Commissioning Strategy

Title Commissioning Plan

(Oil & Gas/ Chemical Plant)
     
     
     
0

Client
Project Name
Project Location      
Jacobs Project Number

Document Number

APPROVALS
Rev Date Pages Rev Description Prepared Checked Disc App
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TABLE OF CONTENTS

1.0 INTRODUCTION

2.0 GENERAL

3.0 OBJECTIVE

4.0 ABBREVIATION

5.0 COMMISSIONING STAGES

6.0 COMMISSIONING PROCESS (GENERAL) FLOW CHART

7.0 COMMISSIONING FUNCTION TEST PROCEDURE (CFTP)

8.0 DEFINITIONS

9.0 COMMISSIONING DELIVERABLES

10.0 ENERGISATION AND PRESSURISATION / LIVENING UP

11.0 ISOLATION PHILOSOPHY

12.0 HSE MANAGEMENT

13.0 COMMISSIONING SPARES

14.0 COMMISSIONING TEAM

15.0 ROLE AND RESPONSIBILITY

16.0 ASSUMPTION

17.0 SYSTEM LIST AND CODES

18.0 CERTIFICATES AND FORMS

19.0 SOFTWARE CHANGE CONTROL

20.0 TEST EQUIPMENT

21.0 RESPONSIBILITIES MATRIX

22.0 PRE-COMMISSIONING ITR INDEX

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1.0 INTRODUCTION
The commissioning scope of work for the project name, Location has been awarded by Client
name to Jacobs Singapore.

This Commissioning Plan is the basis for the Completions (Construction, Mechanical Completion
and Commissioning) work scope and subsequent planning for the project and relevant stages
where scopes of work are completed i.e. FAT’s and Location construction site.

2.0 GENERAL
This document is intended to outline the commissioning strategy to be adopted by JES
Commissioning Team in the execution of the Client name project commissioning work scope. It is
intended to cover all aspects of commissioning, from work planning to implementation, inclusive
of control and monitoring of the activity and resourcing.

To define the commissioning program, the total commissioning scope has been broken down into
the various project stages, each with a particular objective.

This commissioning plan is not intended to be a detailed commissioning function test procedure
(CFTP) for each system, these will be developed independently with details of system
boundaries, isolations, consumables and temporaries and detailed procedure with provision for
signing off the activities (refer to section 6).

3.0 OBJECTIVES
The objectives of this commissioning plan are to provide guidelines for pre-planning and
execution of the Commissioning stages of the project.

The prime objective of the JES Commissioning team shall be to achieve safe and economic
completion of the commissioning activities in line with the overall project MASTER schedule, and
to confirm that the plant equipment/components when finally installed, that design objectives can
be achieved, whilst taking full account of the potential environmental impact to ensure
compliance with legislative requirements.

The JES Team will strive to achieve the following.

 Zero recordable - safe and environmentally correct commissioning.

 No surprises – fully agreed handover process.
 Seamless transition- responsibility from design to start up.
 High performance – Integrated team approach with common objectives.
 Reduce costs – cost effective and efficient use of all resources including field
service representatives’ vendors.
 Zero carryover – complete all planned work scope.
 Plan the work; work the plan – simple and transparent plans.
 Detailed design must reflect completion/ commissioning requirements (hardware
and information/data/documentation) and be designed with effective completion/
commissioning in mind.
 Develop commissioning plans, procedures, and schedules.

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 Each project component is to be completed and commissioned to the maximum

extent possible BEFORE it moves to the next phase (i.e. no carry over work is the
goal, as a minimum no unidentified carryover).
 Commissioning plan to be developed with a “Systems – Sub-systems” approach.
 Build by area, switch to system completion at ~70% / 80% complete and
progress MC with focus on effective commissioning (sequence and priority).
 Client name Operations personnel to be involved/integrated into the
commissioning team
 No Surprises………...Changes……….Preferential Engineering.
 One completion process (MC, Commissioning, & Turnover), with buy-in by all
stakeholders (i.e. do things once with one punch-out process, one punch list and sign-
off).
 Complete MC and start commissioning as soon as sub-systems are assembled
and available.
 Deliver to Client name management and operations a commissioned and tested
plant, ready for start-up before date.

4.0 ABBREVIATIONS
AA Area Authority
CFTP Commissioning Function Test Procedure
CLIENT Client name Pacific Pte Ltd
CMS Commissioning Management System (ORBIT)
COMM Commissioning
CON Construction Contractors
DAC Discipline Acceptance Certificate
FSR Field Service Representative
ICSS Integrated Control and Safety System (DCS – SIS)
ICT Integrated Commissioning Team
ITR Inspection & Test Record / Check Sheet
JES Jacobs Engineering Singapore Pte Ltd
JSA Job Safety Analysis
LUN Livening Up Notice
MC Mechanical Completion
P&ID Piping & Instrument Diagram
PA / PB Punch List A / Punch List B
PC Pre-Commissioning
PMT Client name Project Management Team
PTW Permit to Work

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SAEP Senior Authorised Electrical Person (LV & HV Switching)

SRP System Responsible Person

5.0 COMMISSIONING STAGES

The overview of the Commissioning stages per step is listed below.

