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COMMISSIONING CONCEPT

BMU
Virtual
Quality higher education

Eng. Jesus Alonso

Torres

02/02/218

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CONTENT
CONTENT...............................................................................................................................2
COMMISSIONING:...............................................................................................................5
RETRO-COMMISSIONING..................................................................................................5
RE-COMMISSIONING..........................................................................................................5
ONGOING COMMISSIONING.............................................................................................6
1. COMMISSIONING PLANNING.......................................................................................7
2. Construction and acceptance Phase:..............................................................................11
2. ORGANIZATION OF THE COMMISSIONING............................................................12
3. DOCUMENTATION GENERATED............................................................................25
4. ROLE OF THE SUPERVISOR OR ENGINEER.........................................................26
Commissioning Agencies: will include:................................................................................27
5. TYPICAL RESPONSIBILITIES...................................................................................28
6. EXECUTION OF COMMISSIONING.........................................................................32
MEETINGS...........................................................................................................................32
Sensor Calibration Methods..................................................................................................34
REPORTS..............................................................................................................................35
11. MECHANICAL COMPLETION....................................................................................36
Electric Area..........................................................................................................................37
Structural...............................................................................................................................38
Protection...............................................................................................................................39
Architecture...........................................................................................................................39
12. PRE-COMMISSIONING ACTIVITIES.........................................................................39
Design capabilities.................................................................................................................40
13. COMMISSIONING ACTIVITIES............................................................................40
14. START UP.................................................................................................................41
15. Bibliography...............................................................................................................41

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14.

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Commissioning: "The process of specifying, ensuring and controlling services to

meet people's needs at a strategic level. This applies to all services, whether they are
provided by the local authority, NHS, other public bodies, or by the private sectors."
Pre-commissioning: "The process of acquiring goods, services and construction
projects from suppliers/suppliers and managing these until the end of the contract or
disposal of assets. In addition to the general activities that corporately maximize
effectiveness, efficiency and value for money of this process."
Acceptance: A formal action, taken by a person in authority
corresponding (which may or may not be contractually defined) to declare that some
aspect of the project meets defined requirements, thus allowing subsequent activities
to continue.
Basis of Design: A document that records the concepts, calculations, decisions, and
product selections used to meet the owner's project requirements and satisfy
applicable regulatory requirements, standards, and guidelines. The document
includes both narrative descriptions and lists of individual elements that support the
design process.
Checklists that are developed and used during all phases of commissioning:
Commissioning process checklists to verify that the owner's project requirements are
being met. This includes checklists for general verification, in addition to testing,
training, and other specific requirements.
Receiving Authority: An entity identified by the owner that directs, plans, schedules,
and coordinates the commissioning team to implement the commissioning process.
Commissioning Plan: A document that describes the organization, scheduling,
resource allocation and documentation requirements of the Commissioning Process.
Commissioning Process: A quality-focused process for improving the delivery of a
project. The process focuses on verifying and documenting that the facility and all its
systems and assemblies are planned, designed, installed, tested, operated and
maintained to meet the owner's Project Requirements.
Activities of the Commissioning Process: The components of the start-up
process.
Commissioning Process Progress Report: A written document that details the
activities completed as part of the commissioning process and the significant results
of the activities, which is continually updated during the course of a project. Typically
built into startup.
Construction Documents: These include a wide range of documents that will vary
from project to project and with the needs of the owner and with regulations, laws and
countries. Construction documents typically include the project manual
(specifications), plans (blueprints), and general terms and conditions of the contract.

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Ongoing commissioning process: Following the commissioning process well into

the Occupancy and Operations Phase to verify that the project continues to meet the
owner's current and evolving Project Requirements. Continuous receiving process
activities are ongoing for the life of the facility. Also see Commissioning Process.
COMMISSIONING:
It is the process of planning, documentation, programming, testing, adjustment,
verification, and training, to provide an installation that functions as a fully functional
system according to the owner's project requirements. The objective of the
commissioning is to improve the quality of the delivered project by focusing the
design and construction team on goals, functionality and energy efficiency. The
earlier a Commissioning Provider is involved in the project process the greater the
possibility there is for the Commissioning Provider to influence corrections without
increasing subsequent costs.

Demand for commissioning services is increasing as design and construction

communities require that projects be delivered fully functional, on time, at low cost,
and built to operate in a highly efficient manner. Additionally, certification is becoming
increasingly popular and mandated by some jurisdictions. The start-up process is a
requirement of certified projects. The commissioning process helps achieve all of
these objectives through the review of the design and construction documents of a
project or facility. A third-party provider, independent of the design and construction
teams, can oversee quality delivery of the project and provide the owner with an
advocate who will serve the project through completion.

RETRO-COMMISSIONING

It is the application of the Commissioning Process to projects not previously

commissioned. Many projects delivered without undergoing the commissioning
process have design or construction deficiencies that do not allow them to function
properly or in an energy-efficient manner. The objective of the retro-commissioning
process is to discover these deficiencies and propose or provide solutions to them.
Often, the solutions recommended by the retro-commissioning process can be
implemented at low cost and with little or no disruption to operations.

A large number of opportunities are available in the Retro-commissioning market.

Energy usage is increasing and existing facilities are a large source of energy
consumption where the opportunity to reduce energy use in existing facilities is an
option that cannot be ignored. The retro-commissioning process provides a standard
method to obtain the greatest efficiency gains and resolve current comfort and
operational issues.

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RE-COMMISSIONING

It is the application of the start-up process that applies to projects that have
previously been commissioned. During construction operations, systems may be out
of balance or may be adjusted. As a result, it cannot operate in an efficient manner.
Additionally, the needs of a facility may change as usage, maintenance, and
changing technologies. The Re-commissioning Process underway brings a high
quality delivered project to the standards set by either the owner's original or revised
project requirements. An ongoing Re-Commissioning Process can usually be
implemented relatively cheaply as the documentation is available at the original
commissioning.

ONGOING COMMISSIONING

It is the constant application of the commissioning process of a building that has been
previously commissioned or Commission-retro. Continuous commissioning ensures
that a facility does not stray away from the current owner's Project Requirements;
requirements that must be updated as part of the process. Continuous commissioning
is a very effective method for keeping energy costs low and minimizing system
problems caused by neglect and changes to construction operations.

Commissioning is the systematic process of proactively verifying that systems,

designed, installed, thoroughly tested and capable of being operated and maintained,
will perform as intended and as the owner expects and believes.
Commissioning is a neglected but contractually significant activity that is frequently
contentious. Many points of contention can be disseminated in advance by being
clear about the requirements and harmonization of the requests for proposals,
specifications and obligations of the designer consequently proper planning is
beneficial and will streamline the process. Attention to contractual requirements is
crucial. Careful data collection is also key. With the support of the technical
installation or assembly team, the commissioned project will contribute to the success
of all stakeholders.
Commissioning is important because:
• It takes you from construction to production through a systematic process of testing
and verification.
• It is usually linked to a contractual milestone, such as substantial completion
• Identifies and resolves problems that operators would otherwise have to address,
resulting in production delays, out-of-spec product specifications, loss of revenue to
the customer, etc.
Although most people agree on the value of startup, not everyone agrees on what it

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is. Additionally, different organizations and publications use different terminology, or

the same terms differently. If there is no specific guidance for your sector of activity
(for example, the International Society for Pharmaceutical Engineering Start-up and
Classification Guide). Commissioning answers the basic questions:
• where to start?
• Is the customer getting what the customer paid for?
• How does the equipment, process, facility or the way it is supposed to work
work?
• Ready?
It is absolutely necessary to be clear about what commissioning means on a given
project, and how it fits with respect to satisfying contractual and settlement
requirements, for the owner, general contractor (GC), and subcontractors.
Please note that industrial facility startup has different emphases than
commercial/institutional facility startup.
There are also established practices that are complementary to commissioning, but
may not traditionally be part of the commissioning of a given site, such as PID passes
under a system test, equipment alignment and vibration. rotations, environmental
reviews, lockout/tagout, and HAZOPing activities.
1. COMMISSIONING PLANNING

The construction, commissioning, performance verification, and turnover of

manufacturing facilities automated complex tasks. The complexity is due in part to the
large number of component systems and subsystems installed and functionally
integrated while meeting schedule timelines, budget constraints, code requirements,
and regulatory expectations. Commissioning is a tool at the automation professional's
disposal, which can help overcome these challenges. This article will compare and
contrast start-up strategies for regulated and unregulated industries.

