AWI 412 Commissioning Guidelines

8/19/2019 AWI 412 Commissioning Guidelines

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KHARAFI NATIONAL

COMMISSIONING

ADMINISTRATIVE WORK INSTRUCTION AWI 412

COMMISSIONING GUIDELINES

0 28 Apr. 2015 QAM Comm. Manager CD (PCS, QA&C) DCOO COO

Rev Date Prepared by Reviewed Reviewed Approved

AWI 412 Rev. 0 28 Apr. 2015 Page 1 of 7


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REVISION RECORD SHEET

NOTES

i) Revisions after Rev. 0 are denoted by a vertical line in the left hand marginagainst the revised text, with the revision number displayed next to the revisionline as shown by the example on the left.

ii) Revision 0 is issued for management review and approval. Subsequent revisions shall be1, 2, 3, etc.

Rev Date Description of Revision By Rev Rev App

0 28 Apr. 2015 Issued for Review and Approval SM/ SK SS AAZ DI

2



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CONTENTS

1.0 Purpose

2.0 Scope

3.0 Commissioning Process

4.0 Commissioning Phases

5.0 Responsibilities

6.0 Turnover From Construction

7.0 Temporary Turnover From Construction

8.0 Turnover To Owner

9.0 Pre-Commissioning Scope

10.0 Commissioning Scope

11.0 Division of responsibilities between Kharafi National and Vendors (Suppliers)

12.0 Procedures / Commissioning Forms

13.0 Charging Mechanism

14.0 Attachments



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1.0 Purpose

1.1 The purpose of this procedure is to provide general guidelines for the Commissioning setup as

applicable to KN projects.

2.0 Scope

2.1 This procedure applies to all commissioning activities of the projects. Commissioning set up

includes the complete chain of activities from mechanical completion through pre-commissioning, commissioning, testing and handing over to the Client.

3.0 Commissioning Process

3.1 All forms of building/plants/systems/equipment commissioning share the same goals: to produce a building/plant/system/equipment that meets the unique needs of its Client and

occupants, operates as efficiently as possible, provides a safe, comfortable work environment,

and is operated and maintained by a well-trained staff or service contractor.

3.2 The commissioning process is a team effort, usually led by a commissioning lead, who

verifies that the building/plant/system/equipment meets the Clients expectations at each stage

of the design and construction process (Attachment 1). Also, as the Project requirements mayvary from project to project, the commissioning lead may adapt a specific process to meet the

project goals. This guide outlines a comprehensive process for achieving these goals.

4.0 Commissioning Phases

4.1 Pre commissioning

4.1.1 The Pre-Commissioning activities normally start when the plant or a system achieves

Mechanical Completion. Frequently, however, the Pre-Commissioning activities overlap

Mechanical Completion activities and for this reason the plant should be divided into

manageable system packages, each system package may be Pre-Commissioned as a whole or

partially as convenient. The isolations at the boundaries of the system package shall be

maintained until the completion of pre-commissioning activities.4.1.2 Pre-Commissioning activities include: checking for design conformity, checking the status of

electrical, mechanical and instrument installations, running-in of equipment, flushing and

cleaning activities, drying, etc.

4.1.3 Pre-commissioning activities may be performed either by KN commissioning team or by

vendors or subcontracted to a third party; but in all the cases the pre-commissioning activities

will be performed under the complete supervision of KN commissioning team to avoid any

non compliance with the contractual pre-commissioning requirements.

4.2 Commissioning & Testing

4.2.1 Commissioning activities normally consist of activities associated with running or operating

the systems and/or equipment and include operating adjustments necessary for satisfactoryoperation of the systems and /or equipment.

4.2.2 Also included are “Functional checks” which are methods used to prove that an item of

mechanical equipment or control system functions correctly.

5.0 Responsibilities

5.1 The respective Commissioning Manager/ Commissioning Lead are responsible for all

commissioning activities on the project.

5.2 KN Lead Commissioning Engineers of each discipline, i.e. Mechanical, Electrical and

Instrumentation & Control (I & C) and Testing shall be responsible for their respective scope

of work and shall report to the Commissioning Manager / Commissioning Lead.



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5.3 KN Lock-Out / Tag-Out (LOTO) Engineer is responsible for all Lock-out / Tag-out activities

on site to ensure a safe work environment for all persons working on site during

Commissioning and reports to the Commissioning Manager / Commissioning Lead.

5.4 All subcontractors’ and vendors’ involved in the pre-commissioning and commissioning

activities shall be monitored by KN Lead Commissioning Engineers reporting to the site

Commissioning Managers. The Site Commissioning Manager shall report to KNCommissioning Manager.

5.5 The Commissioning shall provide the manpower estimate to the Proposals Department for the

Cross Functional Team as given in the Attachment 2.

6.0 Turnover From Construction

6.1 Systems or Sub-Systems packages as defined by the Client/Engineering Technical Office shall

be handed over to the Commissioning team by the Construction & pre-commissioning team.

