ZENATOR SYSTEMS
Commissioning Guidelines & Notes
Introduction
The purpose of this document is to provide COMPANY Projects with a detailed procedure for use
during the implementation and recording of Mechanical Completion, Pre-Commissioning and
Commissioning of all COMPANY Projects.
The Completions phase commences with the testing, inspection and validation of discrete Construction
packages with concurrent Handover to the Commissioning Group (for commencement of Pre
Commissioning) and continues until all packages forming the whole Facility have been completed and
accepted. Dynamic Commissioning of each system shall then be carried out in accordance with
approved System specific procedures.
This provides an overview of the various aspects of the Completions process, systems and certification,
documentation required to implement record and validate Completions activities.
1.0
Abbreviations
ZEN
Completions Management System
FAT
Factory Acceptance Test
F&G
Fire & Gas
ITR-A
Inspection Test Record (Mechanical Completion)
ITR–B
Inspection Test Record (Pre-Commissioning)
CONTRACTOR
Kastroy Services Construction Group
MC
Mechanical Completion
MCSSAC Mechanical Completion Sub System Acceptance Certificate
NOSE
Notice of System En-ergization
OWR
Outstanding Work Register
P&ID
Piping & Instrument Diagram
PC
Pre-commissioning
PCSSAC Pre-commissioning Sub System Acceptance Certificate
PTW
Permit to Work
RFCC
Ready For Commissioning Certificate
SAC
System Acceptance Certificate
SLD
Single Line Diagram
LOSH
Limits of System Handover
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1.10
Definition of Mechanical Completion
Mechanical Completion (MC) as a term means bringing the equipment, packages and Hull systems, to a
state of installed completion, whereby single discipline pre-commissioning can commence in accordance
with project specifications. The fabrication yard and where applicable, vendor representatives will
demonstrate MC by inspection, verification and testing of the installation and presentation of the
information in check sheet format (ITR ‘A’ Check sheets) so as to confirm the design specification
Typical work, which may be specified on the relevant Mechanical Completion Records will include, but
not be limited to, the checks and verification of completion of the following:
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Fabrication, assembly and finishing of all structural steelwork.
Installation of platforms, including stairways, safety grills, etc.
Surface preparation, painting or galvanising of all steelwork, pipe work, equipment and facilities
support steelwork.
Installation of all equipment described in the contract and designated for installation together with
its associated piping, electrical components, instrumentation and other services.
Fabrication, installation, connection and hydrostatic testing of all pipe work including flushing
cleaning and drying activities.
Installation of all cable support systems, cable glands, penetrations, junction boxes, outlets, light
fittings and grounding.
Installation, securing, terminating, marking, continuity and tightness checking, of all electrical,
telecommunications and instrumentation cabling and wiring.
Installation of all switchgear, transformers etc., power supply and control panels.
Installation of HVAC ducting complete with all support steel, equipment, accessories, filters,
instrumentation and controls. Carrying out an integrity test of the ducting and mechanical function
tests of equipment.
Checking free rotation and proper orientation of all rotating equipment.
Installation of all, floor coverings, partitions, wall linings and associated insulation, furniture, fittings
and service systems.
Installation of all, instruments, instrument control panels, associated piping, tubing and cabling.
Tightness testing of piping, tubing and continuity checking of cable.
Installation of all, fire protection / detection and gas detection equipment, accessories including
associated piping and wiring.
Installation of, insulation and insulation fixing materials.
Installation of safety equipment including platform safety and hazardous area signs.
Installation and testing of lifting equipment.
1.20
The Mechanical Completion Process
In order to achieve a proper and correctly documented handover from CONTRACTOR to
COMPANY Commissioning Group and from COMPANY Commissioning group to
Operations & Maintenance all Systems shall be divided to form Sub Systems.
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A sub-system is the boundary of equipment, which can conveniently be grouped for the purposes of
dividing a larger system into more manageable sections for mechanical completion and when all the subsystems are agreed as mechanically complete, the larger system can in turn become mechanically
complete.
Each Sub System shall be allocated an alpha numeric code by the COMPANY Commissioning Group,
Every item of equipment within each Sub System e.g., piping, cables instruments etc. shall be referenced
by its assigned Sub System number.