1.0. STAGE 1 – COMMISSIONING PREPARATION

 Provide selected discipline personnel into the JES Commissioning Team.
 Confirm system and subsystems boundary limits.
 Evaluate the design and suggest changes to minimise the completions work.
 Define the Commissioning work scope.
 Prepare Inspection and Test Records (ITR) for pre-commissioning and
commissioning activities.
 Assist in the definition of the Contractors Mechanical Completion/ Pre-
Commissioning.
 Define the sequence for subsystem and system handover to Client name
Operations.
 Set up and populate the CMS Data Base and integration of contractors MC data
bases within the CMS Data Base.
 Prepare Pre-Commissioning and Commissioning Function Test Procedures.
 Prepare multi-level Commissioning sequence logic schedules (levels 2 & 3)
for the commissioning activities for the duration of the project.
 Specify all test equipment, tools, consumables and spares required for the
commissioning scope of work.
 Establish a Permit to Work (PTW) System at the Client name site.

2.0. STAGE 2 - ONSHORE COMMISSIONING

 Carry out Commissioning scope as per approved CFTP’s.
 Establish a site completion team.
 Implement Permit to work procedures.
 Manage CMS data entry, punch listing, updating and reporting, including
handover Certification requirements.
 Review Mechanical completion test, inspection, punch listing and acceptance
documentation from all contractors.
 Witness/participate in Mechanical Completion testing carried out by contractors.
 Receive and accept Mechanical Complete systems.
 Manage and carry out the site commissioning scopes of work, utilising local
skilled labour and resources.
 Commission systems and subsystems including the management of inspection,
testing, acceptance and any punch listing.
 System Loop testing from the instrument through to the DCS and SIS
workstations.
 Commissioning of all Utility / Process systems.

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 Liaise and coordinate with the JES construction and QAQC teams.
 Coordinate and manage all Commissioning vendor field service representative
(FSR) requirements.
 N2/He Leak testing of process hydrocarbon systems (as advised by Client name
PMT).
 Ensure and demonstrate that all commissioning equipment, materials and
commissioning spares are available for the execution.

3.0. STAGE 3 – PROCESS COMMISSIONING

Process Commissioning of the plant by Client Operations:

 Operable system equipment tagged and commissioning tags/locks removed and

client operation tags/locks applied (as required)
 First fills with production materials
 Introduction of feedstock
 Tuning of control loops and testing of interlocks on process materials if required
 Final calibration of field elements on process materials if required
 Conveyor load alignments
 Performance test runs
 Start-up commences upon successful completion of process commissioning
activities.
 Testing combinations of subsystems will be required to verify the performance of
a particular unit operation

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6.0 COMMISSIONING PROCESS (GENERAL) FLOW CHART

Develop
Support Design Commissioning
Reviews Plan

Develop Develop Population of

System/Subsystem Commissioning CMS data base
Boundary Limits Documents &
Procedures
FAT Attendance

Turnover from
Construction

Perform Pre-
functional Checks

Carryout Vendor
Perform Functional SAT’s (as applicable)
As per SYSTEM Testing
CFTP

Perform Integrated
Functional Testing

Develop System
Commissioning
Packages

Develop
Commissioning
Summary Report
(Handover)

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7.0 COMMISSIONING FUNCTION TEST PROCEDURES (CFTP)

Each system Commissioning Function Test Procedure template is identical, but in certain cases
within the procedure system descriptions and activities will vary depending on that particular
system service. The Commissioning Function Test Procedure template layout is as per the
following;

 Purpose;
 Scope;
 Roles and Responsibilities of parties;
 Plant Area / System Description;
 Commissioning Objectives;
 Commissioning Preparation;
 Prerequisite Sub-Systems;
 Preliminary Coordination;
 Temporary Commissioning Measures;
 Required Commissioning Equipment and Materials;
 Equipment Spares;
 Detailed Commissioning Stages (Simulated/Process Media/System Turnover);
 Commissioning Schedule;
 Commissioning Program;
 Commissioning Coordination;
 Special Tool Requirements; and
 Health, Safety and Environment.
 Appendix

The commencement of the commissioning program is dependent on the Mechanical Completion

(MC) of systems/subsystems, as such; MC milestones will trigger commissioning activities. In
many instances, there is logic and dependencies between the activities contained in the various
phases. A detailed Level 3 subsystem sequence logic commissioning schedule will show the
true dependencies and restrictions in completing the activities. This will be developed by the JES
Commissioning Manager and included within the overall level 3 Project Master Schedule.

8.0 DEFINITIONS
8.1 COMMISSIONING
Commissioning is the stage that involves the energisation of systems and dynamic functional
operability of systems to ensure all design functional control logics are tested to as near as
possible normal operational conditions, by subjecting the system to a set of operational
conditions using safe testing mediums (Fresh Water etc), to achieve a state of readiness for
Start-Up & First Product.

8.2 COMMISSIONING & FUNCTION TEST PROCEDURE

The detailed approved procedure for all pre-commissioning and dynamic commissioning
activities associated to particular system.

8.3 COMMISSIONING SCHEDULE

The commissioning stages & activities will be developed into commissioning schedules. The
following commissioning schedules will be developed to allow preparation and planning to be
managed;
 Level 2 – System sequence Logic Schedule
 Level 3 – Subsystem sequence logic schedule

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8.4 MECHANICAL COMPLETION (MC)

MC is the verification of correct fabrication, construction, installation, protection, preservation,
inspection and testing requirements. Neither System nor Subsystem is allowed to be energized
or pressurized by commissioning until accepted as mechanically complete and handed over from
construction to commissioning.

MC verification confirms that construction and installation of equipment, piping, instrumentation,

cabling etc. are physically complete and all inspections, testing and documentation requirements
have been completed. This includes equipment installation checks, cable installation and testing,
hydro-testing, flushing, drying etc.

8.5 PRE-COMMISSIONING (PC)

Pre-commissioning is defined as those activities which required to be performed after
Mechanical Completion to make the facilities, system, and equipment and ready for
commissioning. Pre-Commissioning defines the phase following Construction Verification,
when the Pre-Commissioning Team performs inspections and tests on defined systems and
system components.

