Testing and Commissioning Procedure for

Chemical Dosing Unit

PRO 00024 10.1

PRO - Procedure

03 -- Issued
04 Issued for
forApproval
SONO

REDCO 07-02-2019
20/02/2019

20/02/2019
07-02-2019

20/02/2019
07-02-2019

20/02/2019
07-02-2019

07-02-2019
20/02/2019

0.1
1 20/02/2019
07-02-2019
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SPH - JV
GREEN LINE - ELEVATED & AT -GRADE f\edco International
Testing and Commissioning Procedure
for Chemical Dosing Unit
(REDCO)

RTC/082/2013

Document No.:

Document Type PRO - Procedure

Reason for Issue 04 - Issued for SONO

T&C Engineer Signature Date

Prepared by:
Muneeb Asfaq ~1~
~1 ~
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 id ~ 3 February 2019

Revision History
Rev. No. Description of Revision Date of Revision
0.1 First Issue 3 February 2019

M009-SPH-TCH-PR0-00024 Page 1 of20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

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Total Number of Pages: 20 including front page and excluding appendices

TABLE OF CONTENTS

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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

 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 Procedure Documents............................................................................... 8
2.3 Testing and Commissioning Stages ............................................................................ 9
3 ROLES AND RESPONSIBILITIES ........................................................................... 10
3.1 Manufacturer/Supplier (Culligan Gulf L.L.C.) Representative ...................................11
3.2 T&C Manager ................................................................................................................11
3.3 T&C Site Engineer ........................................................................................................11
3.4 QA / QC Engineer..........................................................................................................11
3.5 QC Inspector .................................................................................................................11
3.6 HSE Manager ................................................................................................................11
3.7 Supervision Engineer ...................................................................................................12
3.8 Supervisor/Foreman .....................................................................................................12
3.9 Technicians/Helpers .....................................................................................................12
4 RESOURCES............................................................................................................ 12
4.1 Labour ...........................................................................................................................13
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 ...................................................................................................... 16
8.1.1 Pre-Requisite For PSAT ...........................................................................................18
8.1.2 Pre-Commissioning..................................................................................................18
8.1.3 Pre-Commissioning of Water Treatment Controller: .............................................18
8.1.4 Pre-Commissioning of Dosing Pump/Tank & Level Switch: .................................18
8.2 SAT (Stand-Alon Test) ..................................................................................................19
M009-SPH-TCH-PRO-00024 Page 3 of 20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

 8.2.1 Pre-Request For SAT ...............................................................................................19
8.2.2 Commissioning ........................................................................................................19
8.3 MEP System Integration Test (SIT) ..............................................................................19
8.4 System Performance Test (SPT) ..................................................................................20

LIST OF APPENDICES
Appendix 1 – Risk Assessment
Appendix 2 – Check List

M009-SPH-TCH-PRO-00024 Page 4 of 20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

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 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.

M009-SPH-TCH-PRO-00024 Page 5 of 20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

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
MCC Motor Control Centre
ANSI American National Standard Institute.
ASTM American Society for Testing and Materials.
PTW Permit to Work
COSHH Control of Substances Hazardous to Health Regulation.
BACS Building Automation Control System.

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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

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 document is to demonstrate the generic approach and procedures to be followed
during Testing and Commissioning of the Chemical Dosing Unit in a safe manner to an approved and
controlled methodology to demonstrate a thorough and considered understanding and approach, all in
accordance with applicable standards, codes of practice and project specifications.

The Job Hazard Analysis in Appendix 1 identifies the hazards and the safe systems of work to be followed
when conducting the activity.

2 SCOPE
Scope of this Procedure for Testing and Commissioning of Chemical dosing unit in a safe manner.

This document includes the following either in the main body or in the Appendices:

x Methodology for Testing and Commissioning of chemical dosing 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 NFPA 90A Installation of Air Conditioning and Ventilating Facilities.

x NFPA 5000 Building Construction and Safety Code
x NFPA 130 Standard for Fixed Guide Way Transit and Passenger Rail System.
x BS CP 352 Mechanical Ventilation and Air conditioning in buildings.
x Qatar Construction Specifications 2010 (QCS 2010)
x Mechanical Specifications, Vol. 7

The following documents are referred to either to support the implementation of the MS or are a pre-
requisite to its implementation:

M009-SPH-TCH-PRO-00024 Page 7 of 20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

x DWG:
Document No. Document Name
M009-SPH-MHV-DWG-GWST080-L1-11017 Lower Ground Level 1 Chilled Water Pump Room - Vac

x Method Statements for:

Document No. Document Name
M009-REI-MEP-MES-00034 Method Statement for Installation of Chemical Dosing System for Chilled Water Treatment

x MAR:
Document No. Document Name
M009-SPH-MEP-MAR-00162 Material Approval Requisition of Chemical Dosing System for Chilled Water Treatment

x MIR:
Document No. Document Name
M009-REI-MEP-MIR-00157 Material Inspection Requisition of Chemical Dosing System for Chilled Water Treatment

x ITP:
Document No. Document Name
M009-REI-MEP-ITP-00038 ITP for testing and commissioning of Chemical Dosing System for Chilled Water Treatment

x Plans:
Document No. Document Name
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 Procedure Documents

The revision of this Procedure shall be done when:

x New information becomes available.

x Main Contractor requires modifications.
x The Project Director requires modifications of Procedure.
x There is a significant change in the works methodology.
x The revised MS shall be submitted by Main Contractor for SONO to DVE verification and PMC for
review & approval.

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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

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 PRO & ITP)
M009-SPH-MEP-ITP-40003
Stage 6 SPT System Performance Test L&T M009-SPH-MHV-PRO-00033

M009-SPH-TCH-PRO-00024 Page 9 of 20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

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M009-SPH-TCH-PRO-00024 Page 10 of 20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

3.1 Manufacturer/Supplier (Culligan Gulf L.L.C.) Representative
The Supplier/Manufacturer Representative shall be inspect all power termination/connections and
Chemical Dosing Unit installation as per manufacturer requirements. After inspection/confirmation power
of Chemical Dosing Unit shall be switched on and he will witness the testing.

3.2 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.

3.3 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 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.

3.4 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.

3.5 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.

3.6 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.

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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

3.7 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.

3.8 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.

3.9 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 to 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
The following equipment and material are anticipated to be used in carrying out the works:

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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

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 Number

1 T&C Manager 1
4 T&C Engineer 1
5 Supervisor 1
6 Foremen’s 2
7 QA/QC Inspector 1
8 Technician 4
9 Helper 10

4.2 Equipment Used

4.2.1 General Equipment used for this activity:

Sr. No. Tool and Equipment

1. TDS (Total Dissolved Solids) or Conductivity Meter.

2. Pressure and Flow Tester

3. Ammeter

4. Mechanical Tool Box

5. Electrical Tools Box

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.

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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

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.

M009-SPH-TCH-PRO-00024 Page 14 of 20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

 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.

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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

8 METHODOLOGY

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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

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M009-SPH-TCH-PRO-00024 Page 17 of 20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

 8.1.1 Pre-Requisite For PSAT

Chemical Dosing Unit commissioning will not commence until the installation
mechanical and electrical IRE signed off.

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

2. Ensure that IRN had been submitted by Construction and approved by all
parties.
3. Electrical cable installation is completed, inspected and Approved.
4. Ensure all installation work related to Chemical Dosing Unit are complete,
Inspected and approved.
5. Ensure sample of test pack has been prepared.
6. Ensure that lock out tag out in place.
7. Ensure HSE in place.
8. Ensure that as build / red line drawing have been provided.
9. Ensure approved Procedure is on the site.

8.1.2 Pre-Commissioning

1. Check installation of Manual & auto dosing system is done properly.

2. Check availability of power at Dosing system.
3. Check electrical connection to the dosing pumps, Water Treatment Controllers,
solenoid Valve & Other electrical accessories.
4. Check Installation of Water Treatment Controller is done as per manufacturer’s
recommendations.
5. Ensure the dosing pump discharge & suction is connected appropriately.
6. Check Dosing Tank Installation is done according to the manufacturer’s
recommendations
7. Check the low-level float switch is connected to water treatment controller as
per recommendations.
8. Check Isolation valves & by pass are provided in the system.

8.1.3 Pre-Commissioning of Water Treatment Controller:

1. Check it shall have clearance from manufacturer/supplier before power supply

connection to any chemical dosing equipment
2. Turn on the Water Treatment Controller after connecting all the accessories &
equipment
3. Open the inlet valve and allow water to flow through
4. Check the Conductivity reading on the screen of the water treatment controller.
5. Cross check the readings with manual testing of water by pocket Conductivity
meter.
6. Calibrate the controller if it needs to be based on the reading.
7. Activate all the relays of water treatment controller manually and ensure they
are functioning properly.
8. Set point for the chilled water system conductivity is 2000 us/cm.
9. The Corrosion Inhibitor dosing pump will be working when the conductivity is
lower than 2000 us/cm.
10. Timer setting for Chilled Water Biocide will be once a month (4-week biocide
Timer).

8.1.4 Pre-Commissioning of Dosing Pump/Tank & Level Switch:

M009-SPH-TCH-PRO-00024 Page 18 of 20

Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

 1. Fill the dosing tank with 100Ltr of potable water.
2. Remove the discharge end and also make sure that the suction line is below
the water level.
3. Start the dosing pump by activating the controller relay manually.
4. Use the measuring cylinder to measure the amount of water is being feed by
Dosing pump. Keep the stroke of pump 100%.
5. Take the float switch out and make sure that relay is getting activated in case
of low level.
6. Register the readings.

After a successful completion of this stage, Pre-Commissioning Certificate

(PCC) will be released.

8.2 SAT (Stand-Alon 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. Ensure sample of test pack has been Approved
4. Ensure that lock out tag out in place.
5. Ensure HSE in place.
6. Ensure that approved as build have been provided.
7. Ensure approved Method Statement is on the site.

8.2.2 Commissioning

1. Since, system is pre-commissioned and in operation contractor can proceed with

final commissioning activities.
2. Conductivity Set Point is 2000 us/cm. Change this set point to less than the
reading on controller.
3. The corrosion Inhibitor dosing pump should start feeding chemical automatically.
4. Take the float switch out, the pump should stop working as this float is to provide
dry run protection.
5. The monthly timer for biocide can be changed according to the commissioning
time and the pump should work based on the new timer automatically.
6. Take the float switch out, the pump should stop working as this float is to provide
dry run protection.
7. Close the inlet valve and the pump will not work as the flow switch is provided to
avoid any malfunctioning of the unit in the case of no flow through system.
8. Note Down all the reading and include them in final commissioning reports.

After a successful completion of this stage Partial Acceptance Certificate (PAC)

will be released.

8.3 MEP System Integration Test (SIT)

Chemical Dosing Unit status are being followed by BACS which needs to be operational. If
BACS is not ready at the time of the Pump Test, the procedure will be postponed till such time
that the BACS interface is ready. Here are the BACS points that will be followed.
Please refer to DD2 - MEP BACS Design Report (M009-SPH-MEP-RPT-00005) Section 4
(Chilled water Network)
After a successful completion of this stage, Acceptance Certificate (AC) will be
released.
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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

8.4 System Performance Test (SPT)
Chemical Dosing System will be interfaced to BAS when it is ready. That means
System Performance Test (SPT) will take place when BAS and other related system
is completed.

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

released.

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Testing and Commissioning Procedure for Chemical Dosing Unit (REDCO)

 APPENDIX 1

RISK ASSESSMENT
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RISK ASSESSMENT Appendix 1

Testing and Commissioning

of Chemical Dosing Unit
f\edco International

Risk Matrix

S EVERITY S EVERITY OUT COME

CATASTROPHC 20 25 5 FA TA LITY
MA JOR N.JURY I
CRITIC AL 4 8 12 4 LLr-ESS
- 20 SERIOUS NJLRY I
SeliOUS 3 6 9 12 15 3 LLr-ESS
M EDILM 2 4 6 8 10 2 MINOR N.JURY I LLr-ESS

M INIMAL 2 3 4 5 1 NCltEORSMALLFA

1 2 3 4 5
L IKELYHOOO VERY VERY AL M OST
UNLIKB..Y LIKB..Y
UN..IKB..Y LIKB..Y CERTAIN

Banksman to control access around operating plant or vehicle

stay with1n c 'ear and defined routes g
Enter Site 5 20
Compliance of speed hm1ts on s1te
Do not stand under suspended load
Keep away from tead1ng edges and excavations

Ensure safe acces & egress to work area is prov1ded. Inspected and l agged.
Ensure proper illum1nation on access and access routes,
Steps/rungs inspected and without damage
Ensure handrails are used and proper foot1ng on steps
Access & egress to wOO< area Ihousekeeping, 4 4 16 6
Do not block access by stor•ng matenals
Proper routing of cables
Prov1de 1nformat•on s1gns
Ensure good housekeeping always

Poge I of6
 · Ensure safe access and egress to work area.
• L1ft us1ng correct lifting pnnciple 1e. feet apart, firmly gnp load, keep load close to the body, keep back straight, avo1d tw1SI1ng
r bending too much, when lifting from ground; bend knees and lift weight using your leg muscles.
Ensure good housekeeping 1n the area 1
Watch out for un even surfaces
and trip, repetat1ve wor1<. poor Ensure no spillage or slippery surface
I illumination, protruding sharp obje<:ts. Ensure proper gloves are used along w1th other PPE
Mobilizing materials to work stacking, stacking at strain/sprain, cuts. Engage additional help is the load is too heavy.
3 3 4 12 6
area. height, storting materials injury, fracture Proper storage of materials i e no storing near edge, improper he1ght, not block1ng access ways etc.
COSHH items. unsafe Ensure proper illumination in the area
Ensure protruding objects are covered.
Ensure MSDS for COSHH items.
Do not store excess of flammable materials at s1te.
Bnng only quanllty required for the day
Ensure no hot works in the area.

STARRT bnefing for operatives prior to start wor1<

Proper Superv1s1on
Keep the wor1< place free of obstructiOns by carry1ng out regular housekeeping
Do not block access by stOflng matenals
3 3 9 4
S1gns must be diSplayed to 1ndicate the routes to be taken by persons, changes 1n routes must be clearly communicated
Wor1<1ng area should be illuminated
Proper rout1ng of cables.
Ensure good housekeeptng always

STARRT briefing to operatiVes

Do not use damaged tools
Inspect tools for damage prior to use
Cuts. muscle strain/sprain,
Do not use homemade tools
crush injury, Oemaged to ear, 4 4 16
Do not throw tools on persons below or above
injury to eyes. fracture
Use tool lanyard when us1ng tools at thight
Carry tools in holster or in tool box when worl<ing at height
Use task spec1fic PPE such as face Shields, goggles, hand gloves, ear prote<:tK>n, dust masks etc.

STARRT bnefong for operatives pr1or to start wor1<

A Competent persons
Keep the wor1< place free of obStructions by carry1ng out regular housekeeping
Minor injury.cuts, bruises 3 9 I· Do not carry tools or materials when using ladder 6
Representative I
Do not lean your body dunng worl<IOQ on ladder or scaffold
Foreman I
Job rotation and adequate supply of drink1ng water
Wor1<1ng area should be illum1naled

Preparation for Chemical

4
Dosing Unit STARRT bnefong to operatives.
If possible use mechamcal means to hft load
load,
L1ft us1ng correct lifting principle i.e. feet apart, firmly gnp load, keep load dose to the body, keep back straight. avo1d twisting
Isharp/protruding ends, load st1pp1ng
.,. bending too much. when lifting from ground; bend knees and lift weight using your leg muscles. Site Engmeer IT&C
1mpa1ring visibility, uneven Cuts, crush injury, muscle
. Ensure good housekeeping in the area, Eng1neer/ HSE
slip & trip, fingers getting stra~n/sprain severe injury, 4 4 16 1 8
• Watch out for un even surfaces Representative I
1nder. load falling on person. property damage
• Ensure no spillage or sl1ppery surface. Foreman I
humid climate. vehicle
• Ensure proper gloves are used along with other PPE
unexpectedly
• Engage add1t1onal help 1s the load IS too heavy
Ensure load IS not Impairing the view

Page 2 of 6
 STARRT bnefing for operatives pnor to start work
Scaffolds shall be erected by tra1ned scaffolders only
Scaffolds shall not be used unless mspected by 3rd party cert1fied scaffol d mspector
Scaffold matenals used must be wtthout damage and tn good condition.
Do not over load scaffold.
Ensure scaffold platform IS provided With safe access, top rails. mid rails and toe board
Tool belts m ust be used while worl<ing at he1ght
Scaffolds to be placed on level & rigid surface.
damaged/not locked. Missing 4 5 20
Wheels of mobtle scaffold must be locked dunng operation
rs. leaning/ swaying
Do not move scaffold when wori<.ers are on top
surface or slop,
ladder must be secured with clamps
Us1ng damaged components.
Tra1ned & competent operatiVes must be deployed
MoVIng scaffold when persons are
The bottom area shall be cordoned off and 01gnage placed
platform,
Regular rest t1me & adequate drink1ng water supply for operatives work1ng at cramped areas to be ensured
Ensu<e scaffold IS prov1ded w1th outngger, t1es etc 1f the heiQht to base IS above 4 1 rat1o
Ensure safe1y harness ts used dunng erectton, dtsmantltng and other work at hetght where there ts a nsk of fall

STARRT bnefing to operatives

Wear full sleeve coveralls
Ensure MSOS ts referred pnor to work near COSHH materials.
Insulation Ensure no hot won<. IS carried out where Coshh materiaIts used
Ensure fire ext1ngu1sher 1s available nearby S1te Engineer fT&C
Coshh material contact dunng Respiratory Problems. bums, Ensure good housekeeping always Eng1neer/ HSE
3 9
cleamng&lubricating uTitatton, brutses, . D1spose COSHH waste at the correct skips for hazardous waste. Spillage to be avOided & dnp trays shall be used Representative I
Ensure first atd k1t and eyewash ts available nearby Foreman I
Ensure proper hyg1ene such as wash1ng hands/chang1ng coveralls after handling chem1cals
Do not eat Of store food where chemicals are used
Chem1cals shall be not be stored near hot work act1v111eS
Use PPE such as nubber/PVC gloves, chem1cal goggles, face shields, chem1cal respirators etc when handling COSHH 1tems

Page 3 of 6
 • STARRT bnefing for operatives pnor to start WO<k
• Competent & tra1ned operative under superv1s1on of Competent supervtosr
• All equtpments must have valid calibrated certtficate
• Ensure LOTO procedure shall be followed.
Check the connection of fan inlet & outlet are done wtth proper alignment.
Check the fan 1s tnstalled as per the approved shop drawmgs and manufacturer's Instructions.
Check for free rot at ton of fan propeller.
Check the fire rated ductwork is properly 1nstalled & tnsulated in line with the approved drawmgs & specifications
Check all motortzed dampers are Installed & connected wtth power supply & controls properly
Check fOt' proper electncal power, control panel and earth1ng connections as per manufacturer's recommendations Fteld
to be pre-tested fOf continuity and insulation resistance.
:1< the Interface of the pressunzatlon fan wtth the fire alarm system
Check for proper Installation of pressure sensor 1n the shaft
Check for proper setttng of the overload relay
Check the tdentlficatton & labelling of the fan & ductwor1<
Check belt tenston and adjustment
Check dnve set fitted properly
Site Engineer fT&C
Motor and fan beanngs are properly lubricated.
Pre·Commissioning Chemical Engineer/ HSE
6 4 16 Check for fan rotatton IS correct. Representative I
Dosing Unit electrical power. control
Check Fan motor start-up and running currents
1ing connections. Foreman I
Check for proper electncal power, control and earth1ng connections as per manufacturer's recommendations F1eld w1nng to
Fan Surface.
e pre-tested for continUity and insulation resi stance.
fan tmpetlers
Check the 1nternal & external surface of the fan IS cleaned
!s I Objects.
Check the fan tmpellers are statiCSIIy & dynamtcