Best 

Practice Procedures in transition
from
Construction to Commissioning
Ridha. Khaldi CSU Supt
(GTP‐ 2018)
 What is Pre‐Commissioning and Commissioning?

• Non‐operating adjustment and cold alignment checks (such as

cleaning, drying and testing without introducing process and
auxiliary fluids prior to equipment energization )

• Pre‐startup, check‐out, system adjustment, equipment and

system activation activities to prepare system(s) and/or facilities
for operation (by introducing auxiliary fluids and with equipment
energization)
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System: 
Is a major subdivision of a plant, being either process or utility, which
performs a major operational function of the plant.
A System includes all the various equipment that allows it to operate. The
division into functional Commissioning Systems generally corresponds to the
prevailing fluids or services.
The Fire fighting, Power generation, Air generation, Control systems,
Telecommunications, Oil, Gas, Water processing, etc., are typical examples of
functional Systems.

Sub‐system:
Is a further sub‐division of a System, which performs a partial operational
function of the System, with little or no interference from the other Sub‐systems.
The Sub‐system is the basic unit for Commissioning

As the basic unit of Commissioning shall be the Sub‐system, it must be

understood that there can be several hundred’s of Sub‐systems on a project.
 The contractual wording to be used for the RFC certificate shall be the one 
provided in the contract. 

Summary of characteristics for RFC: 

Applies to :                 Sub‐system 
Prerequisites :            All Pre‐commissioning Activities successfully completed    
Consequences :         Authorization to begin Commissioning activities :  

There shall be one Pre‐commissioning dossier by Sub‐system.

These dossiers shall contain all the information’s required to demonstrate that
a Sub‐system has reached the "Ready For Commissioning" status (RFC)
 Commissioning Activities
 Commissioning consists of a series of tests and activities that validate the
construction and prepare a plant for operation.
 This is generally considered in two phases:
Phase Activity Milestone
Pre-commissioning Conformity Checks Ready for Commissioning
Static Tests Mechanical Completion
Hydrotests
Flushing & Cleaning
Commissioning Energisation Ready for Start-up
Dynamic Tests
Equipment Running-In
Utilities Start-Up
Pre-Start-Up Activities
Operational Tests

Start-Up Feed-In Provisional Acceptance

Perfomance Tests Plant in Operation
Bringing the Plant On-Line
Pre‐commissioning activities summary
Commissioning activities summary
Commissioning Activities and Project Phases
Construction (later works)

Commissioning Team on Site

Liaison with Construction and Engineering
Manage, supervise and/or carry out the Pre-
commissioning activities
Manage, supervise and/or carry out the early
Commissioning activities
Punch list generation and management
Completion and record of the pre-commissioning
/ commissioning documentation
Mechanical Completion
Commissioning Activities and Project Phases
Commissioning

Commissioning Team on Site

Liaison with Construction, Engineering,
Operations & Maintenance
Manage, supervise and/or carry out the
Commissioning activities
Punchlist management
Prepare the plant for Start-up
Start-up of Utilities
Operational Testing
Ready for Start-up
Commissioning Activities and Project Phases
Start-up

Commissioning Team (Startup Support)

Working with Operations for the rapid and safe
start-up of the facilities
Performance Testing
Punchlist management
 Phasing of Activities
CONSTRUCTION
Plant

COMMISSIONING
COMMISSIONING STARTUP
START‐UP
COMMISSIONING START‐UP
OPERATION
OPERATION

PRE‐COMMISSIONING DOSSIERS

PREPARATION COMMISSIONING Commissioning

MANAGEMENT

PROCESS
STARTUP
Operations
UTILITIES PERFORMANCE
STARTUP TESTS

TIME
MECHANICAL COMPLETION
MECHANICAL COMPLETION

MECHANICAL COMPLETION
MECHANICAL COMPLETION

FINAL ACCEPTANCE
PLANT IN OPERATION
COMMISSIONING
1st REQUEST FOR

OF FIRST SYSTEM

PROCESS READY
UTILITIES READY

FOR START‐UP
FOR START‐UP
OF FIRST SYSTEM

OF  SITE
OF  SITE
 Why transition from Construction to 
Commissioning is so important?
• Safety environment is complex and difficult to manage
L'environnement de sécurité est complexe et difficile à gérer

• Tight schedule: margins are usually eaten up by upstream

project phases and little float to cope with unexpected
events
Un calendrier serré: les marges sont généralement dévorées par les phases en 
amont du projet et peu de flottement pour faire face aux évènements 
inattendus

• Major over‐laps between various activities

Principaux chevauchements entre diverses activités
• Number of participants are quite high compared to other
project phases

Le nombre de participants est assez élevé par rapport aux autres
Phases du projet

• Stakeholders’ priorities sometimes conflict with each

others

Les priorités des parties prenantes entrent parfois en conflit avec
autres

• Require very skilled and experienced personnel

Exigence d’un personnel très qualifié et expérimenté
 What is Mechanical Completion ?