Commissioning is necessary to ensure that facilities, equipment and systems are

installed and functioning correctly, and became increasingly successful, the
documented approach, traceable verification, which ensures a systematic approach
that minimizes commissioning carelessness is underway. It is effective, minimizes
articles, documentation and improves startup by eliminating problems up front.
Additionally, certain start-up activities can be used to support documentation
requirements for regulated industries.

Commissioning that is well planned, documented, and achieves an engineering

approach to commissioning, volume optimization of facilities, systems and equipment
for the end user where it results in a safe and functional environment that meets the
requirements .
That is, Puta verifies what has been specified, has been installed, is working

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correctly, and was rejected most successfully for the user and reasonably ensures
the next step verification so that regulated industries will be successful.
Given this definition, engineers have always commissioned projects to a degree.
Example, when a new pump is installed, proper rotation and flow are verified. Before
it is installed, the model number and construction materials are confirmed.

This work presents a structured model in which commissioning is systematically

integrated with risk management, project management and production engineering.
Three strategies for start-up emerge, identified as direct, advanced, and parallel. Go-
live is the traditional approach of stopping the plant to insert the new unit. Advanced
commissioning is the commissioning of the new unit before installation. Parallel
commissioning is the startup of the new unit into its operating position, while the old
unit continues to operate. The results are presented by two plant case studies,
showing that advanced and parallel commissioning can significantly reduce risk. The
model presents a novel and more structured way of thinking about start-up, allowing
for a more critical examination of how to approach a particular project.

Factors known to affect the start-up process include the following.

Project Type. Therefore situational variables are important; That is, the factors that
resulted in a successful (or not) putting outcome in one case are not necessarily
transferable to a different situation.

Who is in charge of the phase. Commissioning can be completed by a number of

different groups depending on the project. This may be the equipment manufacturers,
operation team, or a separate commissioning team depending on the scale and
requirements of the project. The relationships between these people are also
important (social dimension), therefore also the contractual obligations.
The number/type of phases. Commissioning can also be divided into various sections
such as planning, pre-commissioning, testing, integration, monitoring, documentation,
and delivery depending on the level of complexity of the project. This requires careful
planning.
Project planning and contractual sufficiency. It is widely recognized in the literature
that implementation requires deliberate planning, as opposed to informal treatment
given. Therefore, it needs appropriate consideration in the work breakdown structure
and project planning, the allocation of resources, transfer of those costs in the initial
contract and the creation of specific operating procedures, especially important for
safety critical points by For example, a plant with boilers. This corresponds to the
"integration" tasks in the project management approach.
The Commissioning process has been examined for a wide range of different
projects. The predominant approach can be described as task specific; There is a
tendency to identify specific tasks that need to be completed as part of the start-up.
Thus, the focus has been on completing multiple checks on a system to ensure that it
will function as expected. Thus, there are many reports, too numerous to mention, on
the implementation of experiences in specific case studies. These are undoubtedly

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very useful, especially for application to comparable situations. They are also
systematic, in a way, especially in providing templates and checklists to guide
professionals.
However, there is a lack of holistic or integration models. At the next highest level of
abstraction, that is the process of putting it in general. At this level we are not so
interested in the specific experiences of each case, but rather in the fundamental
principles and methodology. What exists at this level is mainly in the area of
instrumentation and control.
Thus, existing start-up strategies can be classified into three types. These are: (a)
informal, which is action-oriented problem-solving; and (b) template, which involves
using a checklist or operating procedure that you worked on before or in another
situation. Both (a) and (b) are based on the assumption that startup is a routine set of
tasks. The third strategy challenges that premise and requires a deliberately
thoughtful approach. Thus, the third category is (c) methodological, which involves
the analysis of situational needs and the deliberate selection of the most relevant of
the different possible commissioning methods.

Project commissioning is a series of processes to ensure that a project is executed

safely and as expected before the time of delivery to the final recipient. This may
involve a number of staff on the project development team and requires completing a
large number of steps. Commissioning can begin in the early stages of the project
with the planning phase, where the team discusses the goal of the project and
establishes a schedule, schedule, and budget to meet the goal.

In the planning phase, getting the project underway may involve creating a rubric to
evaluate progress at various stages and keep the project on track. If the client is a
university building a new science laboratory, for example, the first step would be to
indicate what type of facility the university needs, and the launch of the project may
include researching the codes. construction and solicit feedback from university staff
members to find out what type of facilities are needed and develop a plan for building
them.

As the project moves out of planning and the development team begins to work on it,
the commissioning of the project continues. Staff will periodically evaluate the project
to see if the needs and objectives remain the same and to confirm that the
development is left blank. As circumstances require, they must be resolved, and
these may include the need to address new requests or failure to properly
accommodate a goal during the project planning stage.

Once the project is completed, the project commissioning moves into the final stage
with a rigorous check and investigation of all the systems in the project to see if they
are working properly. Ideally, as systems are implemented, developers will be able to
test them, but they have to check them again on target. In something like a building,

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this includes tasks like flipping all the light switches, summoning elevators, and
adjusting thermostats to test heating and cooling systems. It may also involve
pushing systems to their limits to see how they respond, such as loading an elevator
to its maximum stated capacity and then measuring their performance.

This approach to quality control is not only useful for new projects. Project
commissioning is also valuable for the rehabilitation and renewal of existing projects.
The same series of steps provides continuous information about the progress of the
project. In the planning stages, team members can discuss what they want to do, how
they plan to achieve it, and the methods they can use to measure success. During
project development they will continually re-evaluate, and will finish with a thorough
audit of the project before handing it off to the recipient.

a. COMMISSIONING PROCESS

The commissioning always bases its planning within the framework of the start-up
documents.
The pre-commissioning plan provides guidance in executing the commissioning
process. The specifications will have priority over the Commissioning Plan.
Commissioning the process: The following is a brief overview of typical
commissioning tasks during construction and the general order in which they occur
on any project:

1. During construction, it begins with an initial commissioning meeting held by the

project manager where the commissioning process is reviewed with team
members.

2. Additional meetings will be required throughout construction, scheduled by the

Project Manager or Planning Engineer with necessary parties in attendance, to
plan, coordinate, schedule future activities, and resolve issues.

3. Equipment documentation, this is distributed to the group and the person in

charge of project planning, during the normal presentation process, including
the detailed start-up; procedures.

4. The Planning Officer works with the Contractor in each discipline in developing
commissioning plans and start-up documentation formats, including providing
the Contractor with construction checklists to be completed during installation
and commissioning during the process. .

5. In general, product verification and checkout performance range from simple to

complex; from component level to equipment to systems and inter-system
levels with testing checklists during construction, installation or assembly
finishing performed before fully operational.

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6. Contractors, under their own direction, will execute and document the
completion of construction checklists upon start-up and initial departure.
Commissioning documents must be in accordance with the checklists and
commissioning were carried out in accordance with the approved plans. This
may include the planner's assistance in witnessing the commissioning of
selected equipment.

7. The project planner develops, organizes the work team and the functional
system, specifies performance testing procedures.

8. Functional testing procedures are reviewed with the project engineer, planner,
and contractors.

9. Functional tests and procedures are executed by Contractors under the

direction of development engineers, and documented by the commissioning
manager.

10. During the initial functional tests and for critical equipment, the Engineer will
witness the tests.

11. Items of non-compliance in materials, installation or configuration are

corrected at the contractor's expense, and the system must be tested again.

12. Planner reviews applied standardization documentation for completeness.

13. The project will not be considered complete until substantially the conclusion
of the functional commissioning tests and procedures defined in the
Commissioning Plan are complete and documented with results to complete
satisfaction in accordance with the objectives set from the first commissioning
meeting.

14. The planner's opinions and coordination of the training provided by the
Contractors should be verified as being completed.