The boundary limits of Sub Systems shall initially be identified by COMPANY Commissioning Group on
marked up, colour coded P&IDs, Layout Drawings and Electrical Single Line Drawings. The boundary
limits shall be reviewed and agreed with COMPANY Commissioning Group prior to final approval.
Sub Systems are defined as mechanical completion sections in which priorities for completion shall be
agreed and established by COMPANY Commissioning Group, and CONTRACTOR.
On completion of approved System/Sub System boundaries, all equipment within the established Sub
System limits shall be listed including in line and remote instruments and associated power and control
cables by type and number.
The listing of equipment shall be further broken down into individual Mechanical Completion Records
(ITR-As) which identify test and inspection requirements for each item of equipment.
This listing of ITR-As shall be entered into the Mechanical Completion Database by ITR-A type no.,
Discipline, System, Sub System and Tag number. The blank ITR-A forms by type are already held in the
database. CONTRACTOR shall be issued with ITR-As in Discipline and Sub System packs by the
Zenator Power Users direct from the database.
CONTRACTOR shall then proceed to carry out the checks as required by the ITR-A sheets.
Flow Chart; Production / Commissioning Flow of ITRs A and B Check Sheets (Appendix A)
Demonstrates the flow of ITR Check Sheets from issue by the Zenator Power User right through the
MC process until the Check Sheets are returned, signed, verified and ready for scanning into Zenator.
1.21
Mechanical Completion Record ITR-A
The Project Mechanical Completion Record ITR-A is a standard form tailored to suit a particular item
or type of equipment which identifies the specific checks and tests to be done and records to be kept to
achieve the verification of compliance with design, specification, regulations, quality control and
certification of the installation as being Mechanically Complete.
The ITR-A pro forma shall be prepared by COMPANY Commissioning Group and assigned a unique
barcode within the Zenator Completions System data base.
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Any future additions, deletions or amendments to ITR-As shall require approval by the Zenator Power
Users who shall maintain responsibility for issuing and recording ITR-As and Handover documentation.
Each ITR-A contains facilities for approval by Authorised signatories and shall not be deemed complete
until approval signatures have been obtained.
An Authorised Signature Matrix (see Appendix E) shall be implemented and maintained by Zenator
Power Users and Commissioning groups.
Where Commissioning group’s review reveals that the requirements of the ITR-As, Design
Specifications or Drawings have not been achieved, CONTRACTOR shall rectify the work and shall resubmit the item of work / ITR-A for approval.
The ITR-A for specific items of equipment shall list the checks which are normally performed upon that
type of equipment but may not be specifically written for each particular item of equipment. In this case
the check box NA can be selected
It should be noted that although ITR-As are necessary evidence of work completion, they are not
intended to supersede, modify or vary contractual agreements.
All MC inspections/tests shall be performed with equipment un-energized.
All inspection and test equipment used for measurement shall be calibrated to a national standard. A list
of test equipment and current calibration details shall be maintained and submitted to COMPANY
Commissioning group.
It is necessary that each inspection item is addressed and each item shall require either a "yes or "no" or
"not applicable" comment. Any item necessitating a "no" must be then identified on a punch list.
ITR-As are divided into the following disciplines.
1.22
DISCIPLINE
Architectural
Electrical
Fire and Gas
HVAC
Instrumentation
Mechanical
Piping
Telecommunications
Structural
Group Printing of ITR-As
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In a Sub System where there is a requirement to print numerous ITR-As. of a specific type and the
checks are mainly generic, a facility to group print these check sheets has been created called a Bulk
Check Sheet.
This involves the printing of a master check sheet and an attached computer generated list of all relevant
tags. These tags are then checked / inspected against the master check sheet and any unique information
recorded on the attached sheet. This facility is generally available at the discretion of the Zenator Power
Users, for the following check sheets.
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1.30
Power / Control Cable Installation & Test
Junction Box Installation
Field Instrument Installation
Fire & Gas Detection Device Installation
Mechanical Completion Handover
Upon completion of each ITR-A Check Sheet and approval by the authorised signatory of all ITR-A’s
within a Sub System, Zenator Power Users will generate an MCSSAC for CONTRACTOR to offer the
Mechanically Complete Sub System to COMPANY Commissioning Group for approval, complete with a
computer printed status index (list) detailing completed ITR-A’s and any outstanding punch-list items
and modified ‘As built’ drawings.
