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JPEP-0-1231-B-0001 Rev.

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Standard of Plant Commissioning Department (SPCD-001)

EXECUTION PROCEDURE

for

COMMISSIONING WORK

JPEP-0-1231-B-0001 Rev. 0

Issue Date: 01 Feb. 2002

This document is of a confidential nature and is the property of JGC CORPORATION,


YOKOHAMA, JAPAN, and shall not be traced, photographed, photostated or reproduced in any
manner, nor used for any purpose whatsoever except by written permission of JGC
CORPORATION.

Responsible Dep.: Plant Commissioning Department.


Prepared by: Checked by: Approved by:
Y.Otsubo M.Watanabe S.Koyanagi
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CONTENTS

1. Scope .......................................................................................................................................... 3

2. Commissioning Work ................................................................................................................. 3

3. Authority and Responsibility ..................................................................................................... 3


3.1 Manager of Plant Commissioning Department .....................................................................3
3.2 Planning K.P. ............................................................................................................................3
3.3 Execution K.P. ..........................................................................................................................4
3.4 Delegation of Authority and Responsibility ...........................................................................4
4. Preparation of Procedures ......................................................................................................... 4
4.1 Planning of Commissioning Work...........................................................................................4
4.1.1 Commissioning Execution Plan .......................................................................................4
4.1.2 Overall Commissioning Schedule ....................................................................................5
4.1.3 General Commissioning Procedures................................................................................5
4.1.4 Performance Test Procedure ............................................................................................6
4.1.5 Issue and Revision of Commissioning Related Procedures at Site................................6
4.1.6 Checking of Documents Related with Commissioning ...................................................7
4.2 Execution of Commissioning Work .........................................................................................7
4.2.1 Detailed Commissioning Procedures ...............................................................................7
4.3 Utilization of Internal Documents ..........................................................................................7

Attachment-1 JOB Key Persons Control List (Example)


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1. Scope
This standard covers the commissioning work execution described in Section 19 of “Quality
Manual” (JGS 000-004-2-01).
This standard describes the function and responsibility within organization and the
execution procedures for commissioning work included in any project contract, so that the
work will meet all contractual requirements and to be executed effectively.
This standard shall apply to the projects, of which commissioning work is under the
responsibility of the Plant Commissioning Department.
2. Commissioning Work
The commissioning work can be divided into following two categories.
(1) Planning of Commissioning Work
Preparation of overall commissioning schedule, review of the engineering deliverables
from an operational point of view, preparation of general procedures for the execution
of various commissioning activities, etc.
(2) Execution of Commissioning Work
Preparation of detailed procedures and execution of various commissioning activities
to be done mainly at the construction site.

3. Authority and Responsibility

3.1 Manager of Plant Commissioning Department


The Manager of the Plant Commissioning Department (The Manager hereafter) may
delegate, in executing commissioning work for a project, the authority and responsibility,
defined in this standard, to the Deputy Manager of the department, or any other equivalent
level person he designates. In such case, the Manager who appears in this standard shall
be read as the person to whom the authority and responsibility are delegated.
(1) The Manager shall be responsible for ensuring that all requirements specified for a
project are fulfilled in execution of commissioning work.
(2) The Manager shall appoint key persons responsible for commissioning work planning
(Planning K.P. hereafter) and for commissioning work execution (Execution K.P.
hereafter) (one key person may be responsible for both of planning and execution),
and shall given them authority and responsibility necessary for execution of the work.
The appointment shall be indicated in the JOB Key Persons Control List. The form of
the list is attached hereto.
(3) The Manager shall be responsible for securing the personnel, equipment, and other
resources, all of which are required for executing commissioning work for a project
and endow each key person with the authority to use such resources.
(4) The Manager shall be responsible for preparing, maintaining and revising the
manuals and procedures defining the commissioning work to be executed by the
Plant Commissioning Department.
(5) The Manager shall be responsible for keeping a record of the on-the-job-training of
the engineers of the Division in accordance with the divisional standards “Recording
Manual of Execution for On-the-Job Training”. The Manager shall refer to the record
in appointing the key persons responsible for the execution of commissioning work
and other personnel.