The QC dossiers for every system shall be compiled with contents as agreed with the Client.

6.2 A system is assumed to be complete when the following conditions are met:

• All devices have been calibrated (to be coordinated with commissioning) and calibrationcertificates are available and valid.

• All construction activities including erection, alignment, welding and PWHT/NDT

activities are completed and certified as per the approved Inspection and Test Plan (ITP).

• The system is mechanically complete, i.e. all pipes, permanent supports, equipments and

devices have been installed aligned inspected and certified.

• Piping systems are pressure tested, flushed and reinstated as per the P&ID.

• Punch list issued and contains only “B” & “C” category points.

• All cables and wires are terminated and tested, inspected and certified as per the approved

Inspection and Test Plan (ITP).

• All construction documentation for the System/Subsystem has been compiled and verified

as completed as per the contents required for the QC dossier.

6.3 Upon notification from Construction that a plant, or system or sub-system has been

completed, the following steps shall be taken:

• The team including representatives from Commissioning, Quality Control and

Construction shall walk down the system and verify the installation according to relevant

drawings, Piping and Instrumentation diagrams (P&ID) and specifications.

• A punch list/snag list shall be prepared, categorizing the items into the three different

criticality levels A, B and C.6.4 The system is ready to be accepted by Commissioning when the following conditions are met:

• The punch list only contains items that do not prevent the start of commissioning (B&C).

• Construction test certificates are available and accepted.

7.0 Temporary Turnover From Construction

7.1 In exceptional circumstances a partial system may be ready to be accepted by commissioning

in order to expedite the commissioning process. Such a partial handover shall be treated as a

temporary turnover until the complete system is ready to be turned over.

7.2 For temporary turnover it is imperative that a thorough safety assessment be done and that a

robust LOTO management is applied.



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8.0 Turnover To Owner

8.1 Quality Control dossiers shall be compiled progressively in parallel to the construction

activities by the QC team. They will also compile all the commissioning test sheets received

from the Commissioning team to be arranged system by system to compile the turnover

package. The packages shall be handed over to the Client as per the contractual requirements.

9.0 Pre-Commissioning Scope9.1 Ensure required documentations are available to the start the pre-commissioning.

9.2 Piping NDE/PWHT reports, pressure test certificates are available as applicable.

9.3 Cleaning of systems (piping flushing, blow out, mechanical cleaning, …)

9.4 Cold loop checks and cable testing together with construction/erection.

9.5 Cold loop checks and testing.

9.6 Hi-Pot testing, cables meggering.

9.7 Motors meggering and rotation check.

9.8 Cables continuity check completed.

9.9 Calibration or verification of calibration of transmitters, switches, etc. and set-up of alarms

and tripping levels.

9.10 Equipment alignment inspection reports available.

10.0 Commissioning Scope

10.1 Establish and/or review the commissioning procedures, check lists and work instructions.

10.2 Ensure required documentation is available to start commissioning.

10.3 Review systems for possible design defect and initiate/manage rectification.

10.4 Defining most appropriate sequencing and prioritizing of commissioning activities to ensure

timely completion of all commissioning activities.

10.5 Accept packages from construction and pre-commissioning staff (mechanically complete,

clean, pressure test, cables checks, termination checks and other construction testes are

completed).

10.6 Function checks of individual components and verification of complete loops.

10.7 Fulfilling testing and performance test owner based on the requirement, contract

requirements, specifications, standards and codes.

10.8

Hand over the systems and/or equipment to the operation staff or end user.

11.0 Division of responsibilities between Kharafi National and Vendors (Suppliers)

• By Vendor - Testing of vendor equipment and supply of commissioning procedures,

guidelines, relevant drawings and operation & maintenance manuals.

• By Vendor - Supply of equipment only (if commissioning not included in contract)

• By KN - Interface testing (or subcontractor)

12.0 Procedures / Commissioning forms

The commissioning procedures of the suppliers, vendors and their respective commissioning

forms shall be used and signed by the vendor, KN and Client as applicable.13.0 Charging Mechanism

The charging of services offered by the Commissioning Department to the in-house projects

will be as given below:



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• Through In-House Works Agreement

For long term Commissioning services, the Commissioning Manager and the concerned

Project Manager shall first agree on the scope of work to be done and its lump-sum

charges. Once agreed, both parties shall enter into an In-house Work Agreement.

• Based on Man-hours

For short term Commissioning services the charging will based on the composite rates forthe man-hours utilized. The Commissioning Manager at the end of the month will raise a

Commissioning Invoice to the project using Attachment 3.

14.0 Attachments

14.1 Attachment 1 - Commissioning Process Flowchart

14.2 Attachment 2 - Commissioning Manpower Estimate

14.3 Attachment 3 - Monthly Timesheet Monitoring Record


Documents

AWI 412 Commissioning Guidelines