15. In the event of postponement of tests, the corresponding specification and

justification is carried out to the extent required.

b. EXAMPLE OF A COMMISSIONING PLAN

1. Attend an initial kick-off meeting and additional meetings as necessary.

Contractor C. General (CG)

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2. Construction and acceptance Phase:

a. Facilitate the coordination of commissioning work between the planner, and with
the GC where they ensure that commissioning activities are being scheduled in the
master schedule.
b. Include the start-up cost in the total contract price.
c. Provide a copy of all construction documents, additions, change orders, approved
submissions, plans, schematics and diagrams related to the equipment ordered by
the planner.
d. In each written purchase order or subcontract, include requirements for shipping
data, operation and maintenance data, commissioning tasks, and training.
e. Ensure that all Contractors executing the commissioning plan agree to
responsibilities with the Contract Documents and schedule. F. A representative may
attend the first commissioning, meetings and other necessary meetings scheduled by
the commissioning engineer or project planner to facilitate the process.
g. Coordinate and schedule staff training.

3. Prepare operation and maintenance manuals, in accordance with the

Contract Documents, including clarifying and updating the original
operating sequences to as-built conditions.

h. Provide all requested Submission data, including detailed start-up procedures and
the Owner's specific responsibilities to maintain performance warranties in force.
i. Assist in equipment testing per agreements with subcontractors.
j. Include all special tools and instruments required to test equipment in accordance
with the project drawings, schematics and documentation, except for independent
data recording equipment that may be used by the issuing entity, through contractors
that may be used by the issuing entity. supply products, analyze the specified
products and verify that the Designer has specified the newest or most up-to-date
version of equipment, and that they must be reasonable for the scope and budget of
the project.

1. Provide the information requested by the commissioning manager regarding the

sequence of operation of the equipment and testing procedures:

1) Review test procedures for equipment installed by factory representatives. .

2. Warranty period:

a. Ensure that subcontractors execute functional performance tests, in the presence

of the commissioning officer, according to specifications.

b. Ensure that subcontractors correct deficiencies and make necessary adjustments

to operation and maintenance manuals and construction drawings for applicable
issues identified in any testing performed.

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2. ORGANIZATION OF THE COMMISSIONING

The correct definition of a commissioning process depends on the industrial

application. In general, it can be defined as a "well-planned, documented, and
managed engineering approach to the commissioning and rotation of facilities,
systems, and equipment to the end user that results in a safe and functional
environment that meets the established design requirements and stakeholder
expectations. Therefore, the start-up process and overall project execution must be
specific to the needs of the end user. Who, then, are the end users, and in what
industrial sectors do they operate?

End-user requirements and start-up plans are developed for a variety of projects that
use automated systems, including batch and continuous manufacturing processes,
regulated pharmaceutical and food manufacturers, creating start-up applications,
construction automation systems, fire protection and safety systems, machinery
safety applications, instrumentation commissioning, heating, ventilation and air
conditioning commissioning, nuclear power, and energy construction projects
electrical. There are currently more than a dozen professional societies, government
agencies, and other national and international regulatory bodies that have issued
guidance documents and standards related to the commissioning of applications that
use automated systems. These include: American National Standards Institute
(ANSI), American Society of Heating, Refrigerating and Air-Conditioning Engineers
(ASHRAE), ASME (founded as the American Society of Mechanical Engineers),
American Society for Testing and Materials (ASTM), Commissioning Building
Partnership (BCA), German Institute for Standardization (DIN), US Environmental
Protection Agency (EPA), International Atomic Energy Agency (IAEA), International
Electrotechnical Commission (IEC), Institute of Engineers Electrical and Electronics
(IEEE), International Institute of Ammonia Refrigeration (IIAR), International
Organization for Standardization (ISO), International Society of Pharmaceutical
Engineering (ISPE), National Electrical Contractors Association (NECA), National Fire
Protection Association (NFPA), the Injecting Drug Association (PDA), the US
Department of Agriculture (USDA), and the US Green Building Council (USGBC).

GENERAL REQUIREMENTS IN THE COMMISSION

These Requirements will constitute the basis of the construction phase start-up
process and procedures. The Service Agent shall add, modify and refine the
commissioning procedures to accommodate field conditions and the actual
manufacturer's equipment, incorporate test data and procedure results, and provide a
detailed schedule for all commissioning. start-up tasks.
Several sections of the project specifications require equipment start-up, testing and
adjustment services. Requirements for commissioning, testing and specification

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adjustment services that are intended to be provided in coordination with the

commissioning services and without duplicating services.

When training or educational services are needed and specified in other areas of the
project, these services are intended to provide in addition to the training and
educational services copied to the project records files.

Since commissioning is a systematic process of verifying that construction systems

perform interactively according to construction documents and operational needs.
The commissioning process shall encompass and coordinate system documentation,
equipment commissioning, control system calibration, testing and balancing,
performance testing and training. Commissioned during the construction and post-
occupancy phases, it is proposed to achieve the following specific objectives in
accordance with the project conditions:

1. Verify that equipment and application systems are installed in accordance with
contact documents and in accordance with the manufacturer's recommendations.
2. Verify and document adequate integrated performance of equipment and systems.
3. Verify that Operations and Maintenance documentation is complete.
4. Verify that all components requiring maintenance can be accessed, cleaned and
removed without disturbing nearby components including ducts, pipes, cables or
wiring.
5. Verify that operating personnel have adequate training to enable them to operate,
monitor, adjust, maintain, and construct repair systems effectively and energy-
efficiently.

a. RULES RELATED TO COMMISSIONING

Standards and documents related to the start-up or commissioning of automated

systems:
ACG Commissioning Guide for Building Owners, Design Professionals, and Service
Providers offers appendices with system verification commissioning checklists and
functional performance testing recommendations.

ANSI/ ISA-5.06.01-2007 Functional Requirements Documentation for

Control software applications refers to the complexity of developing requirements for
automated systems. These requirements can be the basis for commissioning
verification tests.

ASHRAE Guideline 101-2007 HVAC&R Technical Requirements for the

Commissioning Process describes the process for commissioning HVAC systems in
accordance with ASHRAE Guideline 0-2005.

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ASTM Standard Guide E1578-06 Laboratory Information Management Systems

describes in part recommendations for establishing the minimum set of functional
requirements and functional checklists for verification testing.

IAEA NG-T-2.2 Commissioning of Nuclear Power Plants: Training and Human

Resources Conditions provides general guidance on the role of automation engineers
in the commissioning of these facilities.

IEC 62381 Activities during Factory Acceptance Test (FAT), Site Acceptance Test
(SAT) and Site Integration (SIT) for automation systems is being reviewed by the
ISA105 committee to describe best practices related to these capabilities.

IEC 62382 Electrical and Instrumentation provides a standard methodology to ensure

instrumentation loops are properly tested with control systems.

ISO 16484-1:2010 Building Automation and Control Systems (BACS) provides

guidelines for the determination of BACS design, installation and commissioning
requirements.

ISPE Guide for Pharmaceutical Facilities describes the design, commissioning, and
qualification practices recommended and approved by the Food and Drug
Administration (FDA). The guide is being updated by ISPE.

ISPE GAMP 5 A risk-based approach to RoHS GxP computer systems provides a

cost-effective framework to ensure computer systems used in regulated industries are
installed and functioning for their intended use.

NFPA Fire Protection Systems Describes test procedures for alarm systems,
pumps, and smoke control systems.

PDA Technical Report No. 48 Humid Heat Sterilization Systems : Design,

commissioning, operation and maintenance problems related to user requirements
and the design of the control and commissioning system are described.
US General Services Administration Building Guide defines planning, design,
construction and post-construction activities, including defining owners' requirements
during planning and functional performance testing.
Finally, standards that will be examined in more detail include:

ASTM E-2500 Standard Guide for the Specification, Design, and Verification of
Pharmaceutical and Biopharmaceutical Manufacturing Systems and Equipment used
in regulated industries.

IEC 62337 Commissioning of Electrical installations, Instrumentation and Control

Systems in the Process Industry – Specific phases and milestones is used in

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unregulated industries.

There are commissioning-oriented documents too numerous to mention here.

However, no matter what the application, there is a need to understand the needs of
the end user and look for the appropriate guidance documents and standards to help
define the appropriate commissioning or start-up process.

b. COMMISSIONING OF NON-REGULATED FACILITIES

IEC 62237 Summary

IEC 62237 Installation of Electrical, Instrumentation and Control Systems in the

process industry is an example of guidance for unregulated industries. An objective of
the standard is to provide the framework within which the owner and contractor agree
on the responsibilities and deliverables of the project that is completed before billing
for the facilities. The goal is to deliver a high-quality project, on time and on budget.