8.6 SYSTEM
The Client name facilities are sub-divided into basic systems and are defined as per System
Codes (see section 17).

8.7 SUBSYSTEM
A subsystem is a further breakdown of a system into a functional package of equipment which
can be independently commissioned and operated as part of a system, e.g. Instrument and Plant
Air system can be sub divided into multiple subsystems.

 Air Compressors, Dryer and Receiver

 Instrument Air Distribution
 Plant Air Distribution

8.8 DISCIPLINE ACCEPTANCE CERTIFICATE (DAC)

Means the party responsible for Mechanical Completion is stating that all discipline associated
inspection checks and tests for the subsystem contents are completed.

8.9 SYSTEM MECHANICAL COMPLETIONS CERTIFICATE

Means the party responsible for Mechanical Completion states that all disciplines within a
system/subsystem have been completed and all DAC’s have been issued and accepted. A
System Mechanical Completion Certificate will be issued by Construction to Commissioning.

Note: All category (A, B and C) punch lists will have been closed and cleared before any system
mechanical completion certificate is issued.

8.10 COMMISSIONING TURNOVER & ACCEPTANCE

The handover of systems from JES Commissioning to Client name Operations, including
completed Pre-commissioning and commissioning documentation and punch lists as
appropriate.

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System Handover
System handover is the milestone when all category ‘C’ punch list items for a particular system
have been completed, accepted and signed off by Client name.

Plant Handover
Plant handover is the milestone when the individual system handover certificates have been
issued, accepted and signed off by Client name.

9.0 COMMISSIONING DELIVERABLES (Example)

During the commissioning preparation phase the following table is a list of those deliverables that
will be developed by the JES Commissioning team in a timely manner to meet subsystem
handover dates and priorities.

Discipline Sys
Count Title
Custodian No
Common Shared Documents
1 Commissioning and Function Test Procedure Template Comm’g Mgr n/a
2 Commissioning Software Change Control Procedure Comm’g Mgr n/a
3 PC ITR Procedure Comm’g Mgr n/a

4 Lock-Out and Tag-Out Isolation (LOTO) Procedure Comm’g Mgr n/a

5 Livening-Up Notice (LUN) Procedure Comm’g Mgr n/a

6 Commissioning Plan Comm’g Mgr n/a

7 Commissioning Handover Procedure Comm’g Mgr n/a

CMS Data Base Population

Equipment Lists (All Disciplines) - Link all tags to
1 CMS Admin n/a
associated subsystems + allocate PC ITR
Cable Schedules (Elec/Inst/Tel/FGS) - Link all tags to
2 CMS Admin n/a
associated subsystems + allocate PC ITR
3 Piping Line List CMS Admin n/a
Instrument Index - Link all tags to associated subsystems
4 Inst Comm’g Eng n/a
+ allocate PC ITR
Instrument Loops - Link all tags to associated subsystems
5 Inst Comm’g Eng n/a
+ allocate PC ITR
Development of PC ITR's - Link all tags to associated
6 All Eng's n/a
subsystems + allocate PC ITR
System / Subsystem Limits
1 Mark-Up P&ID's Comm’g Mgr n/a
2 Mark-Up Electrical SLD Elec Commg Eng n/a
3 Mark-Up Building Services Schematics Comm’g Mgr n/a
4 Mark-Up HVAC AFD's Comm’g Mgr n/a
5 System List Comm’g Mgr n/a
6 Subsystem List Comm’g Mgr n/a
Cable Schedules (Elec/Inst/Tel/FGS) - Link all tags to
7 All Eng's n/a
associated subsystems

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Tracking Registers
1. Vendor Call-Out Commissioning Requirements Comm’g Mgr n/a
2. 2 Year Operations Spare Parts (To review and advise) Comm'g Mgr / OPS n/a
3. PSV Tracking Register (Calibration/Re-calibration) Inst Commg Eng n/a
4. CFTP Tracking (weekly report) Comm’g Mgr n/a
5. Test Equipment Calibration Tracking Inst Commg Eng n/a
Organization
1. Develop Commissioning Org Chart - Overview Comm’g Mgr n/a
Develop Commissioning System Responsible Persons
2. Comm’g Mgr n/a
(SRP) Chart
3. Develop Commissioning Team Job Descriptions Comm’g Mgr n/a

Work Packs
1. Develop Instrument HOT LOOP Folders Inst Commg Eng n/a
Development of Temp Strainers /Screens Requirements
2. Mech Eng #2 n/a
(suction nozzles of pumps)
Schedules
1. Develop a Level 2 Commissioning Schedule (by SYSTEM) Comm’g Mgr n/a
Develop a Level 3 Subsystem Sequence Logic
2. Comm’g Mgr n/a
Commissioning Schedule
Commissioning Function Test Procedures (CFTP)
1. Reactor System Mech Eng #1
2. Solvent/chemical name System Mech Eng #1
3. High Temperature Reactor System Mech Eng #1
4. Process Vent Scrubber System Mech Eng #1
5. IPA Solvent Recovery System Mech Eng #1
6. Manifold System Mech Eng #1
7. Raw Material and Intermediate Bulk Storage System Mech Eng #1
8. Bulk Handling System Mech Eng #1
9. Drains System Mech Eng #1
10. Flare System Mech Eng #1
11. Vacuum Stripping System Mech Eng #2
12. Instrument & Plant Air System Mech Eng #2
Fire Water & Foam Distribution System (Including
13. Mech Eng #2
Deluge/Sprinkler)
14. Cooling Water System Mech Eng #2
15. Thermal Oil System Mech Eng #2
16. Steam & Condensate System Mech Eng #2
17. Breathing Air System Mech Eng #2
18. Nitrogen System Mech Eng #2
19. Natural Gas / Fuel Gas System Mech Eng #2
20. Deionized Water Mech Eng #2
21. NEWater Mech Eng #2
22. Laboratory System Mech Eng #2
23. Material Handling System (Hoists, Monorails etc) Mech Eng #2

