DOHA CONVENTION

CENTER & TOWER

PROJECT

TESTING AND COMMISSIONING

OF PLUMBING SYSTEM

10.09.2012 00 KAREEM D.GOPINATHAN MUSTAFA S. ILYAS AHMED

SLEIMAN
PREPARED BY: CHECKED BY: REVIEWD BY: APPROVED BY:
DATE REV. EDJV QAQC ETA-DEBBAS JV EDJV QAQC ETA-DEBBAS JV
DEPARTMENT T&C DEPARTMENT PROJECT
DEPARTMET DIRECTORATE

TESTING AND COMMISSIONING OF PLUMBING SYSTEM

DOCUMENT NUMBER: ED-P-M-M-A-GN- 0008
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 DOHA CONVENTION
CENTER & TOWER
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CONTENTS
1. Scope
2. Purpose
3. Application location
4. General requirements
5. Requirements
6. Safety precautions
7. Preliminary checks
8. Water tank
9. Booster pump
10.Water supply system
10.1. Booster Line
10.2. Booster Line – Flow Test
10.3. Water Heater
11.Drainage system
11.1. Sanitary System
11.2. Sump Pump
12.Performance testing
13.Witness demonstrations / completion
14.Test instrumentation
15.Calibration frequency
16.Commissioning standards & methods followed
17.Inspection
18.Reference documentation
19.Records
20.Attachments

TESTING AND COMMISSIONING OF PLUMBING SYSTEM

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1. SCOPE :

Testing & Commissioning group will perform the Testing of the Plumbing System in
compliance with the specified tolerance and limitations outlined with standards, guidelines and
with reference to project specification

The entire Testing and Commissioning shall be performed by in house team with experienced
engineer.
1.1 Reference Documents – Specifications, Drawings, Submittal :
1.1.1 Sixco Construct / Midmac JV Project Quality Plan
1.1.2 Project Specification - Section 22 Plumbing section & Section 01810
1.1.3 Approved Shop Drawings
1.1.4 Approved Material Submittal
1.1.5 Approved Installation Method statement

2. PURPOSE

Purpose of this method statement is to outline the method of commissioning of Following

water supply and drainage system

Water Supply System

o Water Tank
o Transfer Pump
o Booster Pump
o Domestic Water System Pipe Line
o Water Heater

Drainage System
o Drainage & Sanitary ware system
o Sump Pump

ETA-DEBBAS will deploy the In-house team an experienced commissioning engineer to

thoroughly inspect all the working drawings and specification, and become totally familiar with all
systems and the design intent.

3. APPLICATION LOCATION
Inside the Building, Pump room & Roof

TESTING AND COMMISSIONING OF PLUMBING SYSTEM

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4. GENERAL REQUIREMENTS

4.1. SPECIALIST EQUIPMENT & LIAISON

We will have an engineer available to liaise with the manufacturer’s commissioning engineers
and assist with the checking of flow rates, temperature and pressure set points etc. as
necessary.
Items of equipment to be commissioned by specialists include, but are not limited to the
following:-
Booster Pump
Sump Pump

5. REQUIREMENTS

Before commencing commissioning works, the following information/items will be made available:-

1. Full set of up-to-date installation drawings and system schematics detailing all systems
to be commissioned.
2. Pump design flow rates and operating heads.
3. Pump curves.
4. Commissioning & operating and maintenance instructions equipments.
5. Any special operating keys, tools etc.
6. Access to all areas; plant etc. through doors, risers, false ceilings etc.

6. SAFETY PRECAUTIONS

1. Safety awareness should be followed during execution of Testing & Commissioning

works:
2. Secure Work Permit in conjunction with the approved safety plan and Risk Assessment
before Starting the work
3. Usage of proper tools, instrument to be handled by the authorized person only.
4. Usage of proper safety shoes, safety belts, safety helmets, gloves, goggles, mask,
earplugs & any other safety accessories as required during commissioning works.
5. Guards of approved design shall be provided for all V-belts drives, coupling shafts and
exposed rotating machinery.
6. Electrical power supply shall be isolated and panel switchgear shall be locked whenever
carrying out work on any rotating equipment or electrical panels.
7. No commissioning works shall be carried out without adequate lighting available.
8. Approved Project Safety Plan & Procedures shall be followed during execution of
commissioning works.
9. Provide Warning Boards / Tapes as required during Testing & Commissioning works.

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7. PRELIMINARY CHECKS
State of the Building and System
1. All External Drainage and water supply connected and commissioned by infrastructural.
2. All 2nd Fix fixed and ready for Commissioning.
3. Access available to all areas to be tested.

8. WATER TANK
8.1. Material
Water Tank
Float Valve
Gate Valve
Vortex Plate

8.2. Pre-Commissioning
1. Sizes of the tank as per approved drawing / submittal
2. The installation of level indicator
3. Overflow discharge is connected to nearest floor trap
4. Drain valves, inlet pipe line, access door and ladders are installed as approved.
5. Inlet, outlet and filling line valves are closed

8.3. Testing and Commissioning

8.3.1. Clean out whole of the tank (Inside) with normal available running water
8.3.2. Check for leaks and rectify as required.
8.3.3. Check and confirm the water level, after 24 hours in same position
8.3.4. Check and observe for any leakage in flanges and pipe joints and ensure
there are no leaks
8.3.5. Check the Float and valve function
8.3.6. Check the over flow and drain valve operation

Finally do the Flushing, Chemical Cleaning and Disinfection.

9. BOOSTER PUMP

9.1. Pre-commissioning checks prior to start-up

9.1.1. Mechanical

9.1.2. Check and inspect the installation of Domestic Water Pumps is complete,
verify the installation as per approved drawings.
9.1.3. Verify compliance to the attached manufacturer’s installation instructions.
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9.1.4. Obtain installation certification from manufacturer or their authorized
representative.
9.1.5. Check and ensure adequate clearance available for service and
maintenance of pumps and motors.
9.1.6. Check the installation is coordinated with other services.
9.1.7. Ensure the shipping bolts / chambers are removed.
9.1.8. Check all nuts, bolts, screws, fasteners etc., are fixed and tightened as
required.
9.1.9. Ensure the piping is pressure tested. Verify test certificates.
9.1.10. Check all piping connections are complete at pumps, flow meter and
pressure relief line including flexible connections where applicable.
9.1.11. Check and ensure the piping is flushed and cleaned.
9.1.12. Check the alignment is completed as per manufacturer’s instructions.
9.1.13. Check and verify the water level in the water tank is full.
9.1.14. Check and ensure safety guards are in place and secure.
9.1.15. Adjust desired cut-in and cut off pressure as pre requirements.
9.1.16. Rotate the pump manually and ensure free and smooth rotation.
9.1.17. Ensure the pumps are cleaned prior to start up and all identification labels
and tags are in place.

9.2. Electrical

9.2.1. Check all power cabling and control wiring is completed and dressed
neatly.
9.2.2. Check the power isolator is fixed close to the pump motor for emergency
stop and power isolation, as per approved drawings/details.
9.2.3. Check all terminations are completed and tightened as required.
9.2.4. Check the grounding connections are completed and tightened as required.
9.2.5. Ensure the overload protections are set correctly as per the pump motor
load current.
9.2.6. Ensure all identification tags and labelling works are complete.

TESTING AND COMMISSIONING OF PLUMBING SYSTEM

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9.3. Start-Up And Testing

9.3.1. Connect water and electricity supplies

9.3.2. Check that the pre-charge pressure in the diaphragm tank is equal to the
minimum cut in pressure
9.3.3. Close the discharge valves of the pump and prime the booster set and
suction pipe
9.3.4. Adjust the pressure switches according to the desired discharge pressure
9.3.5. Switch on the electricity supply
9.3.6. Start pump 1 by pressing the manual button on the front cover
9.3.7. Pump 1 will start now
9.3.8. Check the direction of the pump. In case of incorrect rotation, interchange
two phases of the electricity supply.
9.3.9. Vent the pump while slowly opening its discharge valve
9.3.10. Repeat point 9.3.6 to 9.3.10 for all pumps
9.3.11. Put the pump in Auto

10. WATER SUPPLY SYSTEM

10.1. Booster Line – Visual Test

1. Check alignment of pipes
2. Check supports spacing
3. Check workmanship of joints
4. Check provision of air vents at top joints.
5. Check direction of flow has been marked on water line.
6. Check accessibility of valves.
7. Identification of valve marked and all manifold correctly installed

10.2. Booster Line – Flow Test

1. Ensure flushing is completed
2. Check all isolating valves are open after flushing
3. Check the water flow at all the taps and outlets (Cold & Hot )

TESTING AND COMMISSIONING OF PLUMBING SYSTEM

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4. Ensure that no leakages observed under the operational pressure

10.3. Water Heater

1. Installation of water heater as per drawing

2. Adequate support is provided
3. Pressure relief valve installed for high pressure / temperature protection
4. All joints are well inserted, firm and tight.
5. Ensure the heater operation
6. Healthy function of indication light
7. Cut off set temperature [ 65 C ]
8. Ensure the hot water at outlets
9. Proper access is available for maintenance
10. Unit is clean & free from damages

11. DRAINAGE SYSTEM

11.1. Sanitary System

11.1.1. Pre-commissioning checks

1. Check alignment of pipes

2. Check supports spacing
3. Check workmanship of joints
4. Check slope of pipes
5. Check rigidity of supports
6. Check spacing and accessibility of cleanouts.