COMPANY Commissioning Group shall carry out a physical review of the offered Sub System,
documentation and accept or return the Sub System to CONTRACTOR for completion. Upon
acceptance of a Sub System by Zenator Power User they shall enter details of completion of the ITR-As
and Handover documentation into the database. Any part of an ITR-A which is unable to be completed,
shall be entered into the database and Zenator Power User shall generate these items Sub System
Punch List Registers.
Only when all Sub System ITR-As have been completed shall a Sub System, be considered 'mechanicallycomplete'. If a shortage of materials or outstanding design changes prevent completion of certain ITR-As
then a punch-list shall be raised and agreed between CONTRACTOR and COMPANY Commissioning
Group. In general and as a matter of principle Sub System Acceptance Punch Lists shall contain only ‘B’
items.
In exceptional circumstances the Commissioning group can agree to accept a Sub System with ‘A’ Punch
List Items, if these items can be effectively isolated from the System on a temporary basis so as to allow
the commencement of Pre-Commissioning in an efficient and safe manner.
Acceptance of a Sub System by COMPANY Commissioning signifies the formal Handover of ownership
of all equipment defined (with exceptions) in the transmission. This means CONTRACTOR requires
COMPANY Commissioning authorisation via the Permit to Work System to carry out any activities on
equipment within the Sub System. e.g. clear Punch List items.
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Note: Upon Commissioning Group signing, MC System Acceptance certificates, carrying Punch List
items, then clearing these remain the responsibility of CONTRACTOR as applicable.
MC Handover is as per Handover Documentation Flow Chart (Appendix C).
1.40
Definition of Pre-Commissioning and Commissioning
Pre Commissioning is the execution of single discipline checks carried out on individual items of
equipment by authorized Commissioning personnel, required to demonstrate unit or component
functionality by introduction of energy, operation under loaded conditions, and prior to the dynamic
operation and testing of the system in which the components reside. Presentation of information is in
check sheet format (ITR‘B’ Check sheets).
Tests shall:
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Verify MC documentation is in place.
Be carried out on a single discipline basis.
Require individual items of equipment to be energized
Validate the design functionality of equipment
Generally not require process fluids
Record any outstanding Punch List items.
Verify equipment Functionality
Commissioning is the activities undertaken to ensure the dynamic verification of the functioning units or
components and facilities forming a discrete operational system, sub system or commissioning package
by demonstrating and recording its accordance with design parameters, regulations and specified
operational requirements.
Operation may be simulated, prior to introduction of normal operating conditions. This activity is
carried out and presented and recorded in accordance with individual detailed procedures developed
specifically for the activity.
Typically; dynamic commissioning activities undertaken after the completion of Commissioning
Completion Records will:
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Be carried out on a System or Sub System containing more than one piece of equipment.
Be carried out by a multi-disciplined team of Engineers.
Be executed with the assistance of, or witnessed by, Operations personnel.
Be executed as a series of steps set out in a procedure and signed off on completion of each
step.
Be executed using permanent utilities.
Be executed using simulated conditions and confirmed when process fluids are available.
Be witnessed by the Certifying Authority where applicable.
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Commissioning Guidelines & Notes
The Commissioning Process
The commissioning process is the overall process by which equipment and systems which have not been
operated before are brought into operation.
The process begins prior to the commencement of Mechanical Completion whereby, the Power Users
identify commissionable packages of Systems and Sub Systems. The boundary limits of Sub Systems will
be identified on marked up P&ID’s, Electrical Single Line Drawings F&G, Telecom plans and Block
Diagrams. Each Sub System is allocated an alpha numeric code and every item of equipment, piping,
cables is referenced by a unique Sub Systems no.
Sub Systems will fall into commissioning sections where all equipment will be further broken down into
individual Pre-Commissioning Completion Records (ITR-B) requirements. This information will be
entered into the Zenator System (Zenator) database by ITR type no., discipline, System, Sub System and
tag number.
The Zenator Completions System will provide the documentation for recording the interim stages of
progress and outstanding work of Discipline, System, and Sub System completion from Mechanical
Completion to Final Handover to Operations.
This definition provides a common database and tracking register for all Mechanical Completion, PreCommissioning and Commissioning activities.
Commissioning Records (ITR Bs) will be issued in Discipline and Sub System packs by the Zenator
Power User direct from the computer database.
Flow of ITR B Check Sheets will be as per the ITR Check Sheet Flow Chart, (Appendix A)
ITRs are used to prove, validate and record the functioning of individual pieces of equipment during the
Pre-Commissioning phase.
A detailed step by step Commissioning Procedure will be produced by COMPANY Commissioning for
each System which will contain all the information required to dynamically test the System in accordance
with Vendor recommendations and design criteria. This procedure will also include an index of all ITRs
for individual pieces of equipment within the System.
1.50
Pre Commissioning Completion Record ITR-B
The Commissioning Completion Record (ITR-B) identifies the specific checks and tests to be carried out
and the records to be kept to prove and validate the functioning of equipment.
ITR-B Check Sheets shall be prepared by Zenator Power Users and assigned in the Zenator
Completions System (Zenator) data base.
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Any future additions, deletions or amendments to ITR-Bs shall require approval by the Lead Discipline
Engineer.
Zenator Power User shall maintain responsibility for issuing and recording ITR-B Check Sheets and
Acceptance documentation.
The ITR is a standard form tailored to suit a particular item or type of equipment on which checks and
tests are required to prove functionality. As an example; the ITR B Check Sheet for pumps, motors,
vessels etc. will list the checks which are normally performed upon that type of equipment but may not
be specifically written for each particular item of equipment.
Each ITR-B contains facilities for Approval by Authorised signatories and shall not be deemed complete
until Approval signatures have been obtained.
It is necessary that each inspection item is addressed and each item will require either a "yes or "no" or
"not applicable" comment. Any item necessitating a "no" must be then identified on a punch list.
An Authorised Signature Matrix (see Appendix B) will be implemented and maintained by
Commissioning.
ITR-Bs will be allocated unique numbers denoting each discipline and the System or Sub System within
which the equipment is located.
The Zenator System (Zenator Power User) will issue indices by Sub System detailing the status of all
ITR-Bs within each Sub System by discipline.
Status Indices of ITR-Bs will form part of Commissioning Procedures as handover documentation
Zenator Power Users shall continuously review the ITR-B indices and System Responsible Discipline
Engineers will assess and authorise any necessary additions and deletions required to maintain the
integrity of Completion and Commissioning.
All inspection and test equipment used for measurement shall be calibrated to a national standard
complete with the relevant documentation.
ITR-B’s are divided into the following disciplines:
DISCIPLINE
- Electrical
- Fire and Gas
- HVAC
- Instrumentation
- Mechanical
- Telecommunications
- Dynamic Commissioning
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Copies of Pre Commissioning Records (ITR-Bs) can be obtained from Zenator Power Users.
1.60
Commissioning Procedures
The objective of the System Commissioning Procedure is to set out guidelines and objectives so as to
allow Systems to be commissioned safely in a controlled manner and a method of documenting the
extent of testing undertaken (and that which remains outstanding), whilst demonstrating system
operability to the Operations group at point of Handover.
The purpose of the System Commissioning Procedure is to define, describe and record all multidisciplined preparations and activities to be progressed, endorsed and recorded in a logical step by step
manner.
Commissioning procedures will be developed by the COMPANY Commissioning group in a standard
format which will be Subject to COMPANY Management Group approval prior to Rev 0 issues.
The technical content of Commissioning Procedures will be developed using all Design drawings,
parameters and specifications in addition to Vendor documentation, manuals and equipment
performance characteristics in accordance with legislative bodies and statutory regulations.
Commissioning procedures will be developed for each System or Sub System to be commissioned by a
multi-discipline team of Commissioning Engineers, with a nominated System Responsible Engineer, of the
primary discipline, for each procedure.
Commissioning procedures shall define agreed safety critical elements within each System for which
specific tests and activities shall be witnessed, signed and endorsed by the appointed Certifying
Authority (C.A.) on satisfactory completion.
The execution and validation of commissioning will be the responsibility of the COMPANY
Commissioning group, with assistance and guidance from the Zenator Power Users with nominated
System Responsible Engineers maintaining overall responsibility for execution of each of their allocated
Systems and procedures.