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Buildings Area Completion (Admin, Guard House,

24. Mech Eng #2
Warehouse etc)
25. Potable Water System Mech Eng #2
26. Water Treatment System Mech Eng #2
27. HVAC System (All Buildings/Offices/Rooms) Mech Eng #2
28. MV Power Distribution System Elec Commg Eng
29. LV Power Distribution System Elec Commg Eng
30. Power Transformers System Elec Commg Eng
31. Grounding / Earthing System Elec Commg Eng
32. Uninterrupted Power Supply (UPS) System Elec Commg Eng
33. VFD System Elec Commg Eng
34. Lighting & Small Power System Elec Commg Eng
35. Access Control System Elec Commg Eng
36. ICSS System (DCS/SIS) Inst Commg Eng
37. Fire & Gas System Inst Commg Eng
38. Telephone & Data System Inst Commg Eng
39. CCTV & Security System Inst Commg Eng

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9.1 DISCIPLINE ACCEPTANCE CERTIFICATE (DAC) TO LUN FLOW CHART

Discipline Discipline System

Check & Acceptance Acceptance
Verification Step 2 Step 3
Step 1
Subsystem Subsystem System

Electrical MC Electrical
ITR Checks DAC

Instrument MC Instrument
ITR Checks DAC

Mech MC ITR Mechanical

Checks DAC
SYSTEM Livening-Up
MC Cert Notice (LUN)
Piping MC ITR Piping Step 4
Checks DAC

HVAC MC ITR HVAC

Checks DAC

Telecoms MC Telecoms PC
ITR Checks DAC ITR’s

System / Subsystem Tri-Party walk through of

System / Subsystem completed by JES
Construction (Multi Discipline) and JES
Commissioning (Multi Discipline), including
Client name prior to issue of SYSTEM MC

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9.2 MC, PC & COMMISSIONING FLOW CHART

Construction to verify
Subsystem Mechanical
Construction issue Completion
Discipline Acceptance
Certificate (DAC)

Construction to raise and issue

System Mechanical Completion
Certificate to Commissioning

Joint MC Inspections Contractor, JES &

Client Name

System MC Cert System MC Cert

Accepted Rejected

Pre-Commissioning to Commissioning issue Commissioning to

Complete Pre- Livening-Up Notice & Complete Commissioning
Commissioning Checks Raise PTW Dynamic Checks as per
approved System CFTP

Commissioning to ensure all

data, records, results and Client name Operations

certification are populated Begin Batch Testing and

within the system Start-Up Operations

Commissioning Function Test Procedure

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10.0 10.0 ENERGISATION AND PRESSURISATION / LIVENING UP

10.1 LIVENING-UP (LUN)

Livening-Up Notices (LUN) are required to be issued by JES Commissioning to notify all
personnel (Construction, Commissioning and Client) that equipment and or systems will be
energized and / or pressurized. Use of barricade tape, livening up signs is mandatory to ensure
awareness of personnel of the change from construction to commissioning and restriction of
access to authorized personnel only.

LUNs are raised after handover from construction team of a particular subsystem; each LUN will
be accompanied with:

 Marked-Up drawings identifying the equipment and extent of boundary to be livened-up.

 Copy of the ITR status index (MC& PC).
 Any other relevant documentation.

Note: No Commissioning PTW will be issued without a valid approved LUN being issued first.

11.0 ISOLATION PHILOSOPHY (LOTO) LOCKOUT/TAGOUT

For Jacobs corporate Lockout Tagout refer to Work Instruction HSEP 15.1, with the following as
reference documents.

 29 CFR 1910.147, The Control of Hazardous Energy, Lockout/Tagout

 29 CFR 1926.417, Lockout and Tagging of Circuits
 HSEP 8.5
 HSEP 19.1
 HSEP 19.4

11.1 MECHANICAL ISOLATION PHILOSOPHY

Isolations must be introduced to ensure safe working conditions for personnel during pre-
commissioning, commissioning, maintenance or inspection of sections of process or individual
pieces of equipment. Isolations are preferred at the equipment itself in a location where it can be
easily seen by the personnel carrying out the work.

Methods of isolation must enable the following:

 System or systems equipment associated pipe work, electrical and instruments to be
taken out of service during pre-commissioning, commissioning, maintenance whilst
other systems continue to function normally.
 Provide proof that equipment is safely isolated from all possible sources of inflow, prior to
any work scope being commenced.
 Provide means to safely reinstate all equipment following the completion of work scope.

11.2 ELECTRICAL ISOLATION PHILOSOPHY

Approved methods of electrical isolation will include at least one primary barrier and where
possible at least one secondary barrier between the equipment or plant and the electrical supply.

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Primary barriers include the following:

 Switch off isolator
 Disconnect battery leads
 Pull out motor control cells
 Lift knife switch or fuse blade
 Remove plug socket
 Remove wires from terminals

Secondary barriers include the following:

Insulation of terminal points, bare cores, socket holders, fuse holders and sockets Locks applied
to:
 Electrical equipment doors and cabinets
 Electrical stop / start stations
 Isolator switches and mechanisms

11.3 INSTRUMENT ISOLATION PHILOSOPHY

Instrumentation will either have an electrical or mechanical / process connection or a
combination of both. Therefore isolations involving instrumentation will be carried out using the
mechanical / process and electrical isolation methodology.