11.1.2. Commissioning checks and Handover

1. Completeness of installation.
2. Cleanliness of installation.
3. Position of fixtures as per layout.
4. Flow of water in taps and cisterns.
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5. Leakage from traps / connections.
6. Performance of over flow in cisterns

11.2. Sump Pump

11.2.1. Pre - Commissioning

1. Check the panel & pumps are free from damages and foreign materials.
2. Check the panel & pumps are installed as per drawing.
3. Check the proper supports for the panel & pumps.
4. Ensure the wiring is done and terminated properly
5. Check the float switches are installed for proper controlling of pumps - Dry Run, Pump 1
Start, Pump 2 Start & High Level Alarm
6. Check the termination of cables and float switches connections against the schematic.
7. Check the panel earthing and motor earthing for the proper protection.
8. Check the installation of gate valve & NRV in discharge water line.
9. Check the sump pit is filled with sufficient water and no dry run is activated
10. Ensure the lifting chain is provided to lift the pump for maintenance
11. Ensure that pit cover is provided
12. Check the panel & pumps for proper cleaning.

11.2.2. Commissioning

1. Ensure the system voltage, frequency, phase sequence

2. Ensure the water availability in pit
3. Ensure the pump operation
4. Ensure the float switch operations
5. Ensure the discharge flow

12. PERFORMANCE TESTING

1. On completion of major plant commissioning, and testing of all water supply systems and
2. Booster pumps to be checked at peak load condition.
13. WITNESS DEMONSTRATIONS / COMPLETION

TESTING AND COMMISSIONING OF PLUMBING SYSTEM

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1. The commissioning engineer will ensure that the following works are carried out:-
2. The final tested and results are demonstrated to the accepting authority on a random spot
check basis, and that repeatability.
3. All equipment final settings are permanently marked, valve indicators, hot water system,
using an agreed method.
4. Submittal of all records of data obtained during testing, in accordance with, and on, the
approved forms.
5. Preparation of test report and hand over certificated and duly signed by the main
contractor and consultant.

14. TEST INSTRUMENTATION

The following test instruments will be used for the commissioning and testing activities. These
will be selected as having the maximum field measuring accuracy and being the best suited to the
function being measured, and will be applied as recommended by the manufacturer

SL. NAME FUNCTION OF THE INSTRUMENT

NO.
1 Tong Tester (Analog)
2 Tong Tester(Digital)
3 Megger
4 Phase Detector
5 Plant speeds - tachometer.
To measure current, voltage and Resistance
To measure current, voltage and Resistance
To measure the insulation resistance of cables, winding
To check the sequence of phases
To check the speed

15. CALIBRATION FREQUENCY

1. All the instruments are calibrated externally once in 12 months or as per the recommendation of
the Manufacturer whichever comes earlier and the records are maintained.
2. All are used under their allowable ranges and limits.
3. All equipments are stored in the service station under the suitable environmental condition
when they are not in use and verified their accuracy at regular intervals.
4. Prior to commencement of Testing & Commissioning activities, Test Certificates of all
instruments will be submitted for Consultant Approval.
5. Certificates will be available for presentation prior to commencement of the works.

16. COMMISSIONING STANDARDS & METHODS FOLLOWED

Project specification and manufacturer’s instructions

17. INSPECTION

TESTING AND COMMISSIONING OF PLUMBING SYSTEM

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1. Inspection request shall be raised promptly to Consultant in accordance to the
approved ITP.
2. Inspection shall be carried out as per approved ITP.
3. Inspection shall be recorded in the approved checklist attached in the approved ITP.
18. REFERENCE DOCUMENTATION

1. Manufacturer’s catalogue.
2. Approved submittal.
3. Shop drawings.
4. Safety Manual.
5. Risk Assessment
6. ITP

19. RECORDS
1. Prepare as-built drawings where necessary to allow the client to amend his own drawings.
2. All the test results shall be recorded and the inspection request, ITP and the forms used
shall be signed by both the contractor and Consultant.
3. All permits shall be signed off and returned.
4. The Certificates for the completion of work shall be submitted to engineers for records
5. Signed-Off Pre-commissioning Check Lists.
6. Commissioning Reports.
7. Calibration certificates of testing instruments.
8. Hand over Certificate

20. ATTACHMENTS
1. Risk Assessment
2. ITP
3. Check List

TESTING AND COMMISSIONING OF PLUMBING SYSTEM

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