Testing and Commissioning Procedure of Pressurization Units

Testing and Commissioning Procedure for
Pressurization Unit
PRO 00043 0.1

1
PRO - Procedure
03
04 --Issued
Issuedfor
forApproval
SONO
REDCO 07-02-2019
21/02/2019
07-02-2019
21/02/2019
21/02/2019
07-02-2019
21/02/2019
07-02-2019
07-02-2019
21/02/2019
0.1
1 21/02/2019
07-02-2019
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GREEN LINE - ELEVATED & AT-GRADE 1\edco International
Testing and Commissioning Procedure for
Pressurization Unit
(REDCO)
RTC/082/2013
Document No.:
00043 11
Revision IB
Document Type PRO- T&C Procedure
Reason for Issue 04 - Issued for SONO
T&C Engineer Signature Date

Prepared by:
Muneeb Asfaq 1~-::,.y 3 February 2019
T&C Manager ( Signature Date
Checked by:
Adnan Aslam ~~~ 3 February 2019
QA/QC Manager Signature Date
Reviewed by:
Monib Ampuan ,.£- 3 February 2019
Project Manager Signature Date

Approved by:
Wessam AIAhmedy k::! ~- 3 February 2019
Revision History
Rev. No. Description of Revision Date of Revision
0.1 First Issue 15 AUG 2018
M009-SPH-TCH-PR0-00043 Page 1 of 18
Testing and Commissioning Procedure for Pressurization Unit (REDCO)
Total Number of Pages: 18 including front pages and excluding appendices
M009-SPH-TCH-PRO-00043 Page 2 of 18
TABLE OF CONTENTS
LIST OF APPENDICES ..................................................................................................... 4
HARDCOPY DISTRIBUTION LIST ................................................................................... 5
ABBREVIATIONS ............................................................................................................. 6
1 PURPOSE .................................................................................................................. 7
1.1 General issues ............................................................................................................... 7
1.2 Purpose .......................................................................................................................... 7
2 SCOPE ........................................................................................................................ 7
2.1 Interdependence with Management Plans ................................................................... 7
2.2 Revision of T&C Procedure Documents ...................................................................... 8
2.3 Testing and Commissioning Stages ............................................................................ 9
3 ROLES AND RESPONSIBILITIES ........................................................................... 10
3.1 Manufacturer / Representative (Xylem water Solution-ltaly) .....................................11
3.2 Sub-Contractor .............................................................................................................11
4 RESOURCES............................................................................................................ 12
4.1 Labour ...........................................................................................................................12
4.2 Equipment Used ...........................................................................................................13
4.2.1 General Equipment used for this activity: ..................................................................13
5 QUALITY ASSURANCE/ QUALITY CONTROL....................................................... 13
6 HEALTH, SAFETY, ENVIRONMENT ....................................................................... 14
6.1 Lockout/Tagout Procedure ..........................................................................................14
6.2 Hazardous Waste Management ...................................................................................15
7 Risk Assessment..................................................................................................... 15
8 METHODOLOGY ...................................................................................................... 15
8.1 PSAT (Partial Stand Alone Test) ..................................................................................15
8.1.1 Prerequisite for PSAT ...................................................................................................15
8.2 SAT (Stand Alone Test) ................................................................................................17
8.2.1 Pre-Request for SAT .....................................................................................................17
8.2.2 Commissioning /Start-Up .............................................................................................17
8.3 MEP System Integration Test (SIT) ..............................................................................18
8.4 System Performance Test (SPT) ..................................................................................18
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LIST OF APPENDICES
Appendix 1 – Risk Assessment
Appendix 2 – Check List
HARDCOPY DISTRIBUTION LIST
This document is not controlled when printed. The controlled version is held by the Document
Controller on the Project Server’s valid Documents Folder.
Hardcopy Distribution List*
Copy No. Name Company Position Signature
001 Qatar Rail Project Owner
002 Qatar Rail Employer’s Personnel
003 SPH Project Director
004 SPH Construction Director
005 SPH Station Manager
006 SPH QA / QC Manager
007 SPH HSE Manager
008
010
011
012
* The final distribution may be modified after consultation with Main Contractor.
** It is the responsibility of the Station Manager to provide this T &C Procedure to the respective
Project or Site Engineers and obtain sign off that they have received and understood the
document. Please refer to the communication protocol
ABBREVIATIONS
ARCH Project Archive