12.0 HSE MANAGEMENT

Pre-Commissioning and Commissioning activities shall comply with all HSE Management Plans
and procedures of the project throughout all stages / phases of the project.

12.1 SAFETY
On Client name Project safety is the over ruling concern for the Commissioning team, therefore
safety will not be compromised in the achievement of commissioning objectives.

To this end safety takes precedence over all other activities and a safe working environment will
be maintained throughout commissioning activities and stages/phases.

Personnel involved with any aspect of commissioning will be fully conversant with current JES
policies, and any applicable safety requirements.

Individuals will be trained in PTW (Permit to Work) procedures in accordance with their roles and
duties.

They will be conversant with pre-job planning using Job Safety Analysis (JSA) that is used to
identify, remove or plan to avoid potential hazards. The Lock-Out / Tag-Out (LOTO) Isolation &
De-Isolation Procedures for Electrical, Instrument, Mechanical & Process systems.

Successful communication to the workforce is seen as a key element for a safe environment.
The communication process will include frequent Safety Meetings, Safety Training and Tool Box

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Talks. Notice boards, posters and HSE bulletins will further communicate the relevant safety
themes.

12.2 PERMIT-TO-WORK (PTW)

A PERMIT-TO-WORK system documents a contract between a person in control of the work
place Area Authority (AA) / System Responsible Engineer (SRP) and the person carrying out the
work / tasks the Performing Authority (PA).

It specifies the work to be carried out, its location, and associated work hazards including
required methods of control.

A permit-to-work system aims to ensure that proper consideration is given to the risks of a
particular job. The permit is a written document, which authorizes specific work, to be completed
within a certain time period and detailing any necessary precautions.

For all Pre-Commissioning and Commissioning works the JES Commissioning Manager is the
overall responsible person.

Close coordination between JES construction manager and JES commissioning manager shall
ensure that all independent and parallel activities are managed safely under the control
management of the PTW system.

PTW training will be given to those persons/groups involved with pre-commissioning and
commissioning.

12.3 JOB SAFETY ANALYSIS

Job Safety Analysis’s (JSA) are intended to fit into the work management process. When a job is
identified; the first action is to establish what tasks it will involve. This initial appraisal should
identify the need for any special safety studies or assessments and identify at the outset if it is
clearly obvious that the task cannot be carried out safely. If the likely hazards cannot be
reconciled at this stage, then the task should be rejected or redefined. The next stage involves
identifying the hazards associated with the tasks, assessing the risks and identifying the
controls/precautions required to mitigate those risks.

Where a task comprises a number of separate activities, these should be broken down into
individual tasks and assessed separately. The extent of the controls identified will depend upon
the level of risk associated with the task. This Job Safety Analysis process is documented and
retained for use before performing the same job in the future.

11.0 COMMISSIONING SPARES

Commissioning spares are specified and procured for use during the engineering and
commissioning preparation phase. Typical spares would include the following:

 As per individual Purchase order (reviewed by Commissioning).

 Instrumentation - I/A regulators, Gauges, digital and analogue input and output cards,
filters, fuses, lamps, tubing fittings / ferrules and consumables including: patch wiring,
crimp pins, wire markers, labelling, heat shrink and cable markers.

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 Mechanical / Piping - ring type gaskets, raised face gaskets, man way door gaskets, ‘O’
ring kits, piping fittings, adaptors, filters and strainers. Consumables will include: hoses,
clamps, small bore valves, nuts and bolts etc.
 Electrical - fuses, lamps, circuit breaks and consumables including control wiring, cable
ties, ferrules, crimp pins and lugs, cable glands, sleeving, heat shrink and cable markers.

All spare parts will be strictly managed and controlled. No spare parts will be issued without
approval of the relevant JES discipline system responsible person commissioning engineer and
JES commissioning manager.

12.0 COMMISSIONING TEAM

The make-up and structure of the commissioning team is designed to take maximum advantage
of JES past projects experience,

The Commissioning organization is designed around a System Responsible Person (SRP)

concept, where the SRP will have total responsibility for the systems assigned. SRP’s will focus
on discrete areas and systems for overall planning schedule optimization, risk management,
problem resolution and interface areas with contractors and client interfaces.

Client name Operations personnel will be fully integrated into the commissioning team as this will
facilitate the seamless handover of systems in a controlled and timely manner, whilst also giving
“hands-on” training to the Client name Operations team members.

1.0. INTEGRATED COMMISSIONING TEAM (ICT)

An ICT comprising of both Jacobs and Client name personnel is deemed the best approach, to
execute the PRE-COMMISSIONING & COMMISSIONING scope of work for the Client name
Project.

An ICT provides the following project benefits:

 Promotes working together as a team to achieve safe and timely commissioning of the
systems and subsystems.
 Reduces time to complete paper work and commissioning documentation.
 Facilitates TURNOVER & ACCEPTANCE of systems from Jacobs to Client name.
 Provides hands-on training and familiarization for Client name operations personnel
assigned to the ICT.

General Principles of ICT

The following shall govern the conduct of the ICT:

 The ICT shall act as one single team.