Commissioning Procedures can be recorded in the data base by the allocation of Dynamic
Commissioning ITR-Cs (C-01C).
1.61
Dynamic Commissioning Completion Record ITR-C
The Dynamic Commissioning Completion Record ITR-C (C-01-C) is allocated to each Commissioning
Procedure in order to track, control and record progress of dynamic testing of each system within the
database.
1.70
Commissioning Handover
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When CONTRACTOR / COMPANY Construction Group have completed the checks as required by
the ITR sheets and when all Sub Systems ITRs have been completed for a Sub System, the Zenator
Power User will raise a Mechanical Completion Sub System Acceptance Certificate (MCSSAC). This will
be endorsed by CONTRACTOR / COMPANY and handed over to the COMPANY Commissioning
Team along with a computer printed list detailing completed ITRs and any outstanding punch-list items.
CONTRACTOR / COMPANY shall include all modified ‘As built’ drawings in the handover
documentation.
On acceptance of a Sub System, COMPANY Commissioning shall commence Pre-Commissioning by
completing the checks required on the ITR B Check Sheets for all equipment within the Sub System. On
completion of all required ITRs for a Sub System, COMPANY Commissioning (assisted by COMPANY
Operations & Maintenance) shall carry out dynamic commissioning of the completed Sub System /
System in accordance with the specific System Commissioning Procedure.
On completion of dynamic commissioning (and re-preservation as applicable) of a System or Sub System
COMPANY Commissioning shall accept and take ownership of that System/Sub System.
COMPANY Commissioning will raise a System Acceptance Certificate (SAC) for each system on a
progressive basis which will be issued to CONTRACTOR for acceptance along with the completed
System Commissioning Procedure, ITR Check Sheets, Punch Lists and supporting documentation.
Acceptance of the final Handover will require any red line mark-up drawings, lists of outstanding
activities and the relevant certification documentation to be identified and made available.
Operations will then take over full ownership of the systems and operate in accordance with the
operational procedures and maintain the equipment and systems under the Maintenance Strategy.
Commissioning Handover is as per Handover Documentation Flow Chart (Appendix C).
1.80
Punch Lists
On completion of an ITR, any item which does not meet the required standards should be signified in
the” no “column, and the specific check number, description of fault / non conformance and
categorisation A or B entered in the comments section of the relevant ITR. Supporting information,
attachments or continuation sheets should be clearly referenced in the comments section.
Punch list details will be entered in the Zenator database, which will format individual items on a
discipline basis for each Sub System. Subsequent clearance of Punch List items will be recorded in the
database.
a) Outstanding Punch lists compiled by Construction and Commissioning in discipline format will
be Submitted to Operations with the completed Sub Systems Completion certificate, and will
be mutually agreed and categorized before being issued as a Punch List Completion check
record.
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b) All punch list items of both categories are to coincide with the relevant discipline ITR item
no's where the "no." column has been utilized. Items will also be supported by relevant
material, order no's, damage reports, material shortage reports, photographs etc. Any item
considered by Commissioning to be a design change will be raised in the form of a design
change proposal with supporting information.
c) Punch lists items will be categorized into A or B status.
Category “A”
Any punch list item that is categorised as 'A' will indicate that the relevant System is
considered unsafe to operate or cannot be operated effectively, will be rejected and returned
in its entirety to CONTRACTOR or Commissioning as applicable. The returned Sub System
shall be accompanied by, the Completion certificate noted, rejected, signed and dated. The Sub
System will be re-Submitted to on completion/resolution of punch list 'A' items.
In special circumstances Zenator Power Users can sanction handover of Sub Systems with ‘A’
Punch List items included e.g. where punch list item can be rendered safe and can be isolated
so as to permit the efficient progress of Pre-Commissioning / Commissioning.
Category “B”
Activities, which do not affect the safety, operation or Start up of the offered Sub Systems or
equipment will be categorised as a “B” item. However the raising of such items for acceptance
should be kept to a minimum as a high proportion of Punch List items for an individual Tag or
Sub System will result in a rejection of the Submission.
In general, acceptance of Sub System Completion certificates will be held until completion of
outstanding “A “ punch list items or until outstanding 'B' items are agreed.
