Commissioning Check Templates
Commissioning Check Templates
Commissioning Check Templates
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Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
Contents
Contents .............................................................................................................................. 3
General .............................................................................................................................. 4
Vendor Verification .............................................................................................................. 5
General ........................................................................................................................... 5
Mechanical .......................................................................................................... 5
Civil ............................................................................................................... 5
Factory Acceptance Testing (FAT) .................................................................................. 6
Electrical, Instruments and Control (E, I & C) ....................................................... 6
Pre-commissioning.............................................................................................................. 7
Preliminaries Checklist .................................................................................................... 7
Pre-commissioning Checklist .......................................................................................... 9
General ............................................................................................................... 9
Network ............................................................................................................... 9
Electrical, Instruments and Control (E, I & C) ....................................................... 9
Mechanical ........................................................................................................ 13
Wet Testing ........................................................................................................................ 15
Commissioning Schedule .............................................................................................. 15
General ............................................................................................................. 15
Wet Well Level Sensor Checks .......................................................................... 15
Pump Checks .................................................................................................... 15
Pump Control Checks ........................................................................................ 16
Generator Checks.............................................................................................. 18
Wet Testing Signoff ........................................................................................... 18
SAT / Performance Testing ............................................................................................... 19
SAT Schedule ............................................................................................................... 19
SAT Pre-start Checks ........................................................................................ 19
Wet Well Level Sensor Checks .......................................................................... 19
Pump Checks .................................................................................................... 19
Pump Control Checks ........................................................................................ 19
Generator Checks.............................................................................................. 21
SAT Signoff ....................................................................................................... 22
This document may not, in whole or part, be copied, photocopied, reproduced or translated
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without prior consent from the CEO, Unitywater.
Printed copies are uncontrolled.
Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
General
In using this document, due consideration of all other relevant Unitywater Standard Drawings and
Unitywater Standard Specifications should be adhered to.
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Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
Vendor Verification
PROJECT TITLE: FINANCE NO:
Mechanical
1. Pump test results been reviewed and conform with applicable standards OK
Civil
CONSTRUCTOR
Name: Position: Signature: Date:
UNITYWATER SIGNOFF
Name: Position: Signature: Date:
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Document No: F8943
Revision No: 4
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Next Review Date: 28/04/2019
Switchboards
10. Any deficiencies have been recorded to a ‘FAT punchlist register’ and rectified OK
Instrumentation
Software
13. Software blocks have been fat tested (if non standard) OK
CONSTRUCTOR
Name: Position: Signature: Date:
UNITYWATER SIGNOFF
Name: Position: Signature: Date:
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Printed copies are uncontrolled.
Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
Pre-commissioning
PROJECT TITLE: FINANCE NO:
2. Check risk assessments and SWMS have been produced for all Pre- OK
commissioning and Commissioning activities
3. The site is safe for commisisoning works to commence. Safety requirements OK
include:
• Covers and grills installed and flush
• Davit mounting points certified
• Fall arest mounting points certified
• Handrails, fencing, gates and chains installed correctly
• Emergency procedures available
• Safety signage in place (PPE, Elecricity, SWL, Danger etc.)
4. Check “danger electric” marker bricks are installed at ground level and painted OK
yellow where applicable
5. Rising Main acceptance testing according to standard and passed OK
8. Changes to any detail as shown on the ‘For Construction’ drawings noted on a set OK
of ‘For Construction’ drawings and marked ‘As Constructed
9. Current Unitywater Standard Drawings are on site (OR, if “Design and Construct”, OK
the ‘For Construction’ drawings have been reviewed by Unitywater)
10. All required civil works testing (ITPs) completed by Contracts Inspector OK
11. Operation and Maintenence Manuals have been received for Vendor supplied OK
components and the Functional Specification is available
12. Electical supply and metering available on site OK
15. Check all cable supports and check for obstructions (e.g. cables not obstructing OK
when lifting pump)
16. Selected control equipment is suitable for selected pump manufacturer OK
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Printed copies are uncontrolled.
Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
CONSTRUCTOR
Name: Position: Signature: Date:
UNITYWATER SIGNOFF
Name: Position: Signature: Date:
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Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
General
Network
Generators
1. Check generator mains and earth cables are installed and connected OK
Switchboards
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Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
12. Check correct glands have been utilised for cable entries OK
21. Check earth leakage circuit breaker has been tested and results are available OK
Level Transducers
24. Check surge protection barriers are installed (control panel and field). Pay OK
particular attention to earth screen terminators.
25. Check connection from hydrostatic level probe No.1 to the transmitter and OK
confirm correct operation
26. Check connection from hydrostatic level probe No.2 to the transmitter and OK
confirm correct operation
27. Check scaling conforms to wet well design requirements OK
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Document No: F8943
Revision No: 4
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Next Review Date: 28/04/2019
31. Check analogue output is correctly connected to RTU and operating correctly OK
32. Check totaliser output is correctly connected to RTU and operating correctly OK
Field Devices
35. Check calibration of all analogue signals (including flow and pressure transmitters) OK
Pump Motors
38. Check pump motor name plate details have been received and applied to asset OK
management form and electrical drawings and a second plate is mounted on the
switchboard pump control door
39. Check pump motor name plate has been applied to MCC or disconnection box OK
R - E @ 1000V ______ MΩ
W - E @ 1000V ______ MΩ
B - E @ 1000V ______ MΩ
41. Record pump motor winding resistance
U - U1 ______ Ω
V – V1 ______ Ω
W – W1 ______ Ω
42. Check all motor protection equipment operates as specified (e.g. water in oil OK
sensor, thermistors, vibration sensors, bearing temperatures etc.)
43. For variable frequiency drive (VFD), check drive settings are setup and settings OK
recorded
44. For soft starter, confirm Soft Starter settings are setup and settings recorded OK
45. For direct on-line (DOL) starter, check overload settings correct and recorded on OK
drawing
46. Perform bump test to confirm correct rotation direction OK
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Printed copies are uncontrolled.
Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
51. Check incoming and outgoing cables have been secured correctly OK
52. Check all conduits have been sealed to prevent gassing through conduits OK
Radio
53. Check radio feeder & antenna installation and cable testing (antenna to radio) OK
have been performed, and results certificate received
54. Check surge protection and fly lead is connected between antenna and radio OK
55. Check Communications earthing kits and earthing are installed on feeder and OK
Surge Diverter respectively
61. Check unit is powered with correct polarity and voltage DC Supply(ies) OK
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Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
65. Record type of control system installed (i.e. SCADAPack, MultiSmart, MT2-PC) _________
66. Record controller information
Manufacturer _________
Model type _________
Serial no _________
Firmware rev _________
Software rev _________
67. Notify control room of impending end-to-end test (minimum 5 days notice) OK
68. Check end-to-end test sheet has been reviewed and approved by control room OK
Mechanical
General
71. Undertake visual examination of installation and finish of all pipework, mechanical OK
devices, valves, fittings and pump units
72. Check accuracy of tagging and labelling OK
75. Check for any debris capable of causing damage to mechanical equipment when OK
pumps are started
76. Check accessibility of access covers and equipment for operational and OK
maintenence purposes
77. Check equipment is guarded appropriately OK
78. Check stairways, landings and access ladders comply with design requirements OK
80. Check that manufacturers’ requirements have been met (i.e. alignment, OK
lubrication, preparation, priming etc.)
81. Check instrumentation nozzles are provided in accordance with design (correct OK
side of equipment e.g. US/DS)
82. Check installation and operation of instrument isolation valves OK
83. Check directional requirements (i.e. pump rotation, check valve direction etc.) OK
84. Check commissioning pressure transmitters or gauges on either side of pump are OK
operational
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Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
86. Check earthing straps are installed accross both flowmeter flanges, earthing rings OK
and to earth as specified by the equipment manufacturer
Pumps
Rising Main
90. Check pressure test has been undertaken according to relevant standard and OK
passed
91. Check pipework connections to UW network have been successfully completed OK
CONSTRUCTOR
Name: Position: Signature: Date:
UNITYWATER SIGNOFF
Name: Position: Signature: Date:
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Printed copies are uncontrolled.
Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
Wet Testing
PROJECT TITLE: FINANCE NO:
General
2. Record Top of Slab RL (m) and distance from Top of Slab to each level OK
sensor in Commissioning Worksheet
3. Record well diameter and total depth for volume calculations in OK
Commissioning Worksheet
4. Confirm wet well level indicated by the level probe is reflective of the actual OK
wet well level and record readings in Commissioning Worksheet
5. Confirm functioning of high and high high (overflow) level alarms OK
Note that the overflow structure may only be brought on-line once ‘As
Constructed’ overflow level has been confirmed (to remain bunged off
until level confirmed)
Pump Checks
6. Ensure correct parameters are set in the VFD or Soft Starter if applicable OK
7. Start pump with discharge valve closed and ensure the pump is running OK
without undue noise, vibration and temperature
8. To ensure motor load balancing, record:
Pump running amps L1 ________A
Pump running amps L2 ________A
Pump running amps L3 ________A
9. Stop pump OK
10. Complete Low Power Tuning (Danfoss VFD) and record values into OK
Commissioning Worksheet
11. Repeat steps 7 to 10 for second pump/drive OK
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Printed copies are uncontrolled.
Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
16. Operate pump from 35 to 50 Hz in 5 Hz increments (if VFD type), check for OK
abnormal movement or vibration
17. Perform visual inspection of pump, all piping, fittings and flanged joints for OK
leakage
Pump Performance and Flowmeter Accuracy YES
22. Ensure assist start level > wet well level > duty start level OK
28. Fault Duty Pump – i.e. open one c/b feeder for phase failure relay OK
35. Ensure assist start level > wet well level > duty start level OK
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Printed copies are uncontrolled.
Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
40. Manually override wet well level > than assist start level OK
42. Manually override wet well level < assist stop level OK
44. Manually override wet well level < duty stop level OK
50. Manually override wet well level < duty stop level (pumps are stopped) OK
58. Manually override wet well level < duty stop level OK
65. Simulate a wet well high high level (manually lowering the probe is the OK
preferred method)
66. Confirm Pump 1 starts OK
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Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
68. Confirm both pumps stop when water level reaches the lowest probe (stop) OK
on the start/stop three point probe
69. Select both pumps to “off” position OK
CONSTRUCTOR
Name: Position: Signature: Date:
UNITYWATER WITNESS
Name: Position: Signature: Date:
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without prior consent from the CEO, Unitywater.
Printed copies are uncontrolled.
Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
3. Record Top of Slab RL (m) and distance from Top of Slab to each level sensor in OK
Commissioning Worksheet
4. Record well diameter and total depth for volume calculations in Commissioning OK
Worksheet
5. Confirm wet well level indicated by the level probe is reflective of the actual wet OK
well level and record readings in Commissioning Worksheet
6. Confirm functioning of high and high high (overflow) level alarms OK
Note that the overflow structure may only be brought on-line once ‘As
Constructed’ overflow level has been confirmed (to remain bunged off until
level confirmed)
Pump Checks
11. Ensure assist start level > wet well level > duty start level OK
This document may not, in whole or part, be copied, photocopied, reproduced or translated
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without prior consent from the CEO, Unitywater.
Printed copies are uncontrolled.
Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
17. Fault Duty Pump – i.e. open one c/b feeder for phase failure relay OK
24. Ensure assist start level > wet well level > duty start level OK
29. Manually override wet well level > than assist start level OK
31. Manually override wet well level < assist stop level OK
33. Manually override wet well level < duty stop level OK
Pump Cycling
39. Manually override wet well level < duty stop level (pumps are stopped) OK
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Document No: F8943
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Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
47. Manually override wet well level < duty stop level OK
54. Simulate a wet well high high level (manually lowering the probe is the preferred OK
method)
55. Confirm Pump 1 starts OK
58. Confirm both pumps stop when water level reaches the lowest probe (stop) on the OK
start/stop three point probe
59. Select both pumps to “off” position OK
Generator Checks
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Document No: F8943
Revision No: 4
Last Review Date: 28/04/2017
Next Review Date: 28/04/2019
SAT Signoff
CONSTRUCTOR
Name: Position: Signature: Date:
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