ENGINEERING DEPARTMENT Document ENG-SOP-

Revision NEW
COMMISSIONING PROCEDURE Issue Date 13 MAR 2019
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Introduction

Purpose of this document

This instruction describes the commissioning strategy to deliver manufacturing

excellence. It applies to all manufacturing, packaging and industrial services, as well as
auxiliary functions where assets need to be installed. These is to prevent glitches in the
project as part of good management practice

Road Map for Project completion

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COMMISSIONING PROCEDURE Issue Date 13 MAR 2019
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Scope

This instruction covers the production line assembly from the machine arrival to project
completion in order to handover for the operations.

Where this instruction be used as approving the completed installation of production line

The Scope are where divided into two

 Electrical
 Mechanical

Where the phase of completion is interpret as a road map shown below

Road Map for system assembly and commissioning transition

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COMMISSIONING PROCEDURE Issue Date 13 MAR 2019
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Responsibility

The equipment vendor is fully responsible of delivering the following

 Installation best practice
 Method of statement
 Loop drawing
 I/O list (for system completion)
 Equipment handling training

Responsible parties for each testing report shall be review prior to installation &
commissioning phase. This identifies the group or individual that is responsible for
taking action on and ensuring completion of each item. The designated owner from the
EHS and Engineering departments will review and approve the checklist and required
documentation in order to begin/initiate the installation process.

The group to be represented on the equipment commissioning sign-off team are as

follow

 Assigned Project engineer

 Production representative
 Quality representative
 Safety representative

The number of responsible parties may vary depending on the owner status at installed
area.

The equipment-sign off team members will meet at site as necessary to complete their
assigned responsibilities where nominated group shall present at site as follow
Machine verification (health check )
Witnessing equipment check
Witnessing functional test
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Witnessing overall function test (wet test)

Procedure

Detail road map of assembly and transition

Initial walkdown

Verification shall be conducted upon arrival of the machine/equipment where to meet

the standard of engineering design as specify for the requirement.

Visual check shall be conducted to the mechanical requirement where there is no sign
of wear tear, broken/faulty or dirty

Identify and verify the item according to the design where meet the condition of
specification

Installation and punch list verification

the equipment manufacturer shall provide method of statement prior to installation kick-
off. Where shall be review by the group in order to minimise any incident at site.

Installation requirement shall adhere to the safety and hygiene standard from the owner

For any witness that do not satisfy the group verification shall be recorded as punch list
and verify with the equipment manufacturer/contractor to acknowledge and must be
complete upon commissioning phase

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 ENGINEERING DEPARTMENT Document ENG-SOP-
Revision NEW
COMMISSIONING PROCEDURE Issue Date 13 MAR 2019
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Pre-commissioning

This instruction is mandatory to make sure smoothness of transition of the dry test and it
is divided into five
 Electrical
 Mechanical
 Instrument/System
 Facilities & building
 Non-operational system

Electrical equipment & cabling shall be test which to define its function and purpose to
be verify by the group as below:
 Voltage rating
 Loop check
 Continuity test
 Megger test
 Visual inspection for complete and correct installation
 Earthing checks
 Static check of switches and control devices
 Lighting and socket outlet checks
 Insulation testing of generator, transformers and motors, panels, distribution
board etc.

Mechanical & structure shall be verified on their integrity test and function to any of the
following
 Hydrostatic test
 Function test
 Integrity check
 For any mechanical structural joint that require weldment shall be carried out
penetration test to ensure the weld is properly done
 Load testing of lifting equipment

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COMMISSIONING PROCEDURE Issue Date 13 MAR 2019
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 Internal inspection of tanks and vessel

 Visual inspection for complete and correct installation
 Dimension control
 Bolt tensioning
 preservation

For any piping that provides to the production area, weldment joint shall be inspect by
using prior to hydrostatic test. this mechanical piping is critical to the production area
and could cause hazard or potential risk of explosion if it is not done properly.
 Penetration test
 Ultrasonic test

For ultrasonic and penetration test shall be carried out by competent person including
the report for to be submit and verify by the group.

Facilities & building

Visual inspection for complete and correct installation
QC documentation
Welding check
Insulation check if necessary
Thickness check carried out
Fire proofing

HVAC
Visual inspection for complete and correct installation
Cleaning of ductwork
Leak testing of ductwork
Alignment check
Mechanical function check of equipment

Non operating systems

Completion station and check on area basis. Dispilins included structural, surface
protection, insulation, fire proofing and architectural
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Instrument/ system

Instrument shall be calibrated and witness by the group to ensure the measure
instrument able to provide information accurately
 Calibration and testing of instrument prior to installation
 Visual inspection for complete and correct installation
 Adjustment of control alarm and shutdown setting
 Function test of control system
 Function testing of field instrument
 Area completion
 Preservation
 Panel performance testing

System

The check list of the pre-commissioning of the system is divided into two
System hardware check
Visual check on the grounding and termination is properly done and tagging
Redundacy check

System Software check

I/O check from the software to the I/O board termination
Software program function check (if applicable)
Interface requirement check
Integration test

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Commissioning
Upon completion of pre commissioning, owner shall provide cold time to execute
punchlist execution and verify prior to execute dry test. this instruction is divided into two

Dry test
Dry test will be conducted based on the functionality and integration for the package
system without using raw material. dry test shall be plan and review by the group in
order to manage the risk. Dry test is intended to test maximum rating capacity of
equipment as stated in the requirement.

