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KHARAFI NATIONAL

COMMISSIONING

ADMINISTRATIVE WORK INSTRUCTION AWI 412

COMMISSIONING GUIDELINES

28 Apr. 2015

Rev

Date

QAM

AWI 412 Rev. 0 28 Apr. 2015

Comm. Manager
Prepared by

CD (PCS, QA&C)

DCOO

COO

Reviewed

Reviewed

Approved
Page 1 of 7

REVISION RECORD SHEET


NOTES
i)

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

ii)

Revision 0 is issued for management review and approval. Subsequent revisions shall be
1, 2, 3, etc.

Rev

Date

28 Apr. 2015

AWI 412 Rev. 0 28 Apr. 2015

Description of Revision
Issued for Review and Approval

By
SM/ SK

Rev

Rev

App

SS

AAZ

DI

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CONTENTS

1.0

Purpose

2.0

Scope

3.0

Commissioning Process

4.0

Commissioning Phases

5.0

Responsibilities

6.0

Turnover From Construction

7.0

Temporary Turnover From Construction

8.0

Turnover To Owner

9.0

Pre-Commissioning Scope

10.0

Commissioning Scope

11.0

Division of responsibilities between Kharafi National and Vendors (Suppliers)

12.0

Procedures / Commissioning Forms

13.0

Charging Mechanism

14.0

Attachments

AWI 412 Rev. 0 28 Apr. 2015

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1.0
1.1

Purpose
The purpose of this procedure is to provide general guidelines for the Commissioning setup as
applicable to KN projects.

2.0
2.1

Scope
This procedure applies to all commissioning activities of the projects. Commissioning set up
includes the complete chain of activities from mechanical completion through precommissioning, commissioning, testing and handing over to the Client.

3.0
3.1

Commissioning Process
All forms of building/plants/systems/equipment commissioning share the same goals: to
produce a building/plant/system/equipment that meets the unique needs of its Client and
occupants, operates as efficiently as possible, provides a safe, comfortable work environment,
and is operated and maintained by a well-trained staff or service contractor.

3.2

The commissioning process is a team effort, usually led by a commissioning lead, who
verifies that the building/plant/system/equipment meets the Clients expectations at each stage
of the design and construction process (Attachment 1). Also, as the Project requirements may
vary from project to project, the commissioning lead may adapt a specific process to meet the
project goals. This guide outlines a comprehensive process for achieving these goals.

4.0
4.1
4.1.1

Commissioning Phases
Pre commissioning
The Pre-Commissioning activities normally start when the plant or a system achieves
Mechanical Completion. Frequently, however, the Pre-Commissioning activities overlap
Mechanical Completion activities and for this reason the plant should be divided into
manageable system packages, each system package may be Pre-Commissioned as a whole or
partially as convenient. The isolations at the boundaries of the system package shall be
maintained until the completion of pre-commissioning activities.

4.1.2

Pre-Commissioning activities include: checking for design conformity, checking the status of
electrical, mechanical and instrument installations, running-in of equipment, flushing and
cleaning activities, drying, etc.

4.1.3

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


vendors or subcontracted to a third party; but in all the cases the pre-commissioning activities
will be performed under the complete supervision of KN commissioning team to avoid any
non compliance with the contractual pre-commissioning requirements.

4.2
4.2.1

Commissioning & Testing


Commissioning activities normally consist of activities associated with running or operating
the systems and/or equipment and include operating adjustments necessary for satisfactory
operation of the systems and /or equipment.

4.2.2

Also included are Functional checks which are methods used to prove that an item of
mechanical equipment or control system functions correctly.

5.0
5.1

Responsibilities
The respective Commissioning Manager/ Commissioning Lead are responsible for all
commissioning activities on the project.

5.2

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


Instrumentation & Control (I & C) and Testing shall be responsible for their respective scope
of work and shall report to the Commissioning Manager / Commissioning Lead.

AWI 412 Rev. 0 28 Apr. 2015

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5.3

KN Lock-Out / Tag-Out (LOTO) Engineer is responsible for all Lock-out / Tag-out activities
on site to ensure a safe work environment for all persons working on site during
Commissioning and reports to the Commissioning Manager / Commissioning Lead.

5.4

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


activities shall be monitored by KN Lead Commissioning Engineers reporting to the site
Commissioning Managers. The Site Commissioning Manager shall report to KN
Commissioning Manager.