 All Client name project objectives and contract requirements shall apply to the ICT.
 The ICT shall comply with all safety protocols and work shall not be undertaken unless
such work can be accomplished in a safe manner.
 All team members are responsible to the Jacobs Commissioning Manager. There shall
be no differentiation between Jacobs and Client name personnel reference to pre-

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commissioning and commissioning objectives. All team members shall function in the
role prescribed to them by the Jacobs Commissioning Manager.
 Assignment of personnel to positions within the ICT will be a matching of skills required
for position versus those that the personnel possess.
 Trust, integrity and respect shall be the main ingredients that will make the ICT function
efficiently and effectively. All members of the ICT shall ensure that they conduct
themselves in the most appropriate manner to ensure a high level of confidence and
alignment amongst team members.
 The ICT shall assume responsibility for the effective execution of the
commissioning work.
 All issues arising from the pre-commissioning and commissioning work should be
resolved within the ICT. Only non-solvable or contentious issues shall be referred to the
respective Project Managers.
 The Commissioning & Function Test Procedures (CFTP’s) and the associated general
work procedures, as approved by Client Name, will be the primary basis of the pre-
commissioning and commissioning work. Nevertheless, any pre-commissioning and
commissioning work not captured within a particular CFTP due to oversight, but deemed
required by the ICT, shall be identified, scheduled appropriately, executed and recorded.
 The ICT will jointly perform all pre-commissioning and commissioning work and sign-off
on the relevant documentation as appropriate.

ICT Objective

 To plan and effectively execute the safe pre-commissioning and commissioning of the
Client name plant and facilities.
 Ensure an orderly, systematic and timely pre-commissioning and commissioning of the
plant and facilities to support Start-up and production.

Note: Jacobs are not directly responsible for Start-up of Client name plant and
facilities, but will provide assistance and support as required.

The following organization chart and mobilization plan reflects the integrated commissioning
organization during the commissioning phases of the project.

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2.0. INTEGRATED COMMISSIONING TEAM ORG CHART

Commissioning
Manager
Commissioning

Operations Personnel
(Client)

Electrical and Mechanical Commissioning QA/QC Turnover Specialist

Instrument Lead Engineer X1 X1
Lead X1 X2 X1

Comm. Comm.
Technician Technician
X1 X1

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13.0 ROLES & RESPONSIBILITIES

1.0. COMMISSIONING MANAGER

The JES commissioning manager is responsible for management of the overall project
philosophies associated with commissioning activities. Supports project safety and
environmental procedures and programs. Manages, coordinates and works to ensure a
seamless transition from construction mechanical completion through to final commissioning
through to handover to Client name Operations team. Primary focus will be to provide
leadership in the development of the commissioning planning process and ensure the systems
are mechanically completed, handed over fully commissioned, and ready to operate as per
approved design intent.

Specifically:

 Manages, coordinates and ensures implementation/execution of the project systems

Completion Management Database (CMS) in accordance with contract requirements.
 Work closely with project Quality Control to leverage mechanical completion /
commissioning activities into the project’s quality control activities, e.g. Factory
Acceptance Tests are performed with an object that no repeat testing will be required to
be carried out.
 Works closely with construction teams on integration of mechanical completion /
commissioning planning activities.
 Develops and executes the project’s commissioning plan and schedule.
 Manages and provides timely feedback to Project Manager regarding progress and
performance monitoring systems including commissioning data management to ensure
continuous alignment of objectives to achieve overall result and schedule.
 Coordinate with all system responsible persons commissioning engineers (SRP) for the
overall completions and commissioning activities with associated manpower
requirements to achieve planned targets.
 Supports the safety and environment management of completions and commissioning
activities.

2.0. SYSTEM RESPONSIBLE PERSON (SRP)

The system responsible person will be responsible for the preparation of commissioning
deliverables in a safe and environmentally way and be knowledgeable about all aspects of
systems he has been specifically allocated, work scope and schedule development, and
validation of mechanical completions data. He shall assist the overall commissioning team to
ensure work is planned and executed in accordance with project specifications and in a safe
manner, he will:

 Validate completions data base for allocated systems (witness and review MC activities).
 Assist with development of Commissioning sequence logic schedule.
 Define and coordinate vendor (FSR) support requirements.
 Liaise with client reference to commissioning activities.
 Coordinate with other SRP’s to maximize commissioning activities.

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 Review in advance engineering changes to minimize impact on commissioning work

scope.
 Identify in advance issues that may affect commissioning execution, and propose
solutions.
 Complete Commissioning scope in a planned and efficient manner.
3.0. CLIENT NAME OPERATIONS
The assigned Client name operations personnel will be fully integrated within the commissioning
team reporting to the JES Commissioning Manager.

During the project commissioning phases the Client name Operations personnel will be involved
as per the SRP descriptions above.

Hands-on training will be given to all assigned Client name Operations persons involved with
commissioning so as all historical data and physical operation of plant and equipment can be
gained, this will allow for a seamless transfer of systems in accordance to the Turnover and
Acceptance Procedure.

Client name Operations personnel assigned to the JES commissioning team shall make
themselves available in accordance to the approved project commissioning sequence logic
schedule so as onshore commissioning is maximized to the fullest extent prior to sail away.

14.0 ASSUMPTIONS
To complete commissioning at relevant phases of the project it is assumed the following typical
standard MC ITR’s will be completed for all equipment; these will be achieved & completed by
virtue of utilizing the CMS certification process.

Instrumentation:
 Installation of all instruments, complete with calibration certificates and tagging.
 Cable/device/junction box checks.
 Simulated loop checks performed for continuity and instrument response.
 All pneumatic tubing installed and leak tested.
 Signal wiring with tray and conduit installed and terminated.
 PLC equipment installed and ready for Hot Loop checking.

Electrical:
 Electrical tray, raceway, conduit, cables/wires and necessary supports installed.
 Cable terminations are completed, checked and correctly tagged.
 Insulation resistance tests.
 Continuity checks.
 High Voltage HI-POT testing.
 Equipment installed and level checked (process substation)
 Breakers are installed – overload protection relay setting.
 Switches and breakers are locked and tagged as required.
 Motor phase rotation checks.