BS British Standard
HSE Health, Safety and Environment
IFC Issued for Construction
IT Information Technology
MS Method Statement
MSDS Material Safety Data Sheet
NCR Nonconformity Report
PD Project Director
PMC Project Management Consultant
PPE Personal Protective Equipment
SPH Joint Venture of Saudi Binladin Group, PORR and HBK
QA / QC Quality Assurance / Quality Control
QCS Qatar Construction Specification
QMS Quality Management System
QS Qatar Standard
SONO Statement of No Objection
QND Qatar National Datum
IRE Inspection Request
T&C Testing and Commissioning.
NFPA National Fire Protection Association
MAR Material Approval Request
IRN Installation Release Note
PRO Procedure
VCD Volume Control Damper
MCC Motor Control Centre
ANSI American National Standard Institute.
PTW Permit to Work
COSHH Control of Substances Hazardous to Health Regulation.
BACS Building Automation Control System.
PSAT Partial Stand Alone Test
SAT Stand Alone Test
SIT System Integration Test
SPT System Performance Test
COC Certificate of Completion
1 PURPOSE
1.1 General issues
This document is to present the T&C Procedure as required by subcontract documents for Green
Line Elevated & At Grade Project.
This document was composed exclusively for the Qatar Railway ‘Green Line Elevated & at Grade’
Project. All the requirements listed in the above referred tender document were taken into account.
The company has Quality Management System Certificate of ISO 9001: 2008, Certificate of ISO
14001: 2004 of Environmental Management System. Furthermore, it applies the BS OSHAS
18001: 2007 on Occupational Health and Safety Management System.
1.2 Purpose
The purpose of this T&C Procedure is to explain step by step method for Testing and
Commissioning of Pressurization Unit guidelines contained herein so as to ensure that the job
execution complies with project requirement and serves the intended function to satisfactory
level.
2 SCOPE
Scope of this PRO is the Testing and Commissioning of Pressurization Unit
This document includes the following either in the main body or in the Appendices:
x Methodology for Testing and Commissioning of Pressurization Unit.

x Equipment and materials used.
x HSE Assessment & Risk Assessment.
2.1 Interdependence with Management Plans

Standards Relevant to Document & Information Management are:
x Employer’s Requirement volume – 4 Section 4.2

x BS CP 352 Mechanical Ventilation and Air conditioning in buildings.
x NFPA 5000 Building Construction and Safety Code
x NFPA 130 Standard for Fixed Guide Way Transit and Passenger Rail System.
x ASHRAE
x Qatar Construction Specifications 2010 (QCS 2010) Section- 22 Part- 4
The following documents are referred to either to support the implementation of the T&C Procedure
or are a pre-requisite to its implementation:
x SPE:
Document No. Document Name
M009-SPH-MEP-SPE-00001 Mechanical Project Specification
x DWG’s For Pressurization Unit Location:
Drawing No. Document Name
Al-Riffa Station LOWER GROUND LEVEL 1 CHILLED WATER PUMP ROOM -
M009-SPH-MHV-DWG-GWST080-L1-11017
VAC)
x DWG’s for BACS Integration:

Drawing No. Document Name
M009-SPH-MHV-DWG-GWST080-AA-80024 Building Automation and control system Part 3 of 25
x MAR:
Material Approval Submittal for chilled Water Pressurization Unit and Expansion
M009-SPH-MEP-MAR-00219
Tank – XYLEM Water Solution (ITALY)
x MS:
Method Statement for Installation of Pressurization Unit, Water Softener & Air
M009-SPH-MEP-MES-00048
Separator
x ITP:
M009-REI-MEP-ITP-00084 Inspection and Test Plan for Testing & Commissioning of Pressurization Unit
x Plans:
M009-SPH-TCH-PLN-00005 Project Testing & Commissioning Plan
M009-SPH-QMS-PLN-00005 Project Quality Plan
M009- SPH-PRJ-PLN-00003 Project Controls Plan
M009- SPH-HMS-PLN-00009 Health and Safety Plan
M009- SPH-PRM-PLN-00002 Information Management Plan
M009- SPH-DCM-PLN-00002 Electronic Document Management Plan (EDMS)
M009-REI-RSK-PLN-00001 Risk Management Plan
M009- SPH-SHM-PLN-00003 Interface Management Plan
M009-SPH-EMP-PLN-00026 Construction Waste Management Plan
2.2 Revision of T&C Procedure Documents

The revision of this T&C Procedure shall be done when:
x New information becomes available.

x Main Contractor requires modifications.
x The Project Director requires modifications of T&C Procedure
x There is a significant change in the works methodology.
x The revised T&C Procedure shall be submitted to DVE for SONO and PMC for review
approval.
2.3 Testing and Commissioning Stages
STAGE STAGE
STAGE NAME RESPONSIBLTY REMARKS
NO ABBRE
Stage 1 FAT Factor Acceptance Test REDCO For stage (1 & 2) Covered IRN Refer to Testing &
Commissioning Plan (MEP Subcontractor) #
Stage 2 IT Installation Test REDCO M009-SPH-MEP-PLN-00003 (ANNEXUTE-A2)
Stage 3 P-SAT Partial Standalone Test REDCO
Part of this procedure
Stage 4 SAT Standalone Test REDCO
Stage 5 SIT System Integration Test L&T For Stage (5 & 6) by L&T (BACS ITP &PRO)
M009-SPH-MEP-ITP-40003
Stage 6 SPT System Performance Test L&T M009-SPH-MHV-PRO-00033
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3 ROLES AND RESPONSIBILITIES