• Construction is completed in accordance with drawings,

specifications, vendor instructions, applicable codes and
regulations and authority requirements

• All inspection, checking and testing works are completed

• System(s) and/or facilities are ready for pre‐commissioning

and commissioning
 Construction Completion Milestones 
• TOS Self‐contained portion of a facility/system for hand over 

• Test Package Set of documentation demonstrating the MC of a system or its 
subsystems or sections that can be isolated for test purposes 

• Punch List Formal inspection and identification of remaining outstanding works 

• Initial Walk down Identification and closure of all category “A” punch items 

• Final Walk down Demonstration and acceptance of a pre‐checked system for 
hand  over & Punch List

• TOD Final dossier including all applicable as‐built engineering documents and
(Turn Over Dossier) construction certificates as per Inspection & Test Plan
attesting the readiness or turn over
 What is needed to administer this transition phase 
•Standardized preparation for mechanical completion and commissioning

•Maximization of electronic data transfer from engineering and project

controls

•Continuous and auditable progress measurement (physical vs. QC

achievements)

•Management of system‐wise completion (Gestion de l'achèvement du système)

•Structured and certified handover for all disciplines

•Controlling tool for the creation and management of all QC and MC forms
 Basis of TAG Assignment 

At initial phase of engineering, each physical Object of

the plant subject to a control:

• shall be TAG ged

• shall belong to a family (Object Class)

• shall be defined in case it does not represent an object

(e.g: Hydrotest Circuit, Loop Folder, etc)
Typical Mechanical completion 
activities
Mechanical
• Visual inspection for complete and correct installation.

• Internal inspection of tanks and vessels.

• Alignment.

• Load testing of lifting equipment

• Flushing.

• Bolt tensioning.

• Dimension control.

• Preservation.
Electrical
• Visual inspection for complete and correct installation.

• Insulation and continuity testing of cables.

• Insulation testing of generator, transformers and motors, panels, distribution
• board etc.

• Earthing checks.

• Static check of switches and control devices.

• Battery preparations.

• Lighting and socket outlet checks.

• Area completion.

• Heat tracing.

• Preservation.
Instrument

 Calibration and testing of instruments prior to installation.

 Visual inspection for complete and correct installation.

 Insulation and continuity testing of cables.

 Cleaning, flushing, pressure and leak testing of pneumatic and hydraulic tubing.

 Adjustment of control, alarm and shutdown settings.

 Loop testing.

 Function testing of control systems.

 Function testing of field instruments.

 Hot oil flushing of instrument tubing.

 Area completion.

 Preservation.
Piping
• NDE carried out.

• Welding procedures.

• Flushing of pipework.

• Chemical cleaning and testing of pipework.

• Preservation of tested pipework.

• Reinstatement of all items after testing.

• Final inspection of pipework.

• Test ISO's and P&ID's showing the extent of each pressure test.

• Hydraulic tubing.

• Bolt tensioning.

• Pipe supports completed.

• Insulation.
HVAC (applicable for containers)

 Visual inspection for complete and correct installation.

 Cleaning of ductwork.

 Leak testing of ductwork.

 Alignment checks.

 Mechanical functions checks of equipment.

 Preservation.

 Flow coding.
Safety
 Visual inspection for complete and correct installation.

 Preservation.

 Area completion.
Structural

 Visual inspection for complete and correct installation.
 QC documentation.
 NDE carried out.
 Welding.
 Load testing of lifting lugs and monorails.
 Surface protection, Insulation and Fire proofing
 Visual inspection for complete and correct application.
 Thickness checks carried out.
 Adhesion checks carried out.
 Preservation.
 Insulation.
 Painting.
 Fire proofing.
Architectural (applicable for containers)

 Visual inspection for complete and correct installation.

 Preservation.

 Doors.
THANK YOU