Mechanical:
 Equipment installed, levelled, grouted and alignment checked.

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Internal inspections of tanks & vessels.

Shaft alignment checks of rotating equipment.
 Belts and guards are installed.
 All access ports are sealed.
 Construction strainers are removed, and permanent strainers are installed.
Telecoms:
 Installation of all components and equipment.
 Cable terminations are completed, checked and correctly tagged.

HVAC:
 Pressure Testing of New Installed Duct Work.
 Charging of closed loop refrigerant circuits.
 Belt alignment and tension checks or rotating equipment.

Piping:
 P&ID checks of system pipe work.
 Cleanliness checks, cleaning by flushing.
 Final gaskets installed.
 Pressure testing performed and documented (Piping Test Packs).
 Systems are blown dry and reinstated (test blinds and jumpers removed).
 Inert gas purge in place (if required), all permanent pipe supports completed, including
spring supports set at correct setting.
 Lines are within plumbness and tolerances.
 Flange Management i.e. controlled tightening / torqueing.
 All hydro test vents and drains have been removed and seal welded, if required as per
piping specification.
 All test records are on file and with site QAQC.

15.0 SYSTEM LIST AND CODES (Delete/Add accordingly)

System
Description (as aligned to CFTP) Definition
Code
Reactor System Process
XXXXX System Process
High Temperature Reactor System Process
Process Vent Scrubber System Process
IPA Solvent Recovery System Process
Manifold System Process
Raw Material and Intermediate Bulk Storage System Process
Bulk Handling System Process
Drains System Process

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Flare System Process

Vacuum Stripping System Utility
Instrument & Plant Air System Utility
Fire Water & Foam Distribution System (Including Deluge/Sprinkler) Utility
Cooling Water System Utility
Thermal Oil System Utility
Steam & Condensate System Utility
Breathing Air System Utility
Nitrogen System Utility
Natural Gas / Fuel Gas System (flare ignition) Utility
XXX System (Deionised Water) Utility
XXX System (NEWater) Utility
Laboratory System Utility
Material Handling System (Hoists, Monorails etc) Utility
Buildings Area Completion (Admin, Guard House, Warehouse etc) Utility
Potable Water System Utility
Waste Water Treatment System Utility
HVAC System (All Buildings/Offices/Rooms) HVAC
MV Power Distribution System Electrical
LV Power Distribution System Electrical
Power Transformers System Electrical
Grounding / Earthing System Electrical
Uninterrupted Power Supply (UPS) System Electrical
VFD System Electrical
Lighting & Small Power System Electrical
Access Control System Electrical
ICSS System (DCS/SIS) Instrument
XXXX System Instrument
Fire & Gas System Instrument
Telephone & Data System Telecoms
CCTV & Security System Telecoms
XXX System Telecoms

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16.0 CERTIFCATES AND FORMS

The following certificates and forms shall be utilized as part of the Commissioning coordination
through the various phases of the project.

 Discipline Acceptance Certificate (DAC)

 System Mechanical Completion Certificate
 Livening-Up Notice (LUN)
 Punch List Input Form (PLIF)
 Job Safety Analysis (JSA)

17.0 SOFTWARE CHANGE CONTROL

The purpose of the Commissioning Software Change Control Procedure is to ensure that any/all
post FAT (Factory Acceptance Test) changes, made to ‘as delivered’ software based control and
safety systems, are defined, approved, implemented and tested with as-built backups taken in a
controlled and structured manner.

Once a package has been delivered to the Client name site, installed, energized and a Site
Acceptance Test (SAT) completed (as applicable), then any software changes undertaken after
that point will be controlled by following the Commissioning Software Change Control Procedure.
This shall also include software changes that are carryover work from the FAT and SAT.

This procedure shall be used by JES Commissioning and is applicable to all software driven
control systems utilized on the Client name Project. This includes the DCS/SIS, package PLCs
and data transfer systems where any modification of the resident software has an effect on the
operation of any function of the system.

This procedure can be used in conjunction with the vendor’s own software change control
procedures however a vendor cannot perform a change on site (Client name & location) without
following this procedure under the supervision of Jacobs’s system custodian.

18.0 TEST EQUIPMENT

Portable test equipment used during the Commissioning program will have valid calibration
certification available and verified by Jacobs Commissioning team.

A test equipment tracking register will be developed and managed by Jacobs Commissioning
team.

Examples of portable test equipment requirements as per the following;

Multi-Meters, Lux 400000 Meter, Clamp Ammeters, Field Instrument Communicators,

Tachometers, Vibration Meters, Druck DPI-615, Infra-Red Temperature Guns, Sound Level
Meter, Dew Point Analyzer, Stop Watch, LAN Cable Meter, Phase Rotation Meter, DTI + Mag
Stand, Phone Line Tester, Anemometer (HVAC) etc.

Note: Portable hand held two (2) way radios will be required on site, presently Client name
purchased operations radios will be utilized.