Below the Appendix B Shown all concerns responsibilities.
Example for RACI Matrix Guideline for MEP Testing & Commissioning Plan
Appendix B - Attachment B - 2
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S:IMEP & PSA\MEP\20 Testing and Commissioning\4 Guideline
3.1 Manufacturer / Representative (Xylem water Solution-ltaly)
The Supplier/Manufacturer (XYLEM Water Solution (ITALY) Supplier) Representative shall be
inspect all power termination/connections and AHU installation as per manufacturer requirements.
After inspection/confirmation power of equipment shall be switched on and he will witness the
testing.
3.2 Sub-Contractor
The Sub-Contractor is responsible for ensuring that the overall requirements are understood and
followed by all parties involved in testing commissioning. All personnel involved in the works will
be responsible for their own action/omission, be accountable for any unsafe actions/conditions
in which they created and to ensure that they follow the safe working procedure of the approved
Procedure.
Subcontractor's key personnel will have the roles and responsibilities as below:
a) T&C Manager The T&C Manager is responsible for Verifying the testing work carried out
in accordance with the requirements of the contract. And ensuring the quality standards set
for the Testing work are achieved and the work team adhere to the QA/ QC and HSE
requirements of the contract.
b) T&C Site Engineer T&C Site Engineer is responsible for Ensuring that the works are being
carried out in accordance with contract requirements and this T&C Procedure. He will
manage the testing activities to ensure that the team carries out the works in time with the
delivery schedule. Implementation of and adherence of the team to the QA/ QC and HSE
policies and procedure.
c) QA / QC Engineer - He is responsible and accountable for conducting surveillance and
inspection duties at various stages of the project delivery to ensure compliance to contract
requirements and to QA / QC requirements. He will ensure that the necessary corrective
action is undertaken against any recorded non-conformance. He will work in close
coordination with all the inter-related disciplines and stakeholders of the project. He is
responsible for preparation of all QA/QC related documents/procedures etc. Work in close
coordination with Supervision Engineer and Main Contractor’s QC Engineer to fulfil the QC
requirements and reports to QC Manager.
d) QC Inspector - He is responsible and accountable for checking the compliance of works to

the design, carrying out Inspections of all relevant construction works. He will be
responsible for inspecting the installation on the checklist and responsible for controlling
/verifying, detailed activities for on-site installations. Work in close coordination with
Supervision Engineer and Main Contractor’s QC inspectors to fulfil the QC requirements
and reports to QC Engineer. Report quality problems or findings to QC Engineer.
e) HSE Manager – He is responsible and accountable for developing, implementing and

monitoring H&S strategies, policies and programs that prevent injury and promote safe
methods of working. He shall also be responsible for developing, implementing and
monitoring environmental strategies, policies and programs that promote sustainable
development. He will be the one to communicate and direct the HSE team, HSE
Engineers/HSE Supervisors, to be responsible for site activities regarding to check, to
review and to make sure that all crew members use appropriate PPE, all machinery,
equipment and vehicles are appropriate for HSE Requirements, work area clean and tidy.
f) Supervision Engineer - He is responsible and accountable for checking the compliance of
works to the design, carrying out comprehensive supervision of all construction works and
final approving that the work executed complies with the approved design and be
responsible for checking the construction works. He will be responsible and accountable to
take reasonable care of himself and the safety of others working nearby. He will make sure
that all the workforce is briefed about the task related hazards, control measures and
availability and use of the relevant PPEs.
g) Supervisor/Foreman - He will be responsible and accountable for supervising all the

activities on site and has full control over the use of the labour, plant equipment, leading,
monitoring and overseeing a team of foremen to ensure they produce quality work. He shall
provide technical guidance regarding the installation and maintenance of MEP systems and
to ensure that the required work is completed according to the shop drawings and is ready
for inspection. He will be responsible and accountable to take reasonable care of himself,
his team members and the others working around him. He will deliver start briefing prior to
the job. He will be responsible and accountable to receive PTW for the daily activities. He
will make sure that required PPE’s are available at worksite and are being used.
h) Technicians/Helpers - They will be responsible and accountable for the safety of themselves
and the others who can be affected by their work activities and shall be responsible for
installing the equipment at the exact location marked by the surveyor and according to the
shop drawings, to perform safely physical installation, handling the material and required
equipment, positioning and installation of materials shall ensure quality installations. Duties
include using, supplying or holding materials or tools, and cleaning work area and
equipment. They will make sure that required work permit has been received from the
relevant authorities and the control measures mentioned in the permit are being adhered
to.
All the workforce is responsible and accountable to take reasonable care of their safety and
safety of the others working nearby them. They will be responsible and accountable to
adhere to all the HSSE rule and regulations told them in Induction trainings, TBTs and
STARRT briefings. They will also be responsible to use the PPE’s provided to them for their
safety and also not to alter with them.
4 RESOURCES
4.1 Labour
Following personnel of the specialized subcontractor will be working at site. The number and
organization may be changed to suit the work requirements
Sr. No. Description