3.2 Planning K.P.


(1) The key person shall be responsible for planning commissioning work so as to satisfy
all requirements specified for a project.
(2) The key person shall be responsible for preparing a commissioning execution plan (or
commissioning plan) describing the scope of works related to commissioning work
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and the basic policy for the execution of such work so as to ensure that all
requirements for commissioning work specified for a project be fully met. The key
person shall be also responsible for developing an overall commissioning schedule.
(3) The key person shall be responsible for preparing general commissioning procedures
each describing the basic ideas of each activity to be done during commissioning work.
Such procedures shall give the basis for the preparation of detailed commissioning
procedures which may be prepared where required at the stage of executing
commissioning work.
(4) The key person may be responsible for preparing all or part of detailed
pre-commissioning procedures.
(5) The key person shall represent, to the other divisions and outsiders, the Plant
Commissioning Department within the scope of the authority endowed.

3.3 Execution K.P.


(1) The key person shall be responsible, at the Plant Commissioning Department, for the
execution of commissioning work so as to satisfy all requirements specified for a
project.
(2) The key person shall be responsible for establishing detailed commissioning work
execution plans on the basis of the commissioning execution plan prepared at the
planning stage keeping up to such plans and ensuring the execution of the plans.
(3) The key person shall be responsible, where required, for preparing a detailed
commissioning procedures for each of the commissioning activities on the basis of the
general commissioning procedure issued at the planning stage

The key person shall be also responsible for submitting records to client of the results
of executed commissioning work for approval.
(4) The key person shall represent, to the other divisions and outsiders, the Plant
Commissioning Department within the scope of the authority endowed.
(5) The key person shall be responsible for execution of activities and guidance for them
so as to satisfy all specified requirements while executing commissioning work.
(6) The key person shall be responsible for reporting non-conformance and defects due to
design, procurement and construction work, if found at any commissioning work
execution stage, to the site management.

3.4 Delegation of Authority and Responsibility


The delegation of authority and responsibility shall be clearly stated in writing. However,
no statement in writing shall be required in cases where the person directly superior to the
person-in-charge acts for her/him.

4. Preparation of Procedures

4.1 Planning of Commissioning Work

4.1.1 Commissioning Execution Plan


(1) Commissioning execution plan shall describe the scope of work related to
commissioning work and the basic policy for the execution of such work so as to
ensure that all relating requirements defined in a project contract and
attachments thereto be fully satisfied.

The plan shall be submitted to the Manager for approval.


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(2) Commissioning execution plan shall, as a rule, cover the items described below.
• Definition of work items related to commissioning
• Scope of responsibility between client and JGC for commission work
• JGC’s organization for the commissioning work and its functions.
• Client’s organization for the commissioning work and communication
procedure.
• Documents to be issued
• Other items to be described specific to the project.
4.1.2 Overall Commissioning Schedule
(1) Overall commissioning schedule shall clearly indicate the time flow of the entire
commissioning work and commencement and completion time of the respective
work items.

The schedule shall be submitted to the Manager for approval.


(2) Overall commissioning schedule shall satisfy the requirements for the project
completion dates defined in a contract and attachments thereto.
(3) Overall commissioning schedule shall serve as the basis for the preparation of
detailed schedules in executing commissioning work.
(4) Overall commissioning schedule, which is a basis to decide the time for completion
of construction work, shall accordingly match with a construction schedule.

4.1.3 General Commissioning Procedures


(1) A separate general pre-commissioning procedures for each pre-commissioning
activity, such as pipe cleaning and the running test of rotating equipment, shall be
prepared.