The standard is organized primarily using the concept of phases on a timeline. Each
item defined in the standard concludes a phase of activities as summarized below:

Table 1: Summary of IEC 62237 Commissioning Process

Phase Completion Definition of Milestone
Phase
1. Construction Ending Building structures Background to be
Of completed prior to installation of systems
mechanics. Ending of
The the
2.Pre- Projection
Mechanical projection concludes the construction phase.
Commissioning Termination Mechanical systems installed and tested in
accordance with applicable specifications and
project plans. Cold start-up can begin when
mechanically complete.
3. Cold Commissioning System of
Put In
March Process in he that the evidence of
operation of the facility systems are completed
with inert material. Hot start can begin when
cold start is complete.
4. Warm-up Until Start
Of Process that tests ease with real
chemicals/materials using commercial
The process. The production phase can begin
Production when the hot commissioning is complete.

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5. Production Proof Of A test that occurs during the production phase

Performance and marks the possibility of running the
facilities at design capacity.
6. Billing Of Background
the For Final installation billing to the owner, satisfying
Project The contractual requirements excluding warranty
acceptation items.
NOTE: Step 1 is the start of the project, and step 6 is the end of the project.

Complete Milestones stages

Completion of the Screening

Completion of the screening item verifies all mechanical systems are installed in
accordance with the design drawings, applicable codes, and safety requirements, as
outlined in the project specifications, which are approved by the owner. The
contractor is responsible for generating and completing test forms, which identify, in
sufficient detail, the systems being tested, date and time of the test, and the
requirements of the test. The owner must participate in witnessing the tests as
required by the contract. Deficiencies recorded during testing can be managed at
closing with a punchlist, ensuring the owner approves the closing of said items. It also
indicates that the items are closed, the systems have been delivered, and the
completed test forms have been approved by the owner.

Pre-Commissioning

The pre-Commissioning phase of the project begins the second sequence of testing
by the contracting staff. IEC 62337 includes an extensive list of specific pre-
commissioning test procedures in Appendix B. These tests ensure the project
documents and project specifications have been met. Relevant specifications include
P&IDs, equipment and instrumentation indices, equipment drawings, circuit diagrams,
power line diagrams, documentation, software and operating manuals. The contractor
and owner must agree on the scope of responsibilities related to equipment-specific
and general test procedures. Examples of these procedures are listed below.

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Table 2: Pre-Commissioning General Procedures and Recommended Tests

The needs of Utility and process tie-ins Parts of replacement
supplier assistance at unit boundaries and
Allow requirements Leakage and leak tests noise maintenance
surveys
pressure of
the
Work instructions pipes and equipment
Mechanical Systems The inspections of
Inspection Testing security
The elimination of Pressure Vacuum Relief / dry system
rust preventives Safety
Lubricant Check Discharge and Vessel packaging and fixed
chemical/mechanical bed requirements
cleaning equipment and
Installation packaging / seals piping
Removing temporary The elimination of
screens temporary bracing
Purging and inerting General cleaning
Motor rotation and alignment
requirements

Pre-commissioning phase testing is an opportunity for owner personnel to begin

training on systems along with subcontractors. Finally, a mechanical completion
certificate is issued by the contractor and is accepted by the owner to indicate
completion of the pre-commissioning phase.

Cold and Hot Commissioning

Upon acceptance of the mechanical completion certificate, the contractor may begin
cold commissioning followed by hot commissioning. Unlike the pre-commissioning
phase, which broadly includes inspection testing, the cold and hot commissioning
phase involves functional testing. Extension of the contractor and owner's personnel
involved in the pre-commissioning phase into service is recommended. Examples of
general categories of functional test procedures used during hot and cold
commissioning are listed below.

Table 3. General Cold and Hot Setting Procedures and Tests:

The rotation of Instrumentation visit

the PLC/controller box
engineand
Pump Oven settings General Equipment
compressor settings Check Vendor
Recommended

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Dosage of Steady State Operations Batch verification or

water and recipe parameter
the
transfers
Temperature, flow Valve testing and Operation manual or
and pressure sequencing equipment development of
control procedures
Mixing and stirring Initial loop tuning Thermal expansion
verification of
requirements of
vibration and noise

Functional testing must be carried out in the appropriate sequence and in a planned
manner to ensure that the systems are operated safely. Commissioning plans and
test forms must be pre-approved by the owner and are used by the contractor to
record observations and control system data. Only trained contractor or supplier
personnel should verify the acceptability of test data. If data is required to fail and a
change to the system is required, the change must be documented in the form
approved by the owner.

Performance Test

After successfully completing the commissioning phase and closing any relevant
punchlist items, the contractor may proceed to the performance testing verification
phase with owner approval. The purpose of performance testing is to verify the
process is operating in a control state. The test must be reviewed and approved in
advance by the owner and must include acceptance criteria, measurement
requirements, sample requirements, and reference to necessary analytical
procedures. The owner, not the contractor, must conduct sample testing unless given
permission to use a third party. The contractor is responsible for submitting a report to
the owner evaluating the results and noting any observations that have failed. The
owner must provide a written response accepting the results or in the case of a
failure, the contractor must be required to remedy the situation in accordance with
contractual requirements. The commissioning process must conclude with a formal
acceptance of the plant through the use of a certificate approved by the contractor
and the owner.

In summary, IEC 62337 is a standardized approach to commissioning for unregulated

industries in which the contractor and owner agree on the contractual obligations for
the delivery of a facility from the construction phase through testing. final
performance. A well-planned commissioning process serves the best interests of the
contractor and owner by minimizing risks associated with project quality, schedule
delays, and budget constraints.

Commissioning of regulated facilities

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Having established a framework for operationalizing unregulated industries, one

question may be important, “Why do regulated industries require a different
approach?” Simply put, in addition to the contractor and the owner, the FDA is an
actor with its own set of requirements. As such, compliance with Good Manufacturing
Practices (cGMPs) as defined is an additional project requirement.
An important focus of the FDA is to "minimize the public health risks associated with
the manufacture of pharmaceutical products." The FDA's general approach to risk
minimization is explained in its guidance document, "Pharmaceutical cGMPs for the
21st Century.

A risk-based approach" It describes methods such as risk management and the use
of quality systems to minimize the risk to public health of adverse events that occur in
pharmaceutical manufacturing facilities. . These concepts were adopted by ASTM
E2500, Standard Guide for the Specification, Design and Verification of
Pharmaceutical and Biopharmaceutical Manufacturing Systems and Equipment. This
standard serves as a model for the regulated industrial start-up process.

ASTM E2500

What exactly is ASTM E2500 and what does it say about the commissioning of
automated manufacturing systems? One should begin with a definition of the term
verification: A systematic approach to verifying that manufacturing systems, acting
individually or in combination, are fit for their intended use, have been installed
correctly, and are operating correctly. This is a general term that covers all types of
approaches to ensuring systems are fit for use, such as training, commissioning and
training, verification, system validation, or other types.

Therefore "commissioning" and "verification" are understood as identical processes.

Several key concepts, which are defined in E2500, highlight the differences between
regulated and unregulated commissioning. These are:

V Risk-based approach
V Scientific basis approach
V Critical aspects of manufacturing systems
V Quality by design
V Good engineering practices
V Skilled
V The use of supplier documentation
V Continuous process improvement
V Risk-based approach

Risk assessments are used to determine the magnitude of potential harm and the
likelihood of it occurring. This principle should be applied to the commissioning
(verification) process to determine, for example, that automated manufacturing

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systems pose the greatest risk to patient health if not installed or used improperly. A
contractor for example, could focus on the manufacturing stages when generating
test forms to ensure that verification procedures are robust and well documented.
These features are also known as "enhanced documentation."

Scientific Base Focus

Patient safety is not a concern in an unregulated commissioning project. For a

regulated system or system, the manufacturing process must be analyzed to
determine critical quality attributes (CQAs) and critical process parameters (CPPs),
which effect patient safety. Start-up activities should focus on improving
documentation and verification of these attributes.