Zenator Power Users shall, maintain on database an updated status of outstanding punch list
items and cleared Punch List items as a permanent record of Sub System status and on final
completion shall be entered into the computerised archive together with ITR A / ITR B data
associated with the relevant Sub Systems.
1.90
Endorsement of Signatory Authority
Zenator Powers Users / COMPANY Commissioning and CONTRACTORs shall agree a list of
nominated personnel authorised to sign acceptance of Completions certification. An Authorised
Signature Matrix (Ref: Appendix B) shall be established identifying the level of authority for nominated
individuals. Zenator Power Users shall be responsible for maintaining and distributing current revisions.
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2.00
Vendors Representatives
CONTRACTOR Construction shall issue a Vendor schedule defining CONTRACTOR requirements
and shall co-ordinate Vendor site visits during installation.
COMPANY Commissioning Group shall issue a schedule of Commissioning Vendor requirements and
shall co-ordinate Vendor site visits during Pre-commissioning and System dynamic Commissioning.
The initial issue of CONTRACTOR Construction and COMPANY Commissioning schedules shall be
reviewed and where possible rationalised and co-ordinated to avoid duplication of effort or resources.
2.10
Vendor Documentation
Zenator Powers Users shall review existing and proposed vendor documentation and procedures to
ascertain Commissioning Check Record requirements for each Sub System.
Any tests or checks required on an ITR which have previously been carried out by the Seller/
Manufacturer, upon which documentary evidence is available shall be assessed for validity, who shall
determine whether such documentation is sufficient in its entirety to fully comply with Project
requirements.
Upon completion of this review COMPANY Commissioning Group shall implement one of the following
options:
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Issue ITRs for all equipment within a Sub System.
This shall apply when no Vendor documentation is available, or that which is available, does
not comply with requirements.
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Issue ITRs with instructions to attach (or reference) Vendor documentation to relevant
Records.
This shall apply when Vendor documentation only partially complies with requirements.
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Issue no ITRs
This shall apply when Vendor’s complies with all requirements and no further testing is
identified.
Vendor Commissioning Procedures will also undergo this review process with the same criteria and
resolution applied.
2.20
Preservation
Preservation and De-Preservation throughout the Mechanical Completion and PreCommissioning/Commissioning phases shall be the responsibility of the CONTRACTOR Construction
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and COMPANY Commissioning groups and should be carried out in accordance with approved
Preservation procedures and Vendor recommended preservation requirements.
Specific post commissioning acceptance re-preservation requirements shall be identified by
CONTRACTOR in the individual commissioning procedures and preparation scope. Implementation of
Post commissioning preservation shall be the responsibility of COMPANY Commissioning Group until
Handover and Acceptance by Operations group of the individual System or Sub system.
The Projects, on completion, will be handed over to COMPANY. As such it will be necessary to
preserve certain equipment and systems until so as to prevent corrosion, deterioration of the
equipment and maintain all systems in perfect operating condition. Where required Vendor preservation
procedures will be strictly applied and followed.
2.30
Safety
General
The safety objective during the execution of CONTRACTOR Construction, Mechanical Completion and
Commissioning activities is to prevent all unsafe actions and working conditions which potentially may
cause injuries, health risks and damage to assets.
All personnel involved shall comply with Project Safety. Health and Working Environment requirements
and also with safety requirements contained in Site Manuals and procedures
Ref: Project HSE Plan, Document No- [Hold]
CONTRACTOR & COMPANY Commissioning Group shall implement a Permit to Work System which
shall remain in force throughout Mechanical Completion, Pre-Commissioning, and Commissioning
phases. The PTW System shall include procedures for the Livening Up of equipment and systems, and
definition of responsibilities during the MC/ Pre-Commissioning / Commissioning phase.
As a minimum all Commissioning activities will be carried out under the approved PTW system with
attachments NOSE, MCSSAC, RFCC MC/PC Status indices, PL Reports, Marked up P&ID / SLD,
PCSSAC, ZENATOR Status reports as specifically required.
Ref: Permit to Work System (PTW). [HOLD]
A Task Risk Assessment shall be carried out prior to the commencement of Dynamic Commissioning of
all systems undertaken by Commissioning in accordance with the approved Commissioning Procedure.