Such procedure shall describe the basic concept of executing each activity and
shall be referred to in preparing a detailed pre-commissioning procedure at a later
date.
(2) A procedure for the execution of pre-commissioning activity shall be prepared for
each item or a group of items, as shown below.
(a) Cleaning
• Water flushing
• Air blowing
• Steam blowing
• Chemical cleaning
• Other special cleaning methods
(b) Running test of Rotating equipment
• Turbine
• Motor
• Pump
• Compressor
• Blower/Fan
• Other special type rotating equipment.
(c) Drying
• Refractory materials
• Special process lines
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(d) Air freeing


(e) Loading of catalyst, chemicals and packings
(f) Air tightness test
(g) Other pre-commissioning activities specific to a project
(3) Any procedure for the execution of pre-commissioning work shall, as a rule, cover
the items described below.
(a) Scope of the procedure
(b) Notes on execution
(c) Outline of execution procedures
(d) Criteria of the completion of pre-commissioning work
(e) Measures to be taken after the completion of pre-commissioning work
(f) Use of properly calibrated instruments shall be emphasized in cases that
other test instruments than that of permanent installation for the project
may be used.
Vibration meters, oxygen concentration meters and instruments appointed by
the Planning/Execution K.P.s shall be calibrated.
(4) Any procedure for the execution of commissioning work shall be approved by the
Planning/Execution K.P.s.

4.1.4 Performance Test Procedure


The performance test procedure shall describe the procedures of performance test run
which is carried to verify all guarantee items specified in the project contract, and
methods of analysis and evaluation of the test run results.
The procedure shall be prepared by a division assigned by the engineering manager for
the project. Any performance test procedure to be prepared by the Plant Commissioning
Department shall be approved by the Manager.
The procedure shall, as a rule, cover the items described below.
a) Performance guarantee items and guaranteed figures
b) Duration of the performance test run
c) Procedure of the performance test run
• Operating conditions of the plant
• Test instruments to be used
• Samples for analysis and analytical test methods
• Frequency of measurements and analyses
d) Methods of correction, analysis and evaluation
e) Conditions for starting of performance test run, an organization responsible for
performance test run, methods of communications or other items may be added as
required.

4.1.5 Issue and Revision of Commissioning Related Procedures at Site


After the issue and revision of procedures related with commissioning (commissioning
plan, overall commissioning schedule, pre-commissioning procedures and performance
test procedure) is turned over to a construction site, the authority to approve the issue
and revision of such procedures may be delegated from the Manager to the
commissioning key person.
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4.1.6 Checking of Documents Related with Commissioning


The Planning K.P. shall check for the current status of documents prepared by each
division for the project, using “JGC DOCUMENT CURRENT STATUS LIST” and
expedite their timely issue.
4.2 Execution of Commissioning Work

4.2.1 Detailed Commissioning Procedures


(1) Detailed commissioning procedures shall be prepared where it is required for each
of units, facilities, lines and equipment based on general commissioning
procedures to be prepared at the planning stage.
(2) The detailed commissioning procedures shall utilize appropriate drawings so as to
show clearly the execution procedure of each work. The contents of those
procedures shall be most appropriate for the site situation.

The procedures shall include a form of commissioning work record and another on
which client verify completion of the work.
(3) All or part of the procedure may be prepared by the Planning K.P.
(4) The procedure shall be approved by the Planning/Execution K.P.

4.3 Utilization of Internal Documents


The various documents described in 4.1 and 4.2 above should be prepared by referring to
the internal documents for similar projects kept at the Plant Commissioning Department.
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Attachment -1

JOB Key Persons Control List (Example)


Yokohama : Planning K.P. Site : Execution K.P.
Person in Charge
No. JOB Outlines Units/Facilities
Site Yokohama

1 JOB CODE : 0-6900 General * *

PJ NAME : PSR Utilities

CLIENT : PETRONAS CDU

LOCATION : Melaka, Malaysia N-HDS

SCOPE : Pre-comm./Commissioning CRU

OFF SITE

PERIOD : Jul. 1993 – Nov. 1994

2 JOB CODE : 0-7000 General

PJ NAME : EXOR-1 CDU / HP

CLIENT : PERTAMINA ARHDM

LOCATION : Balongan, Indonesia RCC

SCOPE : Pre-comm./Commissioning GOD / LCOD

SR/AMINE/SWT

OFF SITE

PERIOD : Feb. 1993 – Nov. 1994

3 JOB CODE :

PJ NAME :

CLIENT :

LOCATION :

SCOPE :

PERIOD :