Critical Aspects of Manufacturing

Start-up activities should also focus on the critical aspects of manufacturing. They
have been defined as "the functions, characteristics, skills and performance or
characteristics necessary for the manufacturing process and systems to ensure
consistent product quality and safety." For example, commissioning an air treatment
temperature control loop for a cold water supply line, serving an office area, would be
under an unregulated commissioning plan. . However, this would not be considered a
critical aspect of manufacturing and therefore would not be of significant stakeholder
interest to the FDA. The commissioning plan should clearly identify critical aspects as
well as the logic used to determine criticality.

Quality By Design

Design specifications, which refer directly to CQAs and CPPs, must be verified after
installation and during performance runs and monitored during the life cycle of the
installation. The verification process continues after the turnover is made for the
owner, up to the point of disassembly at a regulated facility.

Good Engineering Practices (GEP)

GEP is a principle equally relevant to regulated and unregulated industries and

supports successful commissioning efforts. The GEP ISPE Guideline is a useful
reference document in this regard. There are fundamental concepts applicable to all
manufacturing process industries. Specifically, GEP is defined as those activities
related to Project Engineering, Common Engineering Practices, and Operation and
Maintenance. Examples of each category are listed below.

Table 4. Aspects of the GEP

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Common Engineering Operation and

Project Engineering Practices maintenance
Infrastructure Of Rules and procedures Documentation
the
Project
The Organization Of Documentation Practices Manuals and Records
the
ProjectAnalysis
Value Change management He Maintenance Of
Routine
Planning Continuous Improvement Maintenance Breakdown

AND
Design Calibration Internal audits
Design Reviews Asset Management Waste management
Construction Seller / Management Decommissioning and
Of Removal
Suppliers
Storage Of Background For
-GMP Non-Compliance Engineering Equipment
Commissioning and Inheritance and Recycling
Training
Billing

To the

Expert Object (SME)

SMEs are those people who have the training and experience to properly plan,
execute and approve verification activities. They must lead the manufacturing
systems verification effort. It is a regulatory requirement that only appropriately
trained individuals sign and pass verification test forms.

Using Supplier Documentation

Supplier documentation may be used for verification activities, provided the vendor
has an acceptable quality system. A quality system can be defined as those
procedures and processes necessary to produce a product, which consistently meets
approved quality standards. Should the owner determine that there are gaps in the
supplier or vendor provided documentation quality systems, they can use additional
verification testing to mitigate the risk or repeat the testing entirely. Examples of
supplier documentation that can be leveraged are FAT, SAT, and SIT.

Continuous Improvement

Change management should be used throughout the facility lifecycle and involve the

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quality unit when critical aspects of the manufacturing process are being changed.
After release and final acceptance of the facility, but before production batches, the
operational change management system must be applied. Operational change
management is a more rigorous system that requires prior approval of all changes
related to critical aspects.

Introduction to the E2500 Verification Process

The verification process, as defined by E2500, is a phase within the overall life cycle
of the automated manufacturing facility. The main phases of the life cycle presented
in the standard are listed below.

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Table 5. E2500 process

E2500 Phase phase item Milestone Definition
1. Approval End-user needs are defined based on
Needs Of the product and knowledge process,
Requirements the regulatory requirements and
Definition Final user of quality of
the
company. Provides the basis for
2. Specifications Detailed Design Is proceeding to specification and design.
SME develop documents of
And design Implemented
design based on CQAs and CPP.
Design documents are the basis for
defining verification activities.
3. Verification Complete A systematic approach to ensuring that
Commissioning systems are installed and operate
according to specifications. SME verify
testing is complete prior to facility
rotation.
4. Acceptance Billing Fund
SME develop documented
AND
approval that manufacturing systems
Release
are suitable for use. The installation is
released for operation.
NOTE: Step 1 is the start of the project, and step 4 is the end of the project.

E2500 verification summary

Verification test forms should be developed to ensure that high-risk areas of the
manufacturing process receive the greatest amount of rigorous verification by the
contractor. Unlike IEC 62237, E2500 requires a risk assessment to be carried out to
determine the level of detail of verification testing. Additionally, the quality assurance
unit must approve all verification plans, tests, and acceptance criteria related to CQAs
and CPPs. Supplier documentation assembled in rotation packages or vendor-
supplied testing requires additional levels of scrutiny by the quality unit. No such
quality function is required for unregulated applications. Control inspections must be
reviewed and approved by SMEs that had not carried out the test independently. The
SME also reviews and approves deviations from the verification test plan or failed
tests and approves corrective actions.

E2500 Processes Support

The standard defines the role of Quality Risk Management (QRM). QRM should be
used to develop the scope of the commissioning program, which includes controls
and verification methods for critical aspects of the manufacturing operation. The

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greater the risk to the patient, the more rigorous the verification process should be.
Design reviews should be a planned activity completed by SMEs in all phases of the
facility life cycle. The scope of design reviews includes project specifications, design
documents, and continuous improvement changes. Change Management should be
used throughout the life cycle of the facility and involve the quality unit when critical
aspects of the manufacturing process are being changed. After release and final
acceptance of the facility, but before production batches, the operational change
management system must be applied. Operational change management is a more
rigorous system that requires prior approval of all changes related to critical aspects.

In summary, E2500 is not a prescriptive standard that defines commissioning

requirements, but rather describes the general approach to verification testing
requirements. The standard relies on risk-based and science-based methodologies to
ensure manufacturing systems operate in ways that meet end-user requirements and
protect patient health and safety.

Keys to completing a successful startup project involve:

V Understand the differences between the regulated and unregulated industry

V The use of relevant standards and guidance documents to plan and implement
the project
V Developing precise user requirements and design specifications
V Writing and executing robust tests based on an approved design
V Change management through the appropriate procedure
V Complete turnover to the end user in a manner that satisfies contractual, code
and regulatory requirements.

3. DOCUMENTATION GENERATED

The design documents base how each criterion in the Owner's Project requirements
is implemented in the design. For any criteria that cannot be met, documentation
details what was done, its impact on the Project Requirements Manual, and how the
project requirements will include the respective modifications.
EQUIPMENT DOCUMENTATION REQUIREMENTS

Team Matrix:

A complete list of all equipment, devices and systems, with certain information as
noted herein, must be submitted within the stipulated time of issuance of the Notice to
Proceed with Construction. This list is known as the Team Matrix.

The application forms contain all the information you need to participate in the
program - eligibility requirements, indicators, rates, equipment performance

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thresholds, and submission instructions.

Application forms are available on the program website and a separate form is
available for each of the project types supported by the program:

Standard lighting
Steam Process / Steam Trap
HVAC Standard / Water Heaters
VFD Standard
Custom projects
Leak Recognition and Repair
New Construction Lighting
Specialized Team
Viability study
Measurement and Monitoring

Each application form consists of four main sections:

(1) General information,

(2) Client and project information,
(3) In the Incentive Calculation section or
(4) Customer Acknowledgment of Terms and Conditions

4. ROLE OF THE SUPERVISOR OR ENGINEER

The Startup Plan is intended to be used by:

PWGSC Project Manager: who has overall responsibility for the project and is the
sole point of contact between the client, the designer, the PWGSC Commissioning
Manager and all other members of the project team.

PWGSC Design Quality Review Team: conducts detailed reviews during all stages
of design to ensure appropriate design criteria, design intents, design solutions, that
designs are well developed, commissioning specifications are appropriate for this lab,
transmits technical design information to the Designer. During construction, you can
periodically survey the facilities to observe overall progress.

PWGSC Commissioning Manager: Ensures that all commissioning activities are

carried out in order to ensure delivery of a fully operational project complete in all
respects. This includes reviews of all commissioning documentation, no criticism for
performance, reliability, durability of operation, accessibility, ease of maintenance,
operational efficiency under all operating conditions, health protection, the well-being,
safety and comfort of occupants and operation and maintenance personnel.

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Designer (i.e. Consultant): Designs the facility to meet the Client's functional and
operational needs and budget, prepares all work documents, including incorporating
commissioning specifications for construction specifications, supervising construction
activities commissioning, testify and certify the accuracy of reported results, testify
and certify TAB and other tests, develops the PI and PV Report Forms, develops the
Building Management Manual, ensures the implementation of this Commissioning
Plan, verification of the operation of all installed systems, application of the Training
Plan.

Construction team: consists of contractor, subcontractors, suppliers and other

supporting disciplines, and is responsible for construction/installation in accordance
with contract documents, including testing and delivery of training, required
documentation.