Dry test milestone is to make sure the assembly line are performing according to the
function of each of the equipment

Wet test
Prior to performing wet test, fumigation shall be carried out and shall be review by the
group to verify the hygiene requirement.

Typical commissioning preparation activities

The preparatory work shall consist of activities such as:
• Development of commissioning organisation
• Development of system breakdown (partsystem)
• Commissioning packages definition
• Commissioning schedules
• Commissioning budget including spare parts for commissioning
• Commissioning preparation check record (ref. Annex A for typicals)

Commissioning procedure content

Commissioning shall be executed by guidance of a detailed procedure describing:

Objective
Details the operating parameters to be achieved.

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Description
Shall contain a brief description of the system/partsystems to be commissioned,
including marked up P&ID as a basis for all functions to be tested.

Lists of temporary equipment and consumables

Lists all consumables, temporary equipment tools and requirements for suppliers
assistance.

Health/Environment/Safety
A list of all toxic and polluting fluids and materials shall be made, describing their
handling and disposal. A check list of all required safety precautions including
requirements for work permit shall be made. Prior to energization of electrical
equipment a livening up notice shall be issued in order to inform all involved parties of
forthcoming energising.

Preservation
Requirements for removal of existing preservatives/protection shall be made and
subsequent new preservation of the system if the system shall be out of operation for a
period.

Scope
The scope shall detail the work to be done step by step including the commissioning
preparation, check record (ref. Annex A). Irregularities and/or faults shall be logged.
Equipment suppliers start-up procedures shall be incorporated. Performance
parameters shall be included for comparison of results with actual result achieved
during commissioning.

Planning
Detailed commissioning plans for system/part system shall be worked out and shall
include manhours per discipline, including supplier assistance man-hours.

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COMMISSIONING PROCEDURE Issue Date 13 MAR 2019
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Handover and training

The handover shall contain a certificate and other documents agreed with operation.
Handover of systems from Executor to project/operation shall be according to a formal
procedure which as a minimum should consist of:
 Completion acceptance certificate (signed by both parties).
 Commissioning P&ID showing the extent of the completed system.
 Authority certificates (if any).
 Training for user
 Operational procedures and handbooks

Prepared by : Review by : Review by : Approved by :

Assistant
engineering Assistant Production QA manager General Manager Operations
manager manager

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Appendix A – pre-commissioning checklist

Pre - Commissioning checklist

Project Name:
Mechanical completion
Main item included in scope Yes No Remar
k
1 Final construction mechanical drawing available?
2 All mechanical assembly has been fitted?
3 Is the label clearly mark on the piping
4 Safety signage present?
5 Is there any weldment defect?
6 is the bolt tensioning tight and mark
7 Is the preservation done upon completion
8 Removal of rust preventative and oils used to protect
equipment during construction period
9 Record of blinds installed
10 Check pipehangers, supports, guides and pipe
specialities for the removal of all shipping and
erection stops, and for the correctness of cold
settings for the design service. In addition, provide
Owner with instructions for hot settings
11 pipehangers, supports, guides and pipe specialties
installed?
12 Provide construction cleanup, including removal of
excess materials, temporary facilities and
scaffolding, rough sweeping or raking of job sites
and trash pickup
13 Level baseplates and sole plates and grout all
bearing surfaces, cold align units and furnish record
of alignment
14 Flushing and cleaning of pipe and vessel
15 Check for and remove any excess piping stresses
which may be imposed on the equipment
16 Level and calibrate weigh scales with assistance of
the manufacturer’s representative and set tare
weights where possible
17 Complete all insulation work as specified
18 Complete all painting as specified
19 nameplate details at tanks, vessels. Rotating
equipment and other machine available?

Electrical instrument completion

Main item included in the scope Ye No Remark
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s
1 All construction electrical drawing available
2 Is the cabling tray present for each routing
3 Is the cabling bend radius within the tolerance
4 the cabling clearly label according to the drawing
5 Is the cable using the same spec as per drawing
6 Is the panel grounding available?
7 Is the panel grounding connected to building
grounding?
8 Check phase sequence and polarity before
termination
9 Are all the cable using ferroul?
10 Validation of valve as drawing
11 Is the instrument calibrated?
Field calibrate instruments with standard test
equipment and make all required adjustments and
control point settings
12 Electrical wiring continuity test
13 Make insulation tests of motor windings and of
transformer windings from phase to phase, and
phase to ground using a megohmmeter

14 Make insulation test of all wiring using a

megohmmeter
15 Are the wire all terminated?

Waste disposal
Main item including in the scope ye No remarks
s
1 Is the entire area clean from debris?
2 Is the waste of construction is still present?
3 Is there any defect to the building or structure during
construction

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