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1.0. PORTABLE TEST EQUIPMENT (EXAMPLES)

Clamp Ammeter Druck DPI-615 Field Communicator Multi-Meter LUX 4000 Meter Clamp Ammeter

Sound Level Meter DTI + Mag Stand Phase Rotation Meter Temperature Gun Anemometer (HVAC) Dew Point Analyser

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19.0 RESPOSNIBILITY MATRIX

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ACTIVITY RESPONSIBILTY MATRIX

CLIEN

JES JES JES T Vendor/

DESCRIPTION
Eng CONST SRP NAME Supplier

OPS

1. Commissioning Preparation
Design Review – HAZOP’s, system identification,
D I I I
equipment selection & tagging.
System Definitions R D AP
System/Sub-system boundary drawings D R
Population of Completion Management System
AS D R
Database (ORBIT CMS)
Develop Inspection Test Records (ITR’s) AS D R
Develop FAT schedule & Review procedures. D R
Develop Commissioning Subsystem Sequence Logic
D R
Schedule
Develop Commissioning Function Test Procedures
D AP
(CFTP)
Development of all Commissioning deliverables (as per
schedule) AS D R I
Develop manpower requirements and form integrated
Commissioning Team D AP I
Develop Handover and Acceptance Process
(Commissioning to Client name Operations) D AP

Develop FAT program (Commissioning Attendance) I D AP I

2. Factory Acceptance Testing (FAT)
Review vendors FAT Procedures D D AS I
Attend critical vendors FAT facilities and conduct
D D I D
approved FAT
Document all FAT results (Commissioning Attendance) D D R D
Complete package punch list (agree with vendors any
D D R D
O/S scope)
Preservation (pre-release) W W I D
3. Client name Site location
Verification of Construction and Mechanical Completion
D W W
(MC) activities.
Verification of installed equipment D W W I
Witness Rotating Equipment Alignments D W W I
Witness Cable Testing / Earthing Checks D W W

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Witness PSV & Instrumentation Calibrations D W W

Witness piping Flushing/Hydro-Tests D W AS
Input Completed ITR’s within MC data base I D R
Witness MOTOR phase rotation checks D W W
Present & sign-off DAC and System MC Certificates D D AP
Energisation of HVAC and system balancing (buildings) D D W I
Complete system/subsystem walk downs D D AP
Lubrication First Fills D W R
Preservation checks D R R I
Review of Commissioning Spares & Consumables D D AP
Review of 2 Year Spares D D D AP
Receive all MC documentation D R W
Raise & Issue LUN’s I D R
Raise PTW / JSA / LOTO Isolations I D R
Complete Commissioning Pre-Checks (PC ITR’s) D W AS
Complete Commissioning Dynamic Activities as per
D W AS
system Commissioning Function Test Procedures
Sign Off Commissioning Function Test Procedures –
D R AS
update CMS Data Base
Handover of all Commissioning Documentation and
D AP
CMS data
Introduction of 1st Chemicals and blending AS D AS
1ST PRODUCT AVAILABLE FOR EXPORT AS D

AS = Assistance AP = Approve D = Do it
I = Input R = Review W = Witness

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20.0 PRE-COMMISSIONING ITR INDEX

The following table is a list of the Jacobs generic Pre-Commissioning Inspection Test Records
(ITR) / Check sheets that are available for use by the Jacobs Commissioning team.

Selected PC ITR’s will be used for specific tasks, these PC ITR’s will be available from the CMS
data base as linked to associated tagged item / subsystem.

PC ITR
ITR Description
Type
Electrical
LV Switchboard
HV Switchboard
Distribution Panel
Control Panel
LV / HV Motor
Battery
UPS / Charger / Inverter
Generator / Alternator
Power Transformer
Trace Heating Circuit
Electric Heater
Neutral Earthing Resistor
Navigation Aids
Lighting & Small Power Circuit
Miscellaneous Equipment
Socket Outlet Circuit
Protection Relay / Circuit
Circuit Breaker
Fire & Gas
Safety Showers and Eyebaths
Fire Water / AFFF Monitor / Hose Reel / Dual-Agent Hose Reel
Deluge Skid
Fire and Gas Panel
Fire and Gas Detection / Alarm
Fire and Gas Logic
HVAC
HVAC Fan Units
Dampers
Air Handling Units
HVAC Duct Leak Test
HVAC Filter / Coalescer
HVAC Refrigeration Unit
HVAC Electric Heaters & Panels
HVAC System Static Pre-Start Checks

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HVAC System Performance – Branch Duct Balancing

HVAC System Performance – Terminal Duct Balancing
HVAC Area Pressure Testing
HVAC System / Area (Temperature / Humidity Checks)
HVAC System Noise / Vibration Checks
HVAC System Performance Checks
Instrument
Inspection / Calibration (Pressure Relief Valve)
Instrument Hot Loop Function Check
Serial Link Checks
Instrument Pre-Start-Up Checks
Mimic Display Graphic
Instrument Miscellaneous Equipment
Shutdown Valves
Mechanical
Vessel / Tank Closure Certificate
Pressure Vessel
Centrifugal Pump
Screw Type/Rotary/Positive Displacement & Reciprocating Type Pumps
Dosing / Metering Pump
Submersible Pump
General Pump
Heat Exchanger / Cooler / Heater
Air Dryer
Filter / Strainer
Potable Water Unit
Diesel Engine
Coupling Alignment ("Hot" Alignment Check)
Centrifugal Compressor
Reciprocating Compressor
Air Compressor
Gear Box Unit
Manual Hoist
Power Hoist
Crane (Including Pedestal Type Cranes)
Fan / Blower Unit (Including Air-cooled Fin Fan Units)
Winch
Gas Turbine Generator
Hypo Chlorination Generator
Sewage Treatment Unit
Nitrogen Generator
TEG Regeneration Unit
Package Equipment (Incl. Shipped Loose Items)

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Mixers / Agitators
Miscellaneous Equipment
Firewater Pump Unit
Centrifuge / Purifier Unit
Hydro Cyclone / Inertial Separator
Inert Gas Generator / Boiler
Hydraulic Power Unit
Mechanical Running Log
Telecom
Telephone
Public Address Loudspeaker
Telecommunication Equipment Check
Radios, Antenna, TV
Public Address and Alarm Flashing Lights

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