Commissioning Contractor's Agent: to implement all commissioning activities

required by the specifications, including demonstrations, training, testing, test
preparation and reporting. This is a responsibility that is different from that of the
contractor's construction manager. Post Agent be available for emergency and
troubleshooting service during the first year of occupancy by the user for adjustments
and modifications outside the responsibility of the operation and maintenance
personnel.

Commissioning Agencies: will include:

The subcontractor or installation contractor.

Equipment manufacturer: for example. Elevators, emergency generators.
Subcontractor specialist: EMCS example.

Commissioning Specialist Agency: for example, environmental space conditions,

indoor air quality and other facilities that provide environments that are essential to
the client's program but are outside the scope or expertise of other commissioning
agencies. project. If not specified in the commissioning document, the identity of this
specialist will be provided at a later date.

Agency TAB: Equipment and systems related to measuring and adjusting flow rates
and pressures to meet indicated or specify values (e.g., air and hydraulic duct
systems, fans, pumps).

All Commissioning Agencies will be available for emergency service during the first
year of user occupancy for adjustments and modifications outside the responsibility of
the operation and maintenance personnel. These include costs to comply with
changes in facilities and changes in control strategies beyond the level of training
provided to operation and maintenance personnel.

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The names of commissioning personnel, details of instruments to be used, and

commissioning procedures to be followed will be provided at least three months prior
to the scheduled start date to allow for appropriate review and approval.

Client Movement: The step or conditions provided for erection and fit-out, although
not part of commissioning should be given serious consideration by the designer in
order to ensure only minimal disruption to their program activities.

Property Manager: has the responsibility of receiving the renovated premises and is
responsible for the day to day operation and maintenance of the premises and plays
the lead role in the Operation Phase and thereafter.

5. TYPICAL RESPONSIBILITIES

Responsibilities of startup team members are provided in this section to clarify the
startup process.

to. Owner Roles and Responsibilities:

V Review specifications that contain installation requirements.

V Provide user testing requirements to Teaming.
V Approve the Commissioning Plan, Schedule and contractor's schedule to
complete all commissioning activities.
V Participate in start-up activities, including the following:
V Put in team meetings.
V Review and approve Commissioning Plan, Training Plan, pre-functional
checklists, Functional Performance Testing Procedures, Functional
Performance Testing, Integrated System Testing Procedures, Integrated
System Testing, Deferred Testing, Trends, Plan Training and other start-up
documents.
V Attendance at the contractor's training sessions in the operation and
maintenance of systems and equipment.
V Observation of the Contractor's demonstration of the systems and operation of
the equipment.
V Start-up Functions and responsibilities of the Authority, when it participates in
the project.
V Prepare and present the Laying Plan for the approval of the owner.
V Review, comments and approval on the scheduled date of the Contractor for
the implementation of activities.
V Participate in the Contractor's ongoing Pre-commissioning Meeting - conducted.
V Carry out meetings and documents Setting up the equipment.
V Conduct site visits as needed or in conjunction with meetings Set up equipment
to observe component and system installations. Attend selected project

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progress meetings to obtain information on construction progress.

V Review and comment on Presentations and coordination drawings applicable to
the systems that were commissioned.
V Review and comment on Contractor-prepared pre-functional Checklist and
other contractor-prepared documents, including Operation and Maintenance
Manuals and Training Plan.
V Prior to business creation teams, review control sequences and coordinate with
Contractor and A/E in order to prepare functional performance testing and
Integrated System testing procedures.
• Witness start-ups equipment as executed by the Contractor.

V Write test procedures functional performance and

Integrated System testing procedures for Contractor execution of testing.
V Witness, verify and document the results of performance tests and functional
tests of the integrated system.
V Coordinate the resolution of deficiencies detected during commissioning,
deferred testing, and during the warranty period.
V Review the Contractor Training Plan.
V Compile Commissioning and Liquidation Contractor Manual-prepared
documentation including test documentation, deficiencies reports and solution
results; failure to track issues; and recommendations on ongoing
commissioning, best practices, and preventive maintenance.

8.2. Functions and responsibilities of the Engineer:

V Attend commissioning team meetings.

V Review and approve the commissioning plan, Training Plan, pre-functional
Checklist, Performance of functional testing procedures, functional
performance testing, Integrated Testing System testing procedures, deferred
Integrated Testing System and others start-up documents.
V Review and approve the Contractor Training Plan.
V Review and approve the test, adjustment, and balance plan as defined in the
specifications.
V Approve the technical requirements for the correction of deficiencies detected
during commissioning, deferred testing, and during the warranty period.
V Review Operation and Maintenance Manuals.
V Produced by Owner, Receiving Authority and approval of A/E, Commissioning
Plan, pre - functional Checklist, functional performance test procedures,
Integrated System test procedures, Equipment Matrix of all devices, supplied
systems and equipment and other commissioning documents.
V Receiving Authority will produce the Commissioning Plan, the functional
performance of specific test procedures for the project, and project-specific
Integrated System test procedures.

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V Contractor must review and make observations on the documents presented by

the Receiving Authority, and will accept the start-up plan, operation of
functional test procedures and Integrated System test procedures approved by
the owner.

As the project progresses, add specific checklists, test procedures, schedules,

recorded results, action lists, SIGNOFF sheets (signals off) and other
documents to the Commissioning and Closing Manual. Manage updates to the
Commissioning and Closing Manual with the intention that all members of the
Commissioning team will have up-to-date documentation as the
commissioning progresses.
V Provide an individual, subject to owner approval, with experience in
construction and commissioning of building systems to organize, schedule,
perform and document the commissioning plan and commissioning process.
The contractor may assign this individual to act as the Contractor's
Commissioning Coordinator. Contractor's Commissioning Coordinator may
have additional rights, such as MEP Coordinator, but not as Project Manager
or Superintendent. Submit qualifications demonstrating the Commissioning
Coordinator's technical expertise and experience to the owner for approval. In
the event that Contractor decides to subcontract its commissioning obligations,
then Contractor shall submit the subcontractor's qualifications and personnel to
Owner for Owner approval.
V Supply and install systems that meet all requirements of the Contract
Documents. Perform construction inspections, start-ups, pre-functional
checklists, functional performance testing and integrated system testing in
accordance with the Contract Documents and Commissioning Plan. Correct
deficiencies identified during these processes.
V Ensure that start-up activities are incorporated into the baseline schedule and
Work Schedule Progress.
V Submit the owner's inspection and commissioning documentation in
accordance with general commissioning requirements, Project Quality Control,
project closure procedures, specifications, and the commissioning plan.
V Provide copies of all Submissions, manufacturers' literature, maintenance
information, and any other information required for the start-up process.
Contractor shall present to owner the actual installation and review materials
shipped within equipment and actual field form payment sheet used by factory
or field technicians. Project Administration and project closure procedures
(Operation and Maintenance Manuals) for additional required documentation.
V Schedule and lead pre-installation meetings and pre-commissioning meetings
with subcontractors and equipment suppliers related to the commissioning.
Contractor shall invite A/E and owner to attend pre-installation meetings and
pre-commissioning in-service meetings.
V Provide qualified personnel, including subcontractors, as necessary, to fully

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carry out operational testing and demonstrations required by the Contract

Documents and Commissioning Plan, including all deferred examinations or
retests in connection with the work. warranty.
V Correct deficiencies identified during any stage of commissioning prior to the
procedure, unless approved by the owner.
V Train Owner. Coordinate Subcontractor and supplier participation in training
sessions.
V Conduct deferred examinations and make necessary modifications to Operation
Manuals and Records and Document Maintenance for pertinent issues
identified during deferred testing.

Contractor will be responsible for the following activities:

V Provide on-site technical experts in software and hardware programming to

perform operational sequences and controls to correct deficiencies detected
during commissioning. Contractor shall provide Record Documents reflecting
the correction of deficiencies identified during commissioning checks.
V Provide the instruments, equipment, software and communication resources
necessary to demonstrate compliance with the Contract Documents and the
Commissioning Plan during pre-functional checklist activities, performance
testing and functional testing of the associated integrated equipment system to
the automation system.
V Participation in Pre-commissioning and commissioning meetings, including
seasonal occupancy, messaging, or deferred meetings and activities as
deemed appropriate by the owner.
V Prepare Training Plans with the commissioning of the team and carry out the
training as specified in the contractual documents and Commissioning Plan.
V Maintain comprehensive system calibration and checkout records. Submit
owner records.
V Establish, capture, analyze and report trend records as requested by the owner
to justify proper systems operation.

Test, Adjust and Function and responsibilities when involved in the project:

V Attend meetings and meetings of the commissioning team, including seasonal

occupation, after pre-commissioning, or deferred meetings and activities that
are considered appropriate.
V Submit Test, Adjustment, and Balance Plan and forms describing the
methodology for performing the test, adjustment, and balance procedures
specific to this project to Owner/Engineer of Record for review.
V Cooperate with contractor and automation system supplier or contractor, if
applicable, during commissioning.
V Re-balance, as necessary to correct all deficiencies detected during

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commissioning.
V Review graphics and performance testing for accuracy, note deficiencies.
V Provide TAB data to Contractor and Teaming before Contractor begins
functional performance testing.

6. EXECUTION OF COMMISSIONING

To execute a commissioning plan, submit a draft Commissioning Plan for review after
issuance of the order to proceed with construction prior to the installation of materials
and equipment that will undergo commissioning and functional performance testing,
according to what is indicated by him.
Contractor shall incorporate user review comments and resubmit the revised
Proprietary Commissioning Plan within the time determined for receipt of comments
following the review.

MEETINGS
TO. Commissioning Meeting: At the beginning of construction, a commissioning
meeting will be scheduled, planned and carried out with the entire
commissioning team.
- General Commissioning Requirements
There are other meetings and conducted by the commissioning coordinator as
construction progresses. These meetings will cover coordination, deficiency
resolution and planning issues with specific contractors. The coordinator will plan
these meetings and will minimize the necessary time spent by contractors. For large
projects, these meetings may be held monthly, until the final one.
COMMISSIONING
A. The following procedures apply to all teams to be commissioned. Some systems
that are not composed as much of current dynamic machinery, for example, electrical
system power quality, may have very simplified control circuits and commissioning.
B. General: Construction checklists are important to ensure that equipment and
systems are properly connected and operating.
The checklists also ensure that functional performance testing (in-depth system
check) can be carried out without unnecessary delays. Each piece of equipment
receives full build checkout. No sampling strategies are used. The construction test
for a given system must be completed successfully prior to the formal, functional
testing of the equipment or subsystems of the given system.
C. Startup and Initial Order Plan: The coordinator will assist team members

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responsible for the startup commissioning of any team in developing detailed startup
plans for all teams.
The coordinator's primary role in this process is to ensure that there is written
documentation that each of the manufacturer's recommended procedures has been
completed.
Parties responsible for construction and commissioning checklists are identified at the
initial commissioning meeting and on the checklist forms.
1. The coordinator adapts, if necessary, the representative construction checklists
and procedures of the related sections. These checklists indicate the procedures to
be executed as required start and initial verification of the systems and party
responsible for their execution.
2. The commissioning coordinator provides these checklists and tests. Determine
who is responsible for executing and documenting each of the line item tasks and
take note of potential suppliers. Each form will have more than one merchant
responsible for its execution.
3. The person responsible for purchasing the equipment develops the complete start-
up plan by combining (addition) to the AC Checklists with the manufacturer's detailed
start-up and checking procedures from the operation and maintenance manual and
normality check sheets. of field used. The plan will include checklists and procedures
with specific boxes or log lines and documentation of the verification and inspection of
each procedure and a summary with a signature block at the end of the plan.
to. The complete commissioning plan could consist of something as simple as:
1) The commissioning coordinator's construction checklists.

2) Manufacturer's standard write startup procedures; copy of the installation manuals

with check boxes for each procedure and a signature block added by hand.

3) Typically using the manufacturer's check field sheets, the complete commissioning
plan is presented for review and approval.

5. The coordinator views and approves the procedures and format for documenting
them, noting which procedures should be added.

d. Sensor and Actuator Calibration

1. All instrumentation, control and drive elements; Field-installed relative humidity,
CO, CO2 and pressure sensors and gauges, and all actuators (dampers and valves)
on all equipment shall be calibrated using the methods described below. Alternative
methods may be used if approved by commissioning coordination in advance. All test
instruments have had a calibration certificate within the last 12 months. Sensors
installed on the unit at the factory with calibration certification provided do not have to

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be field-calibrated.
2. All procedures used shall be thoroughly documented on construction checklists or
other approved forms, clearly referencing the procedures followed and written
documentation of initial, intermediate and final results.

SENSOR CALIBRATION EXAMPLE:

Sensor Calibration Methods
a. All Sensors: Verify that all sensor locations are suitable and away from causes of
erratic operation.
Verify that sensors with shielded cable rely on one end only. For pairs of sensors that
are used to determine a temperature or pressure difference, make sure they are
reading within 0.2°C of each other for temperature and within a tolerance equal to 2%
of each other's reading per the pressure. Tolerances for critical applications may be
tighter.
b. Sensors Without Transmitters - Standard Application:
Take a reading with a calibrated test instrument at 6 inches from the site sensor.
Verify that the sensor reading (via permanent thermostat, gauge, automation system)
is within the tolerances in the table below the instrument measured value. If not,
install offset, gauge or replace sensor.
c. Sensors with transmitters - Standard application:
Disconnect the sensor. Connect a signal generator to your sensor location. Connect
an ammeter in series between the transmitter and the control panel. Using the
manufacturer's resistance-temperature data, simulate desired minimum temperature.
Adjust the transmitter's zero potentiometer until the ammeter reads 4 mA. Repeat the
procedure for the maximum temperature setting 20 mA for the maximum span
potentiometer or check. Record all values and recalibrate controller as necessary to
conform to specified control ramps, reset schedules, proportional ratio, reset ratio,
and P/I reaction.

Reconnect the sensor. Take a reading with a calibrated test instrument within 6
inches of the site sensor. Check that the sensor reading (via permanent thermostat,
gauge, or system of
automation]) is found within the tolerances in the table below of the instrument-
measured value. If not, change the sensor and repeat. For pressure sensors, perform
a similar process with an appropriate signal generator.

d. Critical Applications: For critical applications (process, manufacturing, etc.) more

rigorous calibration techniques may be required for selected sensors.

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Describe any type of methods used on an attached sheet.

After obtaining approval of the Commissioning Plan, an ongoing Pre-Commissioning
Meeting must be scheduled, planned and carried out with all parties involved in the
commissioning. This meeting should include major subcontractors, specialty
manufacturers/suppliers, A/E, Testing, Adjustment and Balance Firm, Receiving
Authority and owner's representatives as participants.
You will prepare for the ongoing Pre-commissioning meeting by creating drafts of the
following documents with input from the coordinator. Receiving Authority, when
participating in the project, will prepare the Commissioning Plan, functional
performance test procedures and Integrated System test procedures.
Baseline schedule and work progress Schedule activities incorporating start-up.
• Prefunctional checklists.
• Functional performance testing procedures.
• Integrated System Test Procedures.
• Contractor or Receiving Authority when participating in the project will carry
out the Pre-commissioning in meetings and review all aspects of the
Commissioning Plan.

All documentation will be discussed and all procedures and testing forms will be
critical for approval with the coordinator. Contractor will prepare an outline outlining
the responsibilities of the various parties involved in Commissioning for review at this
meeting.

The Laying Plan will be reviewed with all attendees and the scope of work discussed.
Contractor must be prepared to distribute copies of the relevant parts to the various
subcontractors involved in the Commissioning.

REPORTS
• Status reports will be provided on frequencies directed by the commissioning
coordinator.
• You must communicate at least monthly with all members of the start-up team,
keeping them informed of start-up programming and changes.
• Non-compliance and deficiency reports will be submitted to the commissioning
coordinator days following the date of the
non-compliance or deficiency is observed first.
• Final commissioning documentation will be provided to the owner to provide
project closure Procedures, which will become part of the Commissioning and
Closing Manual.

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11. MECHANICAL COMPLETION

The basis for the execution and documentation of mechanical activities is formed.
Mechanical completion is carried out through all phases of the project, starting with
equipment supplier and continuing through manufacturing to phasing.
• Mechanical completion encompasses all disciplines.
• Development responsibilities are outlined in the commissioning plan.
• Executor of the activities of the Department Coordinator. Mechanical Engineer is
responsible for establishing and compiling mechanical completion records and
reporting status in PCS.