2.40
Planning and Reporting
Planning of Mechanical Completion shall be driven by Commissioning Completion Logic which
determines the precedence of priority for each System e.g. Utility Systems such as Diesel, Instrument
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Air, Drains and Electrical Power are required to provide services for all other Project Systems and
therefore shall be prioritised for Mechanical Completion.
Zenator Power Users shall develop Commissioning Logic, which will be over laid against the
COMPANY Commissioning Group programme to produce an overall Commissioning Schedule defining
Mechanical Completion of each Sub System by Milestone. Mechanical Completion Sub System
Milestones shall be determined by:
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Site testing required following Factory Acceptance Testing.
Equipment Delivery dates.
Planned duration of CONTRACTOR Construction and MC activities.
Definition of work scope.
Required MC Handover dates to meet critical start dates of Pre-Commissioning and Dynamic
System Commissioning in order to achieve overall Project Completion Milestones.
2.50
Test Equipment
COMPANY Commissioning Group shall maintain a comprehensive list of all Test equipment to be used.
This list shall prove that all test equipment has a standard of accuracy better than that of the
manufacturer's stated accuracy for the instrument / equipment being tested. Acceptable evidence of the
satisfactory condition of test equipment (e.g. copies of up to date Test Certification) shall be provided in
accordance with Commissioning requirements. All test equipment shall be frequently checked
throughout the mechanical completion period for deterioration. Where test equipment requires an
electrical or air supply, Commissioning shall ensure accuracy of voltage and frequency/ pressure and
quality.
2.60
Check Sheets Completion Rules
All ITR A’s & B check sheets need to follow a standard throughout the MC. & PC. commissioning phases
and total handover to operations and maintenance groups. These standards maintain traceability and
master record compilation in the handover process.
The following rules MUST be adhered:
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All ITR check sheets are completed in BLUE pen
No whiteout or correction fluid used on the document
All signature boxes are completed, signed and dated
Signatures should be completed as per the signature matrix (See Image Below)
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2.70
As Built Drawings
As built drawings play a significant part in the handover process from MC to PC and final handover to
Operations and Maintenance, strict guidelines should be maintained when completing ‘As built
documentation to ensure transparency throughout total project phases. As built stamp must be used on
every document complete in RED accompanied by the issuer’s Signature, Name and Dated. Changes to
any information in the document should be clouded and scratched in RED with the new information
clearly and visibly shown. These documents should be attached with associated ITR or necessary
paperwork and placed in the relevant sub-system or system dossiers and issued on (SAC) completion.
Master drawings such as P&ID’s, Isometrics, SLD’s should be stamped with a BLUE Master Stamp and
remain in the Zenator Power User Control until new Revisions are issued and documented accordingly
and distributed throughout the system process.
As constructed drawings should all be stamped and clearly indicate ‘As constructed and be issued to all
relevant Groups using the correct distribution process.
2.80
Limits of System Handover (LOSH)
A sub-system is the boundary of equipment, which can conveniently be grouped for the purposes of
dividing a larger system into more manageable sections for mechanical completion and when all the subsystems are agreed as mechanically complete, the larger system can in turn become mechanically
complete.
Each Sub System shall be allocated an alpha numeric code. Every item of equipment within each Sub
System e.g., piping, cables instruments etc. shall be referenced by its assigned Sub System number.
The boundary limits of Sub Systems shall initially be identified by COMPANY Commissioning Group on
marked up, colour coded P&ID's, Layout Drawings and Electrical Single Line Drawings. These
documents remain custody of the Commissioning Group.
The boundary limits should follow simple guide lines in order to ensure a simple handover process
throughout the project phases.
Commissioning Guidelines - 20130419
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ZENATOR SYSTEMS
Commissioning Guidelines & Notes
1.
2.
3.
4.
5.
Commissioning Guidelines - 20130419
The separation of process trains into individual systems
Boundary limits finish on a flanged connections or skid packages
Heat exchanger’s, coolers etc are only defined in a single sub-system
*
*
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ZENATOR SYSTEMS
Commissioning Guidelines & Notes
3.0
APPENDICES
Appendix A
Appendix B
Appendix C
Appendix D
Appendix E
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Commissioning Guidelines - 20130419
COMPANY Commissioning Process
COMPANY ITR A & B Distribution Flow Chart
System Handover Process
Handover Flow Chart
Authorized Signature Matrix
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