1 T&C Manager
2 T&C Engineer
3 Supervisor
4 Foremen’s
5 QA/QC Inspector
6 Technician
7 Helper
4.2 Equipment Used
4.2.1 General Equipment used for this activity:
Sr. No. Tool and Equipment
1. Mechanical Tool Box

2. Electrical Tools Box
3. Measuring Tape.
4. Spirit Level
5. Torque Wrench
6. digital Multi-meter
7. Vibration Meter
8. Clamp Meter
9. Multimeter
10. Water Flow Meter
11. Tachometer
12. Digital Insulation Tester
13. Process Meter
14. Loop Impedance & RCD Combined Tester
Note:
x All Instrument should valid calibration Certificate and certificate should be available on site
at the time of testing
x Equipment may be substituted subject to availability and actual requirements on the day.
x The type and quantities of equipment are subject to change to suit the site requirements and
to meet the construction program.
5 QUALITY ASSURANCE/ QUALITY CONTROL

Package Project Director is responsible of pre-working control and shall provide specific resources
to the work to be performed and have to determinate the verification, validation, monitoring,
inspection to the work as well as criteria for product acceptance and quality record needed.
Items which are a part of, or intended to be used permanently on, any of the systems of the project
shall not be used as an element of the testing setups for the purposes of testing.
The concerned Site Engineer or General Foreman will be responsible to ensure compliance for
these operations and the site QA / QC Engineer will carry out quality control checks and report the
inspection results.
6 HEALTH, SAFETY, ENVIRONMENT
The Health and Safety Plan will be strictly adhered to at all times.
x All workers will receive a site induction and be issued with PPE (hard hat, safety glasses,
safety vest, safety shoes) including hard hat with a SPH Inducted sticker before entering to
site to work.
x Regular Tool Box talks are held and attendance logged.
x The Emergency Response Plan is in place and will be strictly adhered to.
x In the event of any accident the HSE Incident Escalation Matrix will be followed at all times.
x Specific HSE Hazards are mitigated in the Risk Assessment.
x To prevent accident during the implementation of the above activities, all relevant safety
measures shall be strictly implemented by the site engineers and the HSE team.
6.1 Lockout/Tagout Procedure

The locking off procedure shall only be performed by trained and authorized personnel and it shall
be carried out in the following order:
1. Prepare for shutdown. This will include:
x Identify the equipment that needs to be locked off and the energy sources used to
operate the equipment.
x Identify the potential hazards of that energy
x Identify the method to control the energy – electrical, valve etc.
2. Inform all affected employees and let them know who is locking off the equipment and
why they are doing it.
3. Turn off the equipment following agreed procedures.
4. Isolate all energy sources in the equipment and ensure all stored energy has been
removed from the equipment.
5. Lock off energy device controls such as switches, valves and circuit breakers using an
appropriate lockout device and secure with safety padlock
6. Tagout the lockout device using an appropriate tag
x Tags used must be highly visible with prominent warning to warn employees of the
danger of reenergising the equipment
x Tags must be durable and be securely fastened to the lockout device
x Tag details must be completed in full
7. Test the energy device controls to ensure equipment is de-energized and locked out.
8. Place key of safety padlock in Group Lockout Box and secure Group Lockout Box with
their own personal padlock.
9. Each person working on the equipment should put their own personal padlock on the
Group Lockout Box prior to commencing any work.
10. Perform activity and do not bypass the lockout. The activity shall be done in conjunction
with and as set out in a ‘Permits to Work’ document.
11. On completion of activities, follow the agreed procedures to reactivate the equipment.
x Remove any blocks put in place and re-install any safety guards.
x Remove personal padlock from Group Lockout Box
x Once all personal padlocks have been removed from the Group Lockout Box, keys
to the safety padlocks are removed and used to remove all lockout devices and
tags.
x Re-start the equipment and test to ensure all is ok.
x Cancel the ‘Permits to Work’ and sign off the work.
x Let the relevant employees know that the equipment is ready for use.
6.2 Hazardous Waste Management