Documentation for an MC (Mechanical Completion) package

The MC package will consist of an MC certificate, an MC Status Index and a Drilling

Record List as described below.
A Mechanical Completion Certificate (MCC) is a form completed by the Executor,
after all MC is carried out.
The MCC Mechanical Completion Certificate is the cover of each MC package. It will
be when an MC package is signed to be ready for the start of the rollout.
Check Records (CR) are the ways in which Performers record the results of all
checks, inspections and tests carried out, for each individual item.
A Punch Register List (PLR) will be prepared by the Executor, along with the MC
activity; in each MC package a PLR printout will be included to document incomplete
work.
An MC Status Index (MCSI) indicating the status of all CRs for the entire MC package
must be included in the MC file documentation.
Delivery upon completion Mechanical
The transfer from mechanical completion to commissioning will be at the
commissioning package level, documented by the Preparation for Commissioning
Minutes (CRCC).
Transfer of Work Record (COWR)
The Work Input Log lists all items that the Project accepts as not being completed
during this phase.
The COWR is used to launch the work from the Executor and will as an input for the
scheduling and planning of the pending works to be carried out during the afternoon

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The COWR Number point and the cross reference to the drilling list Record / Check
records must be given.
COWR work will be marked on drawings or sketches and included in the records.
COWR Material Status List (MSL) and marking drawings/instruction shall contain
sufficient information for configuration of work at a later stage.
Typical mechanical finishing activities
Mechanical completion activities include verification of fabrication and installation.
• Visual inspection of the complete and correct installation.
• Internal inspection of tanks and containers.
• Alignment.
• Load testing of lifting equipment.
• Tension screw.
• Dimension Control.
• Preservation.

Electric Area
• Visual inspection of the complete and correct installation.
• Insulation and continuity testing of cables.
• Insulation test of the generator, transformers and motors, panels, distribution
board, etc.
• Grounding controls.
• Static testing of switches and control devices.
• Lighting and outlet socket checks.
• Area Completion.

Instruments / Telecommunications
• Calibration and testing of instruments before installation.
• Visual inspection of the complete and correct installation.
• Insulation and continuity testing of cables.
• Pneumatic and hydraulic pipe cleaning, washing, pressure and leak service.
• Adjust control, alarm and stop settings.
• Tests with feedback.
• Testing the function of control systems.
• Testing the function of field instruments.
• Area Completion.
• Preservation.

Pipelines
• ECM performs.

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• Welding procedures.
• Removal of all items subject to damage during washing, cleaning and pressure
testing.
• Reddening of pipes.
• Cleaning and testing chemical pipes.
• Proven pipe drying.
• Pipe preservation tested.
• Resetting all items after testing.
• Final pipe inspection.
• ISO testing and P&ID reveal the magnitude of each pressure test.
• Tire and hydraulic tube.
• Tension screw.
• Pipe supports completed.
• Isolation.
• Coding flow.

HVAC
• Visual inspection of the complete and correct installation.
• Duct cleaning.
• Checking the tightness of the ducts.
• Alignment checks.
• Mechanical functions inspections of devices.
• Preservation.
• Coding flow.

Security
• Visual inspection of the complete and correct installation.
• Preservation.
• Area Completion

Mechanical termination of non-operational systems

Mechanical termination of non-operational systems includes completion status and
controls on a surface base. Disciplines included structural, surface protection,
insulation, fire protection and architectural.
Structural
• Visual inspection of the complete and correct installation.
• QC documentation.
• ECM performs.
• Welding.
• Load testing of the lifting mechanism and monorails.

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Protection
Surface, Insulation and Fire Testing
• Visual inspection for complete and correct application.
• Thickness controls carried out.
• adhesion checks carried out.
• Preservation.
• Isolation.
• Paint.
• Protection against the fire.

Architecture
• Visual inspection of the complete and correct installation.
• Preservation.
• Doors.

Mechanical Completion Certificate (MCC): Establishes that all discipline-related

inspections and testing for an MC package have been carried out in accordance with
the relevant contract documents.
Mechanical Termination Status Index (MCSI): It is a computerized listing of all
Tag/Cable/Test/MCCR in an MC package, which gives MC scope of work and status
of a complete package.
Mechanical Completion Check Record (MCCR): It is the Discipline checklist for the
various teams. These records form the basis of the MC - documentation.
MC Punch List (PL): This is how the supplier and contractor record any pending
work.

12. PRE-COMMISSIONING ACTIVITIES

Pre-commissioning activities are the activities that must be performed after

Mechanical completion
Completion of a piece of equipment or system so that it is safe and ready to receive
hydrocarbons/injection water and ready for commissioning. This includes, but is not
limited to:
• Carrying out all remaining works other than commissioning and performance
testing.
• Make operational and commissioning of all systems that can be made operational

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before fluids are introduced.

• Completion and testing of platform equipment and systems
• Testing of all parts and systems of the Works, including communications systems
(if necessary).
• Provision of initial filling of packaging, chemicals, inhibitors, lubricants, glycol, water
and other actions have been carried out.
• Checking, site modifications.
• Internal inspection of vessels
• Cleaning of boats and pipes
• PSV calibration.
• Calibration of all instruments
• Loop check.
• Complete security system check
• Control of the electrical installation and other supplier packages including DCS etc.
• The delivery, storage and cataloging of all spare parts Products for which a defect
notice has been issued that must be rectified and any defects.
• The completion documents together with all design documents lead to the
preparation of the commissioning plan and submission to the company for opinion.
• Hydraulic testing and pneumatic control.
• The training of personnel and information of the Contractor Company and those
involved in the start-up.
• Removal of all waste and construction site.
Ready for commissioning ready for commissioning means the point at which the
Company issues a certificate to the contractor saying that the system is ready for
commissioning.

Design capabilities
The maximum design capacity and minimum design capacity are defined in the
tender document elsewhere.

13. COMMISSIONING ACTIVITIES

You must write necessary procedures and obtain company approval before beginning
work and perform the work in accordance with approved procedures. In addition to
completing as many of the pre-commissioning activities underway as possible in the
manufacturing yard to minimize work time.
A guide to carry out pre-commissioning activities in the yard/offshore is given below.

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These are the minimum requirements:

It is necessary to demonstrate that the equipment has not been damaged and is in
the same condition as it was in the first test. A detailed program and procedure for
carrying out these activities must be submitted for approval by the Society before
starting work.
Factory Acceptance Test (FAT) Requirements At a minimum, factory acceptance
testing becomes essential.
Minimum Pre-commissioning activities to be carried out in the yard
Review systems for compliance with Ds P&I requirements, drawings and data sheets;
Complete any site modifications that may be required and any other instrument-
related activities not mentioned above, but mentioned in the relevant functional
specifications on other parts of the commissioning equipment, machinery or process
line.

14. START UP.

Commissioning is all modification work that involves the scheduled introduction of

commissioning and operation of all systems as planned. A complete procedure must
be submitted for approval to the company giving details of the program and the
procedures to be followed for start-up. The procedure must describe all activities and
the methods for carrying out these activities safely. Detailed information will be
provided on fares, ramp up rates, equipment configurations, performance,
combination of trains, operation of reserve equipment and other matters necessary to
introduce to the Works, plans, flow diagrams. , try to do all other things required by
the Company according to the commissioning plan.
15. Bibliography

1. ALTERMATE ENERGY CENTER, CEMENTER INDIAN INSTITUTE OF

TECHNOLOGY ROORKER (May, 2011)Standards/Manua/Guidelines for
small development
2. AUSTRALIAN NUCLEAR SCIENCE AND TECHNOLOGY ORGANIZATION
(February 2005), “commissioning plan” Sponsor Ansto Replacement Research
project.
3. ALBORNOZ, Esteban (October, 2012), international seminar on experiences
in project construction.
4. GÓMEZ, P Mendez G (June 2011) proposal for the management
of
maintenance.
5. INDIAN INSTITUTE OF TECHNOLOGY ROORKEE (May 2011)

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Standards/manuals/guidelines for small, commissioning.

6. IEEE Std 1248-2002 (2002) IEEE Guide for the commissioning plants.
7. ROJAS RAMÍREZ, A, L. (December 2009) Guide for plant start-up tests.
8. VELASQUEZ, J. (2007) commissioning of control, measurement and
instrumentation equipment.

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