be prepared and record test data recorded. These documents will
be inserted in Appendix B
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.
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.
The following items will be completed before/during this stage of the project:
• Training
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.
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.
7
TESTING/COMMISSIONING PLAN
• quality tests are usually conducted over agreed periods of operation decided by the
Engineer
• 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.
8
TESTING/COMMISSIONING PLAN
APPENDIX A
APPENDIX B
Method Statements
APPENDIX C
APPENDIX D
Commissioning Record
Parameter Settings