5.5

The Commissioning shall provide the manpower estimate to the Proposals Department for the
Cross Functional Team as given in the Attachment 2.

6.0
6.1

Turnover From Construction


Systems or Sub-Systems packages as defined by the Client/Engineering Technical Office shall
be handed over to the Commissioning team by the Construction & pre-commissioning team.
The QC dossiers for every system shall be compiled with contents as agreed with the Client.

6.2

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

6.3

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

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


activities are completed and certified as per the approved Inspection and Test Plan (ITP).
The system is mechanically complete, i.e. all pipes, permanent supports, equipments and
devices have been installed aligned inspected and certified.

Piping systems are pressure tested, flushed and reinstated as per the P&ID.
Punch list issued and contains only B & C category points.

All cables and wires are terminated and tested, inspected and certified as per the approved
Inspection and Test Plan (ITP).

All construction documentation for the System/Subsystem has been compiled and verified
as completed as per the contents required for the QC dossier.

Upon notification from Construction that a plant, or system or sub-system has been
completed, the following steps shall be taken:
The team including representatives from Commissioning, Quality Control and
Construction shall walk down the system and verify the installation according to relevant
drawings, Piping and Instrumentation diagrams (P&ID) and specifications.

6.4

A punch list/snag list shall be prepared, categorizing the items into the three different
criticality levels A, B and C.

The system is ready to be accepted by Commissioning when the following conditions are met:
The punch list only contains items that do not prevent the start of commissioning (B&C).

Construction test certificates are available and accepted.

7.0
7.1

Temporary Turnover From Construction


In exceptional circumstances a partial system may be ready to be accepted by commissioning
in order to expedite the commissioning process. Such a partial handover shall be treated as a
temporary turnover until the complete system is ready to be turned over.

7.2

For temporary turnover it is imperative that a thorough safety assessment be done and that a
robust LOTO management is applied.

AWI 412 Rev. 0 28 Apr. 2015

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8.0
8.1

Turnover To Owner
Quality Control dossiers shall be compiled progressively in parallel to the construction
activities by the QC team. They will also compile all the commissioning test sheets received
from the Commissioning team to be arranged system by system to compile the turnover
package. The packages shall be handed over to the Client as per the contractual requirements.

9.0
9.1

Pre-Commissioning Scope
Ensure required documentations are available to the start the pre-commissioning.

9.2

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

9.3

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

9.4

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

9.5

Cold loop checks and testing.

9.6

Hi-Pot testing, cables meggering.

9.7

Motors meggering and rotation check.

9.8

Cables continuity check completed.

9.9

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


and tripping levels.

9.10

Equipment alignment inspection reports available.

10.0
10.1

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

10.2

Ensure required documentation is available to start commissioning.

10.3

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

10.4

Defining most appropriate sequencing and prioritizing of commissioning activities to ensure


timely completion of all commissioning activities.

10.5

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


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

10.6

Function checks of individual components and verification of complete loops.

10.7

Fulfilling testing and performance test owner based on the requirement, contract
requirements, specifications, standards and codes.

10.8

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

11.0

Division of responsibilities between Kharafi National and Vendors (Suppliers)


By Vendor - Testing of vendor equipment and supply of commissioning procedures,
guidelines, relevant drawings and operation & maintenance manuals.

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

By KN - Interface testing (or subcontractor)

12.0

Procedures / Commissioning forms


The commissioning procedures of the suppliers, vendors and their respective commissioning
forms shall be used and signed by the vendor, KN and Client as applicable.

13.0

Charging Mechanism
The charging of services offered by the Commissioning Department to the in-house projects
will be as given below:

AWI 412 Rev. 0 28 Apr. 2015

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Through In-House Works Agreement


For long term Commissioning services, the Commissioning Manager and the concerned
Project Manager shall first agree on the scope of work to be done and its lump-sum
charges. Once agreed, both parties shall enter into an In-house Work Agreement.

Based on Man-hours
For short term Commissioning services the charging will based on the composite rates for
the man-hours utilized. The Commissioning Manager at the end of the month will raise a
Commissioning Invoice to the project using Attachment 3.

14.0
14.1

Attachments
Attachment 1

Commissioning Process Flowchart

14.2

Attachment 2

Commissioning Manpower Estimate

14.3

Attachment 3

Monthly Timesheet Monitoring Record

AWI 412 Rev. 0 28 Apr. 2015

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