The SPH JV ultimately responsible for all hazardous waste storage activities. The SPH JV
will store hazardous waste as follow:
x Fire prevention systems and pollution control equipment will be provided for storage
facilities where necessary, to prevent fires or the releases of hazardous materials
to the environment;
x Containers intended for hazardous waste disposal will not be used for other
purposes unless they are specifically labelled for that purpose. Rusty, dented or
defective containers for waste accumulation or storage will not be used;
x Hazardous waste will be retained in a secure area with an impervious bunded base;
x Secondary containment is required for liquid hazardous waste or other waste that
might be released into the environment, such as dusts, powders, and shavings.
x The conceptual design for the hazardous waste storage facility is part of the CWMP.
x Hazardous waste will be disposed of in the area designated by municipality.
Incompatible hazardous wastes will not be transported together.
7 Risk Assessment
The Risk Assessment for this work is attached in Appendix 1.
8 METHODOLOGY
8.1 PSAT (Partial Stand Alone Test)
8.1.1 Prerequisite for PSAT
Pressurization unit commissioning will not commence until the installation mechanical and
electrical IRE signed off.
Verify and confirm that the Pressurization unit installation completion checklists are
available and duly signed by concerned parties.
x All Pipe work installation are completed, and all IRE are approved.
x Ensure there is valid permit to work is issue.
x Ensure that IRN are prepared by construction and Approved by all parties.
x Ensure all CHW system are Flushed out Properly and IRE are approved.
x Duct access doors are securely closed.
x All valves and other Controller should be open Position.
x MCC panels are installed and commissioned.
x Ensure sample of test pack has been prepared.
x Ensure that lock out tag out in place.
x Ensure HSE in place.
x Ensure that as build / red line drawing have been provided.
x Ensure approved Procedure is on the site.
1. Ensure that the clearance from manufacturer/supplier before power supply connection
to the equipment.
2. Ensure that the Pressurization unit
3. Installation is complete and mechanical completion is approved.
4. Ensure that no damage has occurred between mechanical completion and During
Pre-commissioning.
5. Check Pressurization unit installation as per the approved shop drawing and
manufacture recommendation.
6. Check for proper electrical power, control panel and earthing connection as per
approved drawing and all field wiring to be pre- tested for continue and insulation
resistance.
7. Verify the correct voltage phase and cycles.
8. Initial check and verification of the following items prior to any start-up are required.
8.1.1.1 MOTOR
1. Check for proper lubrication as per supplier recommendation
2. Check belt alignment
3. Isolator is tested, properly terminated and installed
4. Earthing and protection device properly connected and installed as per project specs
5. Motor enclosure is properly selected as per project specs.
6. Terminal box properly installed and correct location
7. Terminals shall be spaced or properly protected to avoid faults within the Box
8. Cable terminations shall comply with the latest edition of I.E.E regulation
9. Factory Acceptance Test of the motor shall be available upon request
8.1.1.2 Electrical
1. All terminal connection properly torques as per specs.
2. Disconnect switch functional and tested.
3. Starters functional, tested and complying with project specification.
4. Fuses complying with project specs.
5. Overload relays correct size and functional.
6. Auxiliary accessories, i.e., indicating lamp, push button, and selector switch Functional
and no sign of damage.
7. Incoming and outgoing power supply cables are correct and tested.
8. Each panel board is individually bonded to main earth bar located in the electrical rooms
and each panel section shall be cross bonded to adjacent panel section earthing
terminal.
8.1.1.3 VALVES AND ACCESSORIES

1. All system cleaning, pressure and leak test is done and inspected.
2. Following the successful conclusion of pre- commissioning, the Pressurization unit will
be run.
3. Check to see that the running current of the motor can be controlled manually
8.1.1.4 WATER SYSTEMS

1. Obtain the results of both Dynamic and Static flushing procedures prior to starting any
pumps.
2. Obtain the results of the “Pump alignment” (If applicable)*
3. Obtain the results of chemical treatment and analysis to ensure that the chilled water
lines are protected against corrosion and that PH and, Fe and turbidity levels are
consistent with the current CIBSE guidelines.
4. Ensure that all heating / chilled water pipes have been fully insulated and that there are
no breaks which, could cause damage to, or destroy the vapor seal.
5. Ensure that all manual control valves and isolation valves are in the “Fully Open”
position, and that the by-pass valve is closed*
6. Follow the pre-start-up check as listed in attached checklist. Once all parameters have
been met, the system can be safely energized and run.
After a successful completion of this stage, Pre-Commissioning Certificate (PCC)
will be released.
8.2 SAT (Stand Alone Test)
8.2.1 Pre-Request for SAT
1. Ensure there is valid permit to work is issue.

2. Ensure the PCC is Available.
3. MCC panels are installed and commissioned.
4. IRE of T&C of MCC had been signed and approved.
5. Ensure sample of test pack has been Approved
6. Ensure that lock out tag out in place.
7. Ensure HSE in place.
8. Ensure that approved as build have been provided.
9. Ensure approved Procedure is on the site.
8.2.2 Commissioning /Start-Up
1. Ensure that all the PSAT checks are carried out successfully
2. Ensure that pipe alignment is done
3. Ensure the discharge valve is closed
4. Completely open the isolating valve on the suction side of the pump and leave the
discharge isolating/throttle valve partly open.
5. Switch on the electricity supply.
6. Start the pump.
7. Check the direction of rotation of the pump. In case of incorrect rotation, interchange
two phases of the electricity supply.
8. Check for any under vibration/noise (it is just physical hearing of under
vibration/noise during operation).
9. Check current, voltage and rpm of the motor and record the value.
10. Vent the pump during starting by loosening the air vent screw until a steady flow of
liquid runs out of the vent hole.
11. When the piping system has been filled with liquid, slowly open the discharge
isolating/throttle valve until it is completely open.
12. Record pump operating current, pressure and check for smooth pump operation.
Operate pump with-in required duty point.
13. Set the motor overload protection.
14. Check and ensure that the pumps shut off at low water level.
15. The pump may be started for a very short period without being submerged for
checking of the direction of rotation.
After a successful completion of this stage, Partial Acceptance Certificates (PAC)
will be released.
8.3 MEP System Integration Test (SIT)

