Annexure W - Commissioning Management Plan

Transnet Capital Projects
1124367: New Liquid Bulk Facility landside - Commissioning

Management Plan
Transnet Capital Projects

1124367-New Liquid Bulk Facility Landside
Commissioning Management Plan
Document No: 1124367-02X-ENG-DC-0002
Prepared by: Name: Thulane Magoro 14 August 2017

Date
Signature:
Engineering Management
Approved by: Name: Siyabonga Gadu August 2017

Date
Signature:
Project Manager
Prepared by: Name: Benedict Isaacs August 2017

Date
Signature:
BUR (TNPA)
Revision History:
01 August 2017 Updated as per Gate review comments

00 May 2017 Issued for review
Revision: Date: Description:
Commissioning Management Plan Page 1 of 28

Commissioning Management Plan 1124367-02X-ENG-DC-0002-Rev02
CONTENTS
1. PURPOSE ..................................................................................................................... 4
2. PROJECT BACKGROUND .......................................................................................... 4
3. SCOPE .......................................................................................................................... 5
4. STATUTORY REQUIREMENTS................................................................................. 5
5. GOVERNING CODES, STANDARDS AND SPECIFICATIONS ............................. 5
PROJECT SPECIFIC DOCUMENTS .............................................................................................. 6
6. TERMS & DEFINITIONS ........................................................................................... 6
7. SCHEDULE/ESTIMATE ............................................................................................. 7
8. RESPONSIBILITIES .................................................................................................. 7
9. FACILITIES FOR PRE-OPERATIONAL TESTING AND COMMISSIONING...... 9
10. COMMISSIONING STAGES.................................................................................... 10
CONSTRUCTION ................................................................................................................. 10
COLD COMMISSIONING ....................................................................................................... 10
HOT COMMISSIONING......................................................................................................... 11
PUNCH & RECTIFY (C1 – C3) COLD COMMISSIONING ............................................................... 12
HOT COMMISSIONING/HANDOVER (C4 – C5)......................................................................... 13
11. SAFETY DURING COMMISSIONING ................................................................... 13
SITE INDUCTION ................................................................................................................. 14
HANDOVER IDENTIFICATION ................................................................................................. 14
ENERGISATION ................................................................................................................... 14
ISOLATION & LOCKOUT PROCEDURE ...................................................................................... 15
PERMIT TO WORK ............................................................................................................... 15
HOT WORK PERMIT............................................................................................................ 15
RISK MANAGEMENT ............................................................................................................ 15
TAGGING .......................................................................................................................... 16
12. COMMISSIONING PHASES ................................................................................... 16
C0 – COMMISSIONING - PREPARATION .................................................................................. 16
C1 – COMMISSIONING – CONSTRUCTION TESTING ................................................................... 17
C2 – COMMISSIONING – EQUIPMENT TESTING ........................................................................ 18
C3 – COMMISSIONING – SYSTEMS TESTING WITH WATER .......................................................... 18
C4 – COMMISSIONING – PROCESS COMMISSIONING (OPERATIONAL TEAM).................................. 19
C5 – COMMISSIONING – RAMP-UP (OPERATIONAL TEAM) ........................................................ 19
13. PUNCH LIST.............................................................................................................. 20
14. TAKE-OVER CERTIFICATES .................................................................................. 20
Transnet Group Capital Page 2 of 28

COMPLETION CERTIFICATE ................................................................................................... 21

TAKE-OVER, CARE CERTIFICATE (INSTALL CONTRACTS) .............................................................. 21
TAKE-OVER, CARE CERTIFICATE (DESIGN & SUPPLY CONTRACTS) ................................................ 21
TAKE-OVER, CARE & CONTROL CERTIFICATE (TCC) .................................................................. 22
TOTAL CARE, CUSTODY & CONTROL CERTIFICATE (TCCC) ......................................................... 22
15. ANNEXURES ............................................................................................................. 23
ANNEXURE A – COMPLETION CERTIFICATE .............................................................................. 23
ANNEXURE B – TAKE-OVER, CARE CERTIFICATE ....................................................................... 24
ANNEXURE C – TAKE-OVER, CARE & CONTROL CERTIFICATE ...................................................... 25
ANNEXURE D – TOTAL CARE, CUSTODY & CONTROL CERTIFICATE ............................................... 26
ANNEXURE E – COMPLETION/TAKEOVER CERTIFICATE............................................................... 27

1. PURPOSE
The purpose of this Commissioning Plan is to outline the procedures associated with commissioning various
types of Civils, electrical and mechanical systems and equipment. This document shall further describes
and defines the procedures to be followed in commissioning the facilities and systems, which form part of
the landside phase 2 project and its associated infrastructure at the Port of Nqgura.
The commissioning and start-up of Plant/facilities is a demanding and complex phase of the project. It
involves the combined effort of co-operation and coordination with all parties such as the construction
management team, commissioning team, Clients, Engineering, operational team, Contractors and Vendors.
The purpose of this Commissioning Management Plan is also to define the terminology to describe within
various stages of commissioning and establish simple procedures and clearly define the responsibilities of
those involved in order to facilitate an efficient handover and/or start-up.
This Commissioning Management Plan shall further be revisited and revised as necessary during the
Project’s lifecycle from time to time and in accordance with the Contractor’s detailed commissioning plans
as applicable for the respective construction work packages.
2. PROJECT BACKGROUND
The Liquid Bulk Terminal in the Port of Port Elizabeth is nearing the end of its lifecycle. This places a
restriction on any development in the Port of Port Elizabeth and there is no room for expansion of the liquid
bulk terminal to cater for increases in future growth in fuel demand. It is furthermore situated next to
residential and recreational areas preventing the development of light commercial activities as well as
residential and recreational areas whilst operational. The benefit of establishing a new Liquid Bulk Terminal
at the Port of Ngqura is that there is ample land for development that would cater for the increased demand
in liquid bulk fuel in the long term. The Port Development Framework Plan also allows for a future refinery
to be constructed in the Coega IDZ with additional storage tanks and berths on TNPA land.
The benefit of the closure of the Liquid Bulk Terminal in the Port of Port Elizabeth is that valuable land will
become available for other recreational activities, and commercial developments. It will also allow the
development of residential areas in close proximity of the Port of Port Elizabeth on the southern precinct
and surrounding areas.
The strategic decision by the TNPA on shutting down the operations of the Liquid Bulk Terminal in the Port
of Port Elizabeth requires that berth B100 be made available, a second port entrance, associated services
and infrastructure be constructed at the Port of Ngqura by the TNPA as well as a new Liquid Bulk Terminal.
The Liquid Bulk Terminal Operator Oiltanking Grindrod Calulo (Pty)/Ltd (OTGC) was appointed during
December 2016, after following a Section 56 Process in accordance with the National Ports Act. In future
berth B100 will be used for MPT or Dry bulk and a new berth A100 will be provided under phase 3 of the
project. All developments are in accordance with the Port development framework plan (PDFP).

3. SCOPE
This document defines the inspection, testing and handover process to be followed, when transferring
equipment from construction, to pre-operational testing, to process commissioning and finally to operations.
This applies to all civils, mechanical, structural, electrical, instrumentation and piping equipment within the
landside phase 2 project. Where required a detailed commissioning plan as deemed appropriate at the
discretion of the responsible engineer, shall be prepared as required for the various systems. International
best practice norms and standards shall be followed in terms of inspection, testing for safety, setting and
configuring, and rendering the installed equipment fully functional to its intended purpose.
Items such as concrete and steel structures, earthworks are excluded from the commissioning scope as
these items can be handed over directly from construction to operations, without the need for pre-
operational testing and commissioning. A final inspection and sign-off for these items will still be required
in order to issue the C1 certificate. However, after finalisation of the C1 certificate, control of these items
will pass directly to the client, without the need for C2, C3 and C4 commissioning stages.
Note that due to the scale of mechanical, electrical, instrumentation and piping equipment within the
landside phase 2 project commissioning stage C2 to C5 might be combined in single activities but this shall
be confirmed with the commissioning plans from respective contractors.
4. STATUTORY REQUIREMENTS
All aspects of the commissioning process shall adhere to any and/or all relevant requirements of the
following legislation, as appropriate:
 Occupational Health and Safety Act 85 of 1993
 National Environmental Management Act 107 of 1998
 South African National Standards and Codes of Practice
 All local, provincial or S.A. Government laws in force at the time.
5. GOVERNING CODES, STANDARDS AND SPECIFICATIONS

The commissioning process for all electrical and mechanical equipment shall adhere to any specific and
relevant requirements contained in the following national and international standards, where different
standards call for different testing and commissioning procedures for the same equipment, the most
stringent alternative shall apply.
Note: Where reference is made to a code, standard or specification, the reference shall be taken to mean
the latest edition of the code, standard or specification, including latest Addenda, supplements and revisions
thereto.
The commission process in general, shall be in accordance with the recommendations of:
 The International Electrotechnical Commission (IEC), and
 The Institute of Electrical and Electronic Engineers (IEEE)
 International Standards and Codes – ISO, DIN, BS, ASME, ASCE, ANSI, ASTM, EU

Project Specific Documents

This document should be read in conjunction with the following project document:
1. Project Schedule
2. Project Specific health and safety documents
6. TERMS & DEFINITIONS

The following terms as defined in the table below shall have the meaning so assigned, unless
indicated otherwise within the text of this document.
Table 1: Terms & Definitions
Term: Definition:
Client For the purposes of this document, the Client is defined as the Employer of the
facilities who will take-over the commissioned Works from the project team.
Contractor The civil, structural, mechanical, electrical, instrumentation and piping installation
contractors on site.
Supplier/Vendor Any supplier of equipment, materials or services incorporated into the works to be
commissioned.
Employer, For the purposes of this document, the terms Employer, Project Manager and
Employer Project Contractor as defined in the New Engineering Contract conditions will be called
Manager, Client, project manager and installation contractor.
Installation
Contractor
Process Plant A number of process plant product systems grouped together.
Plant Product A number of process areas which can be operated together independently of the
System rest of the process plant.
Area A group of Systems pertaining to a specific process flow sheet within the process
plant product system.
System A group of sub-systems which collectively are interrelated by process control.
Sub-system A group of civil, mechanical, structural, electrical and instrumentation components
within a system which are related.
Component Individual civil, mechanical, structural, marine, electrical and instrumentation
equipment within a sub-system.
Punch The punch list or defects list is a listing of work items within the scope of the
Lists/Defects List contract, which are outstanding or require completion before the contract works can
be accepted as being completed.
Commissioning Process of assuring that all systems and components of a building or industrial plant
are designed, installed, tested, operated, and maintained according to the
operational requirements of the owner or final Client.

Construction Confirmation that the equipment is installed according to drawings, specifications

Completion and operation manuals by means of visual inspection and non-operational checks.
Non-operational checks include adjustments, alignment checks, lubrication and
hydrostatic testing, where applicable, to ready the plant for further commissioning.
Handover A transfer of care, control and custody of a subsystem, system or product system
between successive stages of commissioning.
7. SCHEDULE
Allowance has been made on the master schedule regarding the commissioning activities. This
information can be found on the project schedule. Note that the activities will need to be
developed further with a more detailed plan from the contractor.
8. RESPONSIBILITIES
1. Project Manager:
The Employer’s appointed project manager.
2. Construction Manager:
An individual appointed by the project manager to:
a. Co-ordinate and direct construction activities and the completion of tasks by the
Contractors.
b. Take-overall accountability of the C1-commissioning-construction phase of the
project.
c. Support the commissioning manager during cold commissioning stage C2 and C3.
3. Commissioning Manager:
An individual appointed by the project manager to:
a. Take-overall accountability of the C2 and C3 commissioning phase of the project.
b. Co-ordinate and interface directly with the construction manager and Clients
commissioning team.
c. Support the construction manager during the C1-commissioning stage and the
Client’s team commissioning managers during hot commissioning stages C4 and
C5.
4. Permit Officer:
The Client will appoint one or more qualified persons as permit officers to be responsible
for the review of the technical aspects of the project commissioning safety permit and
isolation program. The permit officer will have knowledge of the operation of the plant
and of the interactions between the different sections of the plant. The permit officer will
be responsible for:
a. Review of safety permit requests.
b. Directing the placement or removal of safety tags, safety barriers and locking
devices.

c. Maintaining the safety permit log and locking device log.

5. Commissioning Engineer:
An engineer appointed by the project manager to take the overall accountability for the
commissioning of a particular piece of equipment or system during Stages C2 and C3. His
primary responsibilities are:
a. Participate in the final stages of installation
b. Prepare and organize equipment tests and ensure record keeping of these tests
c. Ensure compilation of the handover documents and expedite the approvals thereof
d. Interface with Client’s counterpart(s).
6. Discipline Engineer:
In terms of the commissioning activities, the engineer will be seen to be any of the project
discipline coordinators for civil, structural, mechanical, electrical, control &
instrumentation. His primary responsibilities are:
a. Answer technical queries during the installation stage.
b. Check compliance with designs and equipment specifications.
c. Maintain liaison with the equipment suppliers, transmit technical queries and
organize suppliers commissioning assistance.
d. Initiate and expedite approvals of the contractors check out acceptance certificate,
defects list and take-over certificates.
e. Render assistance in the final stages of construction and installation and
throughout testing and start-up.
f. Identify applicable equipment tests to be done during the commissioning process.
g. Initiate compilation of the contractor’s take-over certificates.
h. The engineer will in most cases also be an integral part of the commissioning team
and thus may double as the EPCM commissioning engineer.
7. Client’s Commissioning Manager:
An individual appointed by the Client to:
a. Communicate all allocated Tippler 3 project commissioning and associated
activities to the Client business units.
b. Liaise with the Client’s commissioning manager to ensure the timeous introduction
of the production team to run the hot commissioning and process stabilization
areas and to optimize and ramp-up the said stabilized process areas.
c. Attend regular scheduled commissioning liaison meetings with all project
stakeholders.
d. Schedule and free up operational staff at the required inception stages for
identified process area optimization and ramp-up.
e. Schedule and train all allocated shift foremen, control room operators and field
operators in optimized and ramped up process areas.

f. Issue final plant hand-over and acceptance certificates to the Port of Saldanha
Terminal project business unit manager.
8. Client’s Area Operations Manager:
An individual appointed by the Client to:
a. Communicate all allocated Tippler 3 project commissioning and associated
activities to the Client business units.
b. Liaise with the Client’s commissioning manager to ensure the timeous introduction
of the production team to run the hot commissioning and process stabilization
areas and to optimize and ramp-up the said stabilized process areas. This liaising
shall include the relevant maintenance manager and personnel for any
maintenance activities required during commissioning.
c. Attend regular scheduled commissioning liaison meetings with all project
stakeholders.
d. Schedule and free up operational staff at the required inception stages for
identified process area optimization and ramp-up.
e. Schedule and train all allocated shift foremen, control room operators and field
operators in optimized and ramped up process areas.
f. Issue final plant hand-over and acceptance certificates to the Port of Saldanha
Terminal project business unit manager.
9. Business Unit Manager:
For the purposes of this document, Business Unit Manager refers to an individual employed
and assigned by the Client to manage a specific business entity within Transnet.
10. Commissioning Team:
A commissioning team will be established consisting of members from the project team as
well as from the Client’s team. The team members will work under the commissioning
manager and Client’s commissioning managers respectively. The commissioning team will
be responsible for the commissioning of a particular system and handover to the
operational team.
11. Vendors & Design Engineers:
The vendors and design engineers who will assist during plant commissioning and start-
up, in specific areas and tasks, may complement the commissioning team.
9. FACILITIES FOR PRE-OPERATIONAL TESTING AND

COMMISSIONING
In general, all mechanical, electrical, instrumentation and piping equipment will undergo some
form of pre-operational testing and commissioning. All civil, structural, earthworks items are
excluded from commissioning and are handed over directly from construction to operations, on

issuing of a signed C1 certificate.
The facilities to be pre-operationally tested include the following
 Electrical system (Distribution Systems, Factory Acceptance Testing of MCC, control

system, 11kV reticulation)
 Mechanical system (Water pumps, and HVAC)
10. COMMISSIONING STAGES

The commissioning stages are outlined per functional group in the sections below.
Construction
Stage: C1 Construction Testing

Activity: Equipment inspection and testing
Conditions: Not energized
Example tasks: (Typical) Wiring point to point
Pressure vessel leak check
Pressure testing of associated plant.
Responsible Person: Construction Manager
Responsible Team: Construction management team and construction contractors
Milestones: Construction complete
Completion Certificate approval
Cold Commissioning
Stage: C2 Equipment Testing

Activity: Equipment inspection and testing
Conditions: Energized
Example tasks: (Typical) Motor bump test
Instrument I/O checks to the control system
Responsible Person: Commissioning Manager
Responsible Team: Commissioning team
Milestones: Completion Certificate
Take-Over, Care Certificate approval (TC)

Stage: C3 Systems Testing

Activity: Systems testing
Conditions: Inert materials
Example tasks: (Typical) Interlock checks
Sequence checks
Pump flow checks
Vibration checks
Conveyor alignment
Responsible Team: Commissioning team
Milestones: Completion Certificate
Take-Over, Care Certificate approval (TC)
Hot Commissioning
Stage: C4 Process Commissioning

Activity: Process start-up and testing
Conditions: Process materials
Example tasks: (Typical) Run systems with process materials at relevant capacities required
for commissioning.
Run complete plant
Responsible Team: Commissioning team and Client
Milestones: Take-Over, Care and Control Certificate approval (TCC)
Stage: C5 Ramp-up
Activity: Ramp-up
Conditions: Process materials
Example tasks: (Typical) Increase throughput to design capacity and quality
Responsible Person: Operations Manager
Responsible Team: Client operations team
Milestones: Total Care, Custody & Control Certificate approval (TCCC)
Please note:
The Construction Manager shall be responsible for each section of the plant up to completion of
the C1 commissioning stage. The Commissioning Manager will then assume responsibility for
each section of the plant as it is handed over from construction up to the end of the C3

commissioning stage. The Commissioning Manager shall further together with the client assume
responsibility for each of the plant as it is accepted at the end of the C5 commissioning stage.
Punch & Rectify (C1 – C3) Cold Commissioning

Once all installation/erection tests and inspections have been signed off, the contractor will
request that pre-commissioning be carried out on equipment, machinery or systems. The
Commissioning Manager will coordinate the pre-commissioning meetings by convening the
relevant parties from client operations, the contractor(s) as well as suppliers where relevant. The
contractor will put forward the pre-commissioning plan for approval, indicating the proposed
activities, safety and risk assessments, scheduling, risk assessment and resourcing. The pre-
commissioning activities on any equipment and/or system will include for, but not limited to:
1. Energising power supply
2. Testing major electrical equipment (transformers, MCCs, motor direction, etc.)
3. Verifying signalling circuits and interlocks and operate instruments and controls as a
complete signal and control system
4. Powering up the distributed control system (DCS) including operator’s console
5. Energising and test control loops and I/O signals within the battery limit of the pre-
commissioning system
6. Functional verification and testing of all safeties and emergency stops
7. Setting torque switches and adjust limit switches
8. Checking oil and lubricant levels
9. Testing electrically or pneumatically operated motor operated valves (MOVs)
10. Verifying control circuits and interlocks and operate instruments and controls as systems
11. Bumping motors for rotation, do vibration tests uncoupled, then couple
12. Ding vibration testing on coupled drives
13. Checking tracking of individual conveyors and belt alignment monitoring
14. Running the equipment as a system and check operation of safeties, interlocks, belt
speeds, chute blocked detection, luff and slew performance, etc. without product
15. After the conformance to pre-commissioning performance specifications is witnessed,
verified and signed off by the various parties, data sheets and test records are completed
for handover to commissioning team
16. Mechanical acceptance certificates provided so that hot commissioning may commence.
For the Cold Commissioning (C1 to C3) activities, time has been allowed for contractors to rectify
punch items, as well as the turnaround time for approvals when applying for the different cold
commissioning certification. The breakdown of mechanical/electrical cold commissioning activities
are as follows:
1. Initial punching by project team
2. Rectify punch item category A and B emanating from initial punching
3. Back punch after rectification by project team
4. Initial Client punch
5. Rectify punch items emanating from initial Client punch.
6. Client back punch after rectifications

7. Practical completion/C1 achieved (Individual item installation complete)

8. Test individual item
9. C2 achieved (Individual item starts)
10. Complete all remaining punch items categories before C3 application
11. Final punch of remaining Category C-E punch items
12. Area dry operational test interface with other units in area (Data books, as-built drawings
submission required)
13. C3 achieved (Area operational)
For civil works, the activities for cold commissioning would not be as long as for the installation
packages, as there will not be any physical C2 to C5 activities. Once C1 has been achieved, C2 to
C5 activities become a documentation exercise until handover. The breakdown of civil and
earthworks cold commissioning activities is as follows:
1. Initial punching by project team
2. Rectify punch item category A and B emanating from initial punching
3. Back punching by project team
4. Initial Client punch
5. Rectify punch items emanating from initial Client punch.
6. Client back punch after rectifications
7. C2 to C5 commissioning stages’ paperwork to handover certificates
8. Complete all remaining punch items categories before C5 application.
Hot Commissioning/Handover (C4 – C5)

For the hot commissioning (C4 and C5) activities, time has been allowed for contractors to fine
tune the plant with material load to obtain C4 approval. Following which time has been allowed
for plant optimisation and ramp up to obtain C5 approval. The hot commissioning activities have
been broken down into the following stages:
1. HVAC system as directed by the Engineer
2. Performance testing of the HVAC system as directed by the Engineer
For civil works, the activities for hot commissioning are a documentation exercise to achieve the
handover certificate and include the following activities:
1. C4 achieved
2. Project team/Client interface
3. C5 achieved
11. SAFETY DURING COMMISSIONING

The key safety issue associated with commissioning is the management of the interfaces between
commissioning, construction and the operation. Plans will be implemented to ensure a smooth

transition from a construction phase, to cold commissioning, to hot commissioning and ramp up
phases, when equipment is energised, tested and run. The interface between commissioning and
construction and operations activities at the project site will be managed with agreed isolation
and tagging procedures, training sessions and regular meetings for review and coordination.
There will be one common safety system for isolation between all phases from construction to
operations but with different authorities for approvals at each phase. Details of specific safety
related practices are given in the following sections.
Site induction
All commissioning team members and vendor representatives will be inducted prior to working on
site. In the case of short visits and when induction is impractical, the visitor will be accompanied
at all times on the plant site by an inducted person. Items to be emphasised during commissioning
inductions include:
1. Emergency telephone numbers and radio channels
2. Location of evacuation points
3. Wearing of personal protective equipment
4. Standard operating procedures
5. Hazardous chemicals, pressures
6. Job safety analysis
7. Isolation and tagging procedures
8. First aid and paramedic facilities.
The Safety Officer or delegate will conduct site inductions.
Handover identification
The handover identification program facilitates the transfer of equipment systems from the
custody of construction to cold commissioning and then to hot commissioning. Handover
identification is achieved by access control and signage at the entrances to buildings and areas
identifying the status of the equipment within the area or building and the person responsible for
activities within the area. Different colour tags are used to identify the operational status of
specific equipment. The handover identification program performs two functions. First, it
provides a boundary within which work or testing may be performed safely. Secondly, it provides
personnel with a notification of the extent that certain equipment or systems will be either out of
service or have their service restricted. Any other group wishing to work on equipment in the
area must obtain authorisation from the authority indicated on the entrance signage.
Energisation
Following the transfer of a section of the plant from construction to cold commissioning the
responsible commissioning manager will ensure that all inspection and testing necessary for the
safe energisation of the equipment has been completed. A site wide notification is then issued
which identifies the equipment that is about to be energised. This procedure applies to the

energisation of systems including Low Voltage (LV) electrical equipment, mechanical equipment,
process vessels and piping systems. The notice of energisation warns of the potential exposure
to electrical hazards, moving equipment, hazardous equipment or hazardous materials.
Isolation & Lockout Procedure

The Client’s ‘Permit to Work’ and ‘Lockout Procedures’ will apply throughout commissioning. The
Commissioning Manager shall ensure that the latest Client Lockout Procedures are being used
and implemented. All devices will be locked out at transfer from construction to cold
commissioning. Devices will only be activated during periods of testing and immediately on
completing the testing whereby the devices will be locked out again. The Commissioning Manager
responsible for a project area (responsible person) will approach the appropriate authorised
person who will apply the principal lock to the isolation device for any piece of operable equipment
in that area in the presence of the responsible person. The authorised person will also attach to
the lock an isolation tag that provides the required details of the isolation. Anyone who works on
isolated system will apply a lock to the principal isolation device during the period that they are
actively working on the isolated system. When it is necessary to operate a piece of equipment
the authorised person will ensure that the equipment is safe to operate and that no other locks
remain before removing the principal lock.
Permit to work
Work permits are used to control the performance of work on components and systems under
the control of commissioning. Work control is necessary to ensure that any previous
commissioning work is not invalidated and that components and systems are available to support
the project commissioning schedule. Work control complements the safety isolation procedure in
the protection of personnel and equipment from hazards due to pressures, temperatures or
voltages. The work authorisation authority, in this case the Client, will review the work with the
requestor and analyse potential risks and hazards presented by the work or by simultaneous
activities on nearby or related systems and equipment. If necessary, they will develop a list of
procedures or measures to protect the requestor, its workers, others and the equipment or system
from these hazards throughout the planned work activity. The work authorisation authority, after
determining that the requested work can be accomplished, will provide a work window based on
the requestor's work duration estimate and prepare the work authorisation to identify the work
desired.
Hot Work Permit

Hot work permits operate in a similar way to work permits but are applied to activities where
there is a fire hazard, such as grinding, flame cutting and welding. The permits are only issued
for a single shift and require a work site inspection at the end of the task to ensure that there is
no further risk of fire.
Risk management

Commissioning testing frequently requires equipment to be operated in a manner that is not

covered by a standard operating procedure. In these circumstances a risk assessment, including
a risk mitigation plan must be compiled and approved prior to the start of the task. The risk
assessment will consider each step of the task and evaluate potential hazards for likelihood and
severity. Measures to minimise the risks will be identified and a member of the work team will
be nominated to be responsible for the application of each control measure.
Tagging
A system of tags will be used to provide a record of inspection and checks to facilitate a systematic
check out of equipment and ensure the safety of all involved. The systems of tags proposed for
this project will be as per the Client’s lock out procedure. No tag present means that equipment
is still under construction and not ready for any testing.
1. Blue Commissioning Tag:
The contractor commissioning team attaches this blue tag to each piece of equipment
after installation is completed and Client commissioning engineer have signed off the
relevant check-out acceptance certificate. This signifies that C2 cold commissioning can
commence.
2. Red Personal Danger (Isolation) Tag:

The red personal danger tag is part of a procedure that is used to assure the positive
lockout of equipment for the following purposes:
a. To prevent the operation of equipment, either electrical or mechanical, at a time
when this would endanger the safety of men working on such equipment
b. To prevent the operation or energising of equipment which could possibly result in
damage to the equipment
c. This system is an essential part of job safety and must be strictly observed as it
involves the life and safety of men.
3. Green Tag:
The green tag indicates that the equipment has been handed over to operations. This will
typically happen for the C4 commissioning phase.
12. COMMISSIONING PHASES

The following phases of construction and commissioning and the mandated deliverables from an
integral part to achieve project completion are as follow:
C0 – Commissioning - Preparation
All the necessary and applicable deliverables as applicable and required for commissioning would
be required prior to the start of cold commissioning.

The following handover documentation are required, as applicable, at completion of this phase:
1. Area technical review minutes and actions.
2. Cold commissioning team identified and approved by Client’s manager.
3. Hot commissioning team identified and approved by Client’s manager.
4. Commissioning risk assessment conducted, approved and distributed to commissioning
team.
5. Piping and instrument diagrams.
6. Process flow diagrams.
7. Mechanical equipment list.
8. Piping line list.
9. Valve list.
10. Electrical component list.
11. Electrical equipment list.
12. Instrumentation list.
13. Software factory acceptance testing completed and signed off.
14. Works instructions and training manual developed and signed off.
15. Critical spares list completed and available.
16. Planned maintenance schedule compiled and available.
17. Vendor installations maintenance procedures available.
18. Plant maintenance personnel training manuals developed and maintenance personnel
training complete. (Where applicable on “new” vendor technology)
19. Equipment data sheets.
20. Factory acceptance tested software control narrative.
21. References to associated vendor information/drawings.
C1 – Commissioning – Construction Testing

The civil, mechanical, electrical, control & instrumentation hardware installation, Contractors shall
be required to hand-over documents pertaining to the process area to the project construction
manager. Cold commissioning will not commence for the process area until the project
construction manager is satisfied that the plant has been constructed in accordance with the
project execution approved design and technical specifications. The project construction manager
will issue the relevant handover, Completion Certificate to project commissioning manager. Such
Completion Certificate template is represented in Annexure A.
Notes:
1. The punch listing or facility inspection is performed by the responsible engineer,
construction manager’s representatives, contractor and clients team members and all
known defects are listed

2. Issuance of a Completion Certificate to the contractor for the relevant system shall be
made, provided that the data books have been submitted and approved and all punch list
category ”A ” items are rectified and completed.
The following handover documentation, as applicable, are required at completion of this phase:
1. Completed C1 check sheets
2. Punch list (Prioritized A, B, C & D category ratings)
3. Completion Certificate (Issued per subsystem per contractor)
4. All relevant drawings red lined to as-built status and signed off
5. P&IDs red lined to as-built status and signed off
6. PFDs red lined to as-built status and signed off
7. Software factory acceptance test certificate.
C2 – Commissioning – Equipment Testing

The Commissioning Manager and the associated commissioning resources will complete all
mechanical, electrical, instrumentation and software installation loop tests pertaining to a process
area, to ensure all energised equipment are functioning correctly as per approved design and
technical specification. Once all the equipment testing is complete and the necessary data books
and certificates have been submitted and punch list categories “A” and “B” items have been signed
off, the Commissioning Manager may issue the Take-Over, Care Certificate (TC) to the discipline
installation contractor(s). The Take-Over, Care Certificate is represented in Annexure B.
Notes:
1. The accepted areas of the plant will be declared “Live” and a “Permit to Work” system will
be implemented. These areas will be identified and clearly marked on a plot plan and
displayed at the contractors meetings.
2. The individual equipment is demonstrated (without product) to the full commissioning
team to prove that start and stop functions are controlled.
3. Permits to Work will be issued to allow either construction to continue or give permission
to test equipment. Any permit to work shall be conducted in accordance with the Client’s
lockout procedure.
1. Software loop checklist.
2. Punch list category “A” and “B” items completed.
3. Take-over, Care certificate.
C3 – Commissioning – Systems Testing with water

The Commissioning Manager and the associated commissioning resources will test the operation
of the equipment grouped together into systems, using mainly sea water only. The control
modules and equipment modules pertaining to a process area will be tested to ensure correct
functioning as per approved design and technical specifications. The process system start-up and

operation will then be demonstrated to the Client’s commissioning team with the introduction of
process materials (sea water). Once the Commissioning Manager is satisfied that all cold
commissioning activities are completed, a Take-Over, Care & Control Certificate (TCC), as
represented in Annexure C, will be issued by the Project Manager and accepted by the Client’s
Commissioning Manager. This will signify the commencement of process system hot
commissioning.
Notes:
1. Completion by contractor(s) of the entire Punch list category “A” and Punch list category
“B” items for the relevant system(s) to be tested, is a pre-requisite to starting C3-
Commissioning.
2. Punch list category “C” items completed.
3. The Contractor shall be required to compile all vendor data, permits, test certificates,
inspection approvals and “As-Built” information during this stage (data packs).
4. During the C3-Commissioning – Systems testing stage, the necessary HAZOP study shall
be completed, prior to starting with C4-Commissioning – Process Commissioning.
1. Take-Over, Care & Control Certificate (TCC)
2. Punch list category “C” items completed.
C4 – Commissioning – Process Commissioning (Operational Team)

The Client’s Commissioning Manager and the associated Client’s commissioning team resources
shall be required to introduce process material into the system to ensure all process controls are
functioning correctly as per approved design and technical specifications. The Client’s
Commissioning Manager and the associated Client’s Commissioning resources will ensure that the
process system with all associated control loops is stabilised and controlling as per the approved
design and technical specifications. All unit/system process controls have been tested with
process materials and process control loops are functioning. Once the Commissioning Manager
is satisfied that all hot commissioning activities are completed, a Total Care, Custody & Control
Certificate (TCCC), as represented in Annexure D, will be issued by the Project Manager and
accepted by the Client’s Commissioning Manager.
1. Total Care, Custody & Control Certificate (TCCC)
2. Punch List category “C” items have been completed.
C5 – Commissioning – Ramp-up (Operational Team)

The process area Operations Manager and the associated operations commissioning engineers
will continue ongoing optimisation and ramp-up of the stabilised process system as per approved
design and technical specifications. Once all training of production site personnel has been
completed by the area Operations Manager(s) and the associated resources to the satisfaction of
the area Operations Manager(s), the area Operations Manager(s) will issue the Clients manager
with the final process area handover documents. The Clients manager will, in-turn issue the

process area handover document to the business unit manager. This signifies the final acceptance
of the process system by business unit operations and initiates project close-out.
Note:
1. During C5 Commissioning the necessary HAZOP study shall be required in order to identify
all necessary and associated operational risks inclusive of all associated mitigation
measures.
No handover documentation, as applicable, is required at completion of this stage as everything

should have been handed over already in the previous commissioning phases.
13. PUNCH LIST

During cold commissioning a list of deficiencies is generated to identify items that have to be
corrected before the completion of the project. These deficiencies are ranked according to
seriousness and urgency to manage their correction. The classifications and their definitions are
listed in the table below:
Category: Definition:
Critical (Safety, Interference with production) Mandatory prior to C2
A
commissioning
Not critical (General defects. Cannot be rectified when plant is running) can
B
be rectified during the next stage of commissioning.
Not critical (Remaining work, but can be rectified when plant is running)
C
must be rectified before the final plant acceptance.
Extra Work (Not in contractor’s scope of work; “Nice-to-have”; Not essential
D
to safety or process; subject to Site Instruction or Change Notice.)
A central database will be maintained on site for all punch list items to facilitate management of
the corrective actions and ensure that all deficiencies are corrected in a timely manner and that
the corrective actions are fully documented. The punch list will be managed in turn by the
commissioning manager, the Client’s commissioning manager and the ramp up manager. The
current commissioning manager will review all deficiency items generated on the project and
approve them prior to entry into the database
14. TAKE-OVER CERTIFICATES

As the entire plant may not be handed over at once, the Client’s team and project manager’s
construction teams may have to co-exist for a period of time. To minimise the problems, which
such a situation creates, the interface between the Client and contractor must be clearly defined.

Areas and systems that have been handed over to the Client are “out of bounds” to the contractor.
The contractor must seek special permission if work has to be done by him in such areas. On the
other hand, the Client’s activities must be confined only to areas and systems that have been
taken over from the contractor(s).
Completion Certificate
This certificate as represented in Annexure A, may be prepared for equipment, systems or areas
and serves to handover the equipment from C1-commissioning-construction completion to C2-
commissioning-equipment testing. This certificate does not exempt the contractor from his
contractual obligations. It does not certify that the contract is completed nor serves any
authorisation for payment. The engineer responsible for the particular system or piece of
equipment will draft the Completion Certificate, as represented in Annexure B, only after the
following has been fulfilled:
1. The installation of the equipment is essentially complete with only minor defects
remaining.
2. All prescribed inspection and testing has been carried out satisfactorily and the QCPs have
been approved and signed.
3. All equipment and systems conform to the equipment design and technical specifications.
An important part of the Completion certificate is the list of defects. Prior to handover, the
equipment or facility is inspected by the engineer in co-operation with the contractor and the
Client’s team and all known defects are listed with indication of party responsible for the
correction. There can be several sources of defects: e.g. faulty or incomplete installation, poor
design, omissions, fabrication errors, etc. However, at this stage the defects should be minor in
nature and should never jeopardise the safety of operations. It must be recognised that a number
of defects can be detected only after actual operation commences. Therefore, the listed items of
defects on the Completion Certificate does not exempt the contractor or the supplier from their
respective responsibilities and warranties.
Take-Over, Care Certificate (Install Contracts)

A Take-Over, Care Certificate, as represented in Annexure B, issued by the project manager to
the installation contractor/s to:
1. Handover equipment or systems at the completion of C2-commissioning-equipment
testing provided that all punch list “A” and “B” items are completed.
2. Handover equipment in accordance with the contract conditions.
3. Establish the date from which the installation contractor’s defects liability period
commences.
Take-Over, Care Certificate (Design & Supply Contracts)

A Take-Over, Care Certificate, as represented in Annexure C, issued by the project manager to
the design and supply contractor to:

1. Handover equipment or systems typically at the completion of C4-commissioning-process

commissioning provided that all punch list “A” and “B” items are completed.
2. Handover equipment in accordance with the contract conditions.
3. Establish the date from which the Design and Supply Contractor’s defects liability period
commences.
Take-Over, Care & Control Certificate (TCC)

A certificate as represented in Annexure D, may be issued by the project manager for acceptance
by the Clients manager to:
1. Handover work that has passed final inspection and C3-commissioning-systems testing by
the commissioning team and is ready for the Client’s team to commence with C4-
commissioning-process commissioning.
2. Indicate beneficial occupation of the plant has been taken.
The Client’s manager will not be expected to take responsibility for the safe operation of the
various systems without proper technical documentation. It is therefore essential that all the
handover documents including all test certificates and defects lists in the data packs, as-built
P&IDs and vendor operating and maintenance manuals where required be made available to the
Client’s manager by the time of systems acceptance. It is the responsibility of the engineer for a
particular system to ensure that this takes place and is ready prior to the preparation of the Take-
Over, Care & Control Certificate, as represented in Annexure D. An optional flow sheet for
procedure and routing forms part of these procedures. The Client’s personnel shall under no
circumstances operate equipment or work in areas that have not yet been handed over from the
contractor to the Client’s manager on this TCC certificate (beneficial occupation).
Total Care, Custody & Control Certificate (TCCC)

A Total Care, Custody & Control Certificate, as represented in Annexure E, issued by the Client’s
commissioning managers to the Client’s Area managers to:
1. Handover the plant to production and optimisation after successful C4-commissioning-
process commissioning. This certificate indicates final project acceptance in all respects
of installation and performance. Optimisation, full load performance testing and training
of operators and shift foremen during C5-commissioning-ramp-up are still to be
completed. These tasks are the responsibility of the area operations managers.

15. ANNEXURES
Annexure A – Completion Certificate

Annexure B – Take-Over, Care Certificate

Annexure C – Take-Over, Care & Control Certificate

Annexure D – Total Care, Custody & Control Certificate

Annexure E – Completion/Takeover Certificate


Mechanical Completion Certificate (MC)
Completion of Construction and Installation (i.e. Check-Out Acceptance)

Mechcanical Completion Certificate No:
Date: Originator:
Project Name: Project Manger:
Contract No: Contractor/Supplier:
Contract Description:
Facility: System:
Unit/Equipment No:
Comments:
If yes, attached defects list to this

Defects list items outstanding Yes No
certificate
Note:
1) Category "A" defects MUST be complete prior to approval of this certificate.
2) Defects list item no's:
It is hereby certified that the Installation / Equipment defined above has been successfully Inspected,
Tested, Rectified as noted above, and is released for the “Cold Commissioning” stage of work and that the
attached Defects shall be rectified by the stipulated due dates.
This release in no manner relieves the Contractor and/or his sub-contractors and/or Suppliers of his
Contractual obligations in terms of the Contract, and/or warranty, and/or performance guarantee. It is the
Contractor’s obligation to ensure that the Installation / Equipment is safe in terms of the OHS Act of South
Africa to progress into the “Cold Commissioning” stage of work.
The Designer hereby declares that the Installation of the Equipment defined above is safe to use in terms of
the OHS Act of South Africa and is ready to be energised and used for “Cold Commissioning” purposes.
Designation: Name: Date: Signature:
Contractor/Supplier
NEC Supervisor
NEC Project Manager
Resident Engineer
Client Construction Manager
Client Commissioning Manager
TNPA
Transnet Operating
Division Manager TPT
TFR
Employer (Transnt Group Capital)

Take-over, Care Certificate (TC)
Completion of Cold Commissioning

Take-over, Care Certificate No:
Date: Originator:
Facility:
Unit/Equipment No:
Comments:

certificate
Note:
1) Category "B" defects MUST be complete prior to approval of this certificate.
It is hereby certified that the System / Equipment defined above has been successfully “Cold
Commissioned”, Rectified as noted above, and is released for the “Hot Commissioning” stage of work and
that and that the attached Defects shall be rectified by the stipulated due dates.
Contractual obligations in terms of the Contract, and/or warranty, and/or performance guarantee.
the OHS Act of South Africa and is ready to be used for “Hot Commissioning” purposes.
Contractor/Supplier
NEC Supervisor
NEC Project Manager
Resident Engineer
TNPA
Transnet Operating
TFR

Take-over, Care and Control Certificate (TCC)
Preliminary Plan Acceptance (i.e. Beneficial Occupation)

Take-over, Care & Control Certificate No:
Date: Originator:
Facility:
Unit/Equipment No:
Comments:

certificate
Note:
1) Category "C" defects MUST be complete prior to approval of this certificate.
It is hereby certified that the Facility / System / Equipment defined above has been successfully “Hot
Commissioned”, Rectified as noted above, and is released for the “Start-Up and Performance Testing” stage
of work and that the attached Defects shall be rectified by the stipulated due dates.
Contractual obligations in terms of the Contract, and/or warranty, and/or performance guarantee. The
Employer hereby accepts the responsibility as “User” of the above referenced Facility / System / Equipment
for Operations Control and Maintenance under the OHS Act of South Africa.
Contractor/Supplier
NEC Supervisor
NEC Project Manager
Resident Engineer
TNPA
Transnet Operating
TFR

Total Care,Custody & Control Certificate (TCCC)
Final Plan Acceptance

Total Care, Cutody & Control Certificate No:
Date:
Originator:
Project Name:
Project Manger:
Plant:
Facility:
Comments:

certificate
Note:
Subject to the attached Category “C” Defects being rectified by the stipulated due date, the Employer
hereby accepts the above referenced Plant as complete in all regards of installation and performance.
Contractor/Supplier
NEC Supervisor
NEC Project Manager
Resident Engineer
TNPA
Transnet Operating
TFR

Completion/Take Over Certificate
Contract No:
Contractor:
COMPLETION/TAKE OVER CERTIFICATE
Date of Contractor's application for Take-Over by Notice
APPLICABLE SECTION OF PART OF THE WORKS
The whole of the works / Section or part of the works
Description of Section or
Part
DATE OF COMPLETION OF THE WORKS and remedial work to the satisfaction
of the Project Manager, warranting the issue of a Completion/Take Over
certificate (Commencement of Defects Correction/Defects Liability Period)
DATE OF ISSUE OF THIS COMPLETION/TAKE OVER CERTIFICATE
RELEVANT INFORMATION:
Date of Completion of Tests on Completion
THIS TAKE-OVER CERTIFICATE IS ISSUED SUBJECT TO:
Date by which Contractor undertakes to complete outstanding work
The satisfactory completion of the outstanding work required of the Contractor as set out in the
(a)
attached Defects Certificate
The completion of such outstanding work by Contractor, by the date/dates listed in the attached
(b)
Defects Certificate.
The understanding that should the Defects as per the attached Defects list not be completed by
(c) the dates stipulated there in, then this Take-Over Certificate will be deemed to have not having
been issued.
(d) The following comments:
We, the undersigned hereby agree that the relative Works under this Contract have been substantially
completed and the issue of a Take-Over Certificate to Contractor is authorised.
Contractor/Supplier
NEC Supervisor
Construction Manager
Commissioning Manager/Engineer
Contract Administrator
Client Representative
NEC Project Manager
Completion Certificate (CC)
Completion of Construction and Installation (i.e. Check-Out Acceptance)

Completion Certificate No:
Date: Originator:
Facility: System:
Unit/Equipment No:
Comments:

certificate
Note:
1) Category "A" defects MUST be complete prior to approval of this certificate.
It is hereby certified that the Installation / Equipment defined above has been successfully Inspected,
Tested, Rectified as noted above, and is released for the “Cold Commissioning” stage of work and that the
attached Defects shall be rectified by the stipulated due dates.
Contractual obligations in terms of the Contract, and/or warranty, and/or performance guarantee. It is the
Contractor’s obligation to ensure that the Installation / Equipment is safe in terms of the OHS Act of South
Africa to progress into the “Cold Commissioning” stage of work.
the OHS Act of South Africa and is ready to be energised and used for “Cold Commissioning” purposes.
Contractor/Supplier
NEC Supervisor
NEC Project Manager
Resident Engineer
TNPA
Transnet Operating
TFR
Take-over, Care Certificate (TC)
Completion of Cold Commissioning

Take-over, Care Certificate No:
Date: Originator:
Facility:
Unit/Equipment No:
Comments:

certificate
Note:
1) Category "B" defects MUST be complete prior to approval of this certificate.
It is hereby certified that the System / Equipment defined above has been successfully “Cold
Commissioned”, Rectified as noted above, and is released for the “Hot Commissioning” stage of work and
that and that the attached Defects shall be rectified by the stipulated due dates.
Contractual obligations in terms of the Contract, and/or warranty, and/or performance guarantee.
the OHS Act of South Africa and is ready to be used for “Hot Commissioning” purposes.
Contractor/Supplier
NEC Supervisor
NEC Project Manager
Resident Engineer
TNPA
Transnet Operating
TFR

Take-over, Care and Control Certificate (TCC)
Preliminary Plan Acceptance (i.e. Beneficial Occupation)

Take-over, Care & Control Certificate No:
Date: Originator:
Facility:
Unit/Equipment No:
Comments:

certificate
Note:
It is hereby certified that the Facility / System / Equipment defined above has been successfully “Hot
Commissioned”, Rectified as noted above, and is released for the “Start-Up and Performance Testing” stage
of work and that the attached Defects shall be rectified by the stipulated due dates.
Contractual obligations in terms of the Contract, and/or warranty, and/or performance guarantee. The
Employer hereby accepts the responsibility as “User” of the above referenced Facility / System / Equipment
for Operations Control and Maintenance under the OHS Act of South Africa.
Contractor/Supplier
NEC Supervisor
NEC Project Manager
Resident Engineer
TNPA
Transnet Operating
TFR

Total Care,Custody & Control Certificate (TCCC)
Final Plan Acceptance

Total Care, Cutody & Control Certificate No:
Date:
Originator:
Project Name:
Project Manger:
Plant:
Facility:
Comments:

certificate
Note:
Subject to the attached Category “C” Defects being rectified by the stipulated due date, the Employer
hereby accepts the above referenced Plant as complete in all regards of installation and performance.
Contractor/Supplier
NEC Supervisor
NEC Project Manager
Resident Engineer
TNPA
Transnet Operating
TFR

Annexure W - Commissioning Management Plan

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Annexure W - Commissioning Management Plan

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Transnet Capital Projects

1124367: New Liquid Bulk Facility landside - Commissioning

Transnet Capital Projects

Prepared by: Name: Thulane Magoro 14 August 2017

Approved by: Name: Siyabonga Gadu August 2017

Prepared by: Name: Benedict Isaacs August 2017

01 August 2017 Updated as per Gate review comments

Commissioning Management Plan Page 1 of 28

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COMPLETION CERTIFICATE ................................................................................................... 21

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5. GOVERNING CODES, STANDARDS AND SPECIFICATIONS

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Project Specific Documents

6. TERMS & DEFINITIONS

Table 1: Terms & Definitions

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Construction Confirmation that the equipment is installed according to drawings, specifications

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c. Maintaining the safety permit log and locking device log.

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9. FACILITIES FOR PRE-OPERATIONAL TESTING AND

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issuing of a signed C1 certificate.

The facilities to be pre-operationally tested include the following

 Electrical system (Distribution Systems, Factory Acceptance Testing of MCC, control

10. COMMISSIONING STAGES

Stage: C1 Construction Testing

Stage: C2 Equipment Testing

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Stage: C3 Systems Testing

Stage: C4 Process Commissioning

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Punch & Rectify (C1 – C3) Cold Commissioning

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7. Practical completion/C1 achieved (Individual item installation complete)

Hot Commissioning/Handover (C4 – C5)

11. SAFETY DURING COMMISSIONING

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The Safety Officer or delegate will conduct site inductions.

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Isolation & Lockout Procedure

Hot Work Permit

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Commissioning testing frequently requires equipment to be operated in a manner that is not

2. Red Personal Danger (Isolation) Tag:

12. COMMISSIONING PHASES

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C1 – Commissioning – Construction Testing

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C2 – Commissioning – Equipment Testing

C3 – Commissioning – Systems Testing with water

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C4 – Commissioning – Process Commissioning (Operational Team)

C5 – Commissioning – Ramp-up (Operational Team)

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No handover documentation, as applicable, is required at completion of this stage as everything

13. PUNCH LIST

14. TAKE-OVER CERTIFICATES

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Take-Over, Care Certificate (Install Contracts)

Take-Over, Care Certificate (Design & Supply Contracts)

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