Prior to start this stage PAC should be available. Pressurization Unit has to be integrated to
BACS for monitoring interface outputs and functions such as
x Pressure,
x Temperature
x Water Flow,
x Electrical Readings, V, A, kW etc.
x For More Detail please see the BASC drawing (M009-SPH-MEP-DWG-GWST080-AA-80022)
After a successful completion of this stage, Acceptance Certificate (AC) will be
released.
8.4 System Performance Test (SPT)

System Performance Test is the test of the dynamic function and operation of equipment
(Pressurization Unit) and system (Chilled water system) using manual or monitoring
methods after completion of water balancing of the Pressurization Unit. Water Balancing
will be submitted as a separate procedure named “Water Balancing of Chilled Water
System”.
After a successful completion of this stage, Certificate of Completion (CoC) will be

released.
APPENDIX 1
RISK ASSESSMENT
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RISK ASSESSMENT Appendix 1
SPH ·JV
GREEN LINE- ELEV.t.TEO & AT-GRADE
~ Testing and Commissioning of

Pressurization Unit
f\edco International
Risk Matrix
S EVERITY CONSEQUENCE RATING SEVERITY OUTCOME

CATASTROPHIC 5 10 15 20] 25 5 FATA LilY
MO.JOR INJURY I
CRITICAL 4 12 . . 20 4 LLNESS
SERIOUS N.JURY I
Sffi!OUS 3 6 9 12 15 3 LLNESS
MEDIUM 2 4 6 8 10 2 IIIIINOR INJURY I LLNESS
MINIMAL 2 3 4 5 1 NONE OR SW>.LL FA
1 2 3 4 5
L IKELYHOOD VERY VERY ALMOST
UNLIKELY LIKELY
UNLIKELY LIKELY CERTAIN
• All visitors to site must undertake s1te induction
Site
Impact. struck by moving
excavation, slip and trip, leading

I
Imachenery, suspended load. fall into Potential of injury or accident
Injury I fatality
I 4 I 5 20 1
Banksman to control access around operating plant or vehicle
• stay within clear and defined routes
• Compliance of speed limits on site.
9
edges • Do not stand under suspended load.

• Keep away from leading edges and excavations.
-
Ensure safe acces & egress to work area is provided. Inspected and tagged.
Poor illumination, damaged Ensure proper illumination on access and access routes,
;tepslrungs, blocked access. Stepslrungs inspected and without damage. Site Engineer I
2 1 ,...,..,"'~..,.., & egress to Imaterials stored at access, poor 1Cuts. bruises, sprains. severe I
4 I 4 16
Ensure handrails are used and proper footing on steps.
6
HSE
Representallve I
· · · cable running on Do not block access by storing materials.
Proper routing of cables. Foreman I
Provide Information signs.
Ensure good housekeeping always
Page I of 4
RA Execution SPH • JV
~ IIm'I'Tol llillm ~
Probabllo Consoq Risk
m!l What could hurt me I others or Impact ~ liW·h"b11rom
mw:m n h ir n
What harm could occur? ...
ty/likeli uence Level What must be in place to revent harm? (includes ecific responsibilities where a plicablel
Ensure safe access and egress to work area,

Lift using correct lifting principle i.e. feet apart, firmly grip load, keep load close to the body, keep back
avoid twisting or bending too much. when lifting from ground; bend knees and lift weight using your
muscles.
Ensure good housekeeping in the area,
· Watch out for uneven surfaces.
and trip, repetative work, poor
1ina tion, protruding sharp
!objects. improper stacking, stacking Muscle strain/sprain, cuts,
• Ensure no spillage or slippery surface.
• Ensure proper gloves are used along with other PPE. I
Site Engineer I
HSE
3 I'"U':'"'""" materials to 3 4 12 • Engage additional help is the load is too heavy. 6
· ·height. starting materials crush injury, fracture
COSHH items, unsafe
• Proper storage of materials i.e. no storing near edge, Improper height, not blocking access ways etc.
Ensure proper illumination in the area.
I Representative I
Foreman I
Ensure protruding objects are covered.
Ensure MSDS for COSHH items.
Do not store excess of flammable materials at s1te
Bring only quantity required for the day.
Ensure no hot works in the area.
Ensure fire extinguisher is available near by.
STARRT briefing for operatives prior to start work.

Proper Supervision.
Keep the work place free of obstructions by carrying out regular housekeeping.
I I I'
Do not block access by storing materials.
3 3 9 I
nor injury,cuts, bruises
I Signs must be displayed to indicate the routes to be taken by persons, changes in routes must be clearly 4
communicated.
• Working area should be illuminated
• Proper routing of cables.
• Ensure good housekeeping always
• STARRT briefing to operatives
I I 1· • Do not use damaged tools

4 1
Preparation for
Pressurization Unit
u~1r19 oamageo
wrong use of tools.
1001s ,
I
cuts, muscle strain/sprain,
crush injury, Demaged to ear,
I 4 16
·
Inspect tools for damage prior to use.
Do not use homemade tools
I 8
injury to eyes. fracture I 4
•
•
Do not throw tools on persons below or above.
Use tool lanyard when using tools at thigh!.
• Carry tools in holster or in tool box when working at height.
• Use task specific PPE such as face shields, goggles, hand gloves, ear protection. dust mask s etc.
• STARRT briefing for operatives prior to start work.

AI I I I I• Competent persons.
• Keep the work place free of obstructions by carrying out regular housekeeping. I
Site Engineer /T&C
Engineer/ HSE
Minor injury,cuts, bruises I 3 I 3 I 9 I· Do not carry tools or materials when using ladder 6
• Do not lean your body during working on ladder or scaffold.
• Job rotation and adequate supply of drinking water
I Representative I
Foreman I
• Working area should be illuminated
Po9" 2 of 4
RA Execution SPH - JV
~ rmm:J IIW:ml ~
a ill
~
i.!liiEil11ii:t :na:m ..
What could hun m~ I others or Impact
'tq:ma.su.,a;:.tm:J.I«dE
ty/Likell Consoq Risk
h uence Level What must be In place to prevent harm? (Includes eCific res onsibillties where a hcable
r:mr.lll!ll WJ:l.I.!.WttJH~
Unauthorized operatives. • STARRT briefing for operatives prior to start work.

Untrained operatives. • Competent & trained operative under supervision of Competent superviosr.
Electrocution,
Uncalibrated equipments • All equipments must have valid calibrated certificate.
Bum,
LOTO. •
Ensure LOTO procedure shall be followed.
strain and sprain,
Incomplete Installation. •
All area should be evacuated, prior to start of activity.
Personellnjury.
Damaged Equlpments used. •
Post awareness & warning signages prior to starting of activity to warn others.
Figner Injury.
Improper allignment of Motor & •
Do not lean your body during working on ladder or scaffold .
Hand injury,
Pulleys. •
Job rotation and adequate supply of drinking water.
Pre-Commissioning of Damage to equipment,
Improper electrical power. • Working area should be illuminated.
5 Respiratory illnesses, 4 4 16 1 8
Pressurization Unit control and earthing connections. • Proper coordination with team working near by activity. Representative I
allergic a lveolitis and
Sharp Edges I Objects. • Dust Mask must be wom before start of dust Cleaning. Foreman/
irritation,
Overing heating, • Proper hand protection gloves shall be worn.
Irritation to eyes.
Poor Ventillation. • Mandatory PPE must be worn all the time on Site.
Finger I hand injury,
Poor Coordination • Check for proper electrical power. control panel and earthing connections as per manufacturer's
Cuts. sprain.
Poor illumination, recommendations Field wiring to be pre-tested for continuity and insulation resistance.
Internal injury,
Falling Materials/ Personals, • Check drive set fitted properly.
Fracture.
Repetitive work, • Check for proper electrical power. control and earthing connectoons as per manufacturer's
Trailing cables. recommendations. Field wiring to be pre-tested for continuity and insulation resistance.
• STARRT briefing for operatives prior to start work.

• Notice to SPH prior to the testing.
• Competant and trained operative required to carry out the work under supervison of competant Supervisor.
• Ensure there is valid permit to work is issue.
• Ensure that lock out tag out (LOTO) in place.
• All area should be evacuated, prior to start of activity.
• Post awareness & warning signages prior to starting of activity to warn others.
• Post watchman to keep unauthorized persons away.
Unauthorized operatives.
• Ensure safe access & egress.
Untrained operatives,
• Ensure proper illumination.
Uncalliberated equipment, Electrocution.
• Coordinate with other team working in the area.
LOTO, Bum.
Vibration or noise. • Proper Communication system shall be provided.
strain and sprain,
Testing and • Adequate superviosion and monitoring by the Foreman I Supervisor.
Poor Communication. Personellnjury.
6 Commissioning of ( Ensure MCC panels are installed and commissioned.
Falling Materials/ Personals, Figner Injury. 4 4 16 8
Pressurization UNIT Heat exhaustion. • Ensure sample of test pack has been Approved.
Hand injury.
• All equipments must have valid calibrated certificate. Foreman I
Poor illumination. short term hearing loss.
• Ensure approved Procedure is on the site.
Slip& trip, Damage to equipment.
Fire, • Ensure that all the pre-commissioning checks are carried out successfully.
Damage to property.
Damaged equipment. • Fonal visual inspection will be carried out by competant and authorized person only.
• Ensure all the fire dampers in shaH in all the floors close completely and the shaH is totally isolated.
• Extreme care when working in wet and slippery areas.
• Personnel should never run on worksite.
• Keep worksite clean and tidy at all times.
• Adequate and compulsory PPE should be mandatotry while performing the task.
• Competent and experienced staff only supervise the activity.
• In case of an emergency, Emergency Rescue plan of main contractor will be followed.
• Ensure the availability of Fire Watcher. Fire Warden and First aider on site during the test avtivity.
• Fire Extinguishers & Fire Blanket shall be placed nearby.
Page 3 of 4
RA EJcecutlon SPH - JV
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Probablll Conseq Risk
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~
• STARRT briefing to operatives

• LOTO protocols must be in place
• Check relevant Authority (e.g. power, water council) records for location of services.
No work permission from authorities
• If in doubt. use experienced/accredited service locators. Site Engineer /T&C
UnTrained staff,
Fatality,Serious Injury or •.Use of Job specific PPE. Engineer/ HSE
7 Existing services Explosion, electrocution, 4 5 20 1 10
property damaged •.Competent staff and supervision. Representative I
damage service.
·Avoid make contact with other services. Foreman/
Isolate the live conductors when working with power tools.
All protection and control devices shall be correctly set and operational.
All unused cable entries and openings shall be sealed properly with dummy plugs of suitable lP rating.
Page 4 of 4

Testing and Commissioning Procedure of Pressurization Units

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Testing and Commissioning Procedure of Pressurization Units

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Testing and Commissioning Procedure for

PRO 00043 0.1

Reason for Issue 04 - Issued for SONO

T&C Engineer Signature Date

Project Manager Signature Date

Hardcopy Distribution List*

Copy No. Name Company Position Signature

001 Qatar Rail Project Owner

002 Qatar Rail Employer’s Personnel

003 SPH Project Director

004 SPH Construction Director

005 SPH Station Manager

006 SPH QA / QC Manager

007 SPH HSE Manager

ARCH Project Archive

x Methodology for Testing and Commissioning of Pressurization Unit.

2.1 Interdependence with Management Plans

x Employer’s Requirement volume – 4 Section 4.2

x DWG’s for BACS Integration:

M009-SPH-QMS-PLN-00005 Project Quality Plan

M009- SPH-PRJ-PLN-00003 Project Controls Plan

M009- SPH-HMS-PLN-00009 Health and Safety Plan

M009- SPH-PRM-PLN-00002 Information Management Plan

M009- SPH-DCM-PLN-00002 Electronic Document Management Plan (EDMS)

M009-REI-RSK-PLN-00001 Risk Management Plan

M009- SPH-SHM-PLN-00003 Interface Management Plan

M009-SPH-EMP-PLN-00026 Construction Waste Management Plan

2.2 Revision of T&C Procedure Documents

x New information becomes available.

2.3 Testing and Commissioning Stages

3 ROLES AND RESPONSIBILITIES

S:IMEP & PSA\MEP\20 Testing and Commissioning\4 Guideline

d) QC Inspector - He is responsible and accountable for checking the compliance of works to

e) HSE Manager – He is responsible and accountable for developing, implementing and

g) Supervisor/Foreman - He will be responsible and accountable for supervising all the

Sr. No. Description

Sr. No. Tool and Equipment

1. Mechanical Tool Box

5 QUALITY ASSURANCE/ QUALITY CONTROL

6.1 Lockout/Tagout Procedure

6.2 Hazardous Waste Management

8.1.1 Prerequisite for PSAT

8.1.1.3 VALVES AND ACCESSORIES

8.1.1.4 WATER SYSTEMS

8.2 SAT (Stand Alone Test)

8.2.1 Pre-Request for SAT

1. Ensure there is valid permit to work is issue.

8.2.2 Commissioning /Start-Up

8.3 MEP System Integration Test (SIT)

8.4 System Performance Test (SPT)

After a successful completion of this stage, Certificate of Completion (CoC) will be

~ Testing and Commissioning of

S EVERITY CONSEQUENCE RATING SEVERITY OUTCOME

MEDIUM 2 4 6 8 10 2 IIIIINOR INJURY I LLNESS

MINIMAL 2 3 4 5 1 NONE OR SW>.LL FA

• All visitors to site must undertake s1te induction

excavation, slip and trip, leading

edges • Do not stand under suspended load.

Ensure safe access and egress to work area,

STARRT briefing for operatives prior to start work.

• STARRT briefing to operatives

I I 1· • Do not use damaged tools

• STARRT briefing for operatives prior to start work.

Unauthorized operatives. • STARRT briefing for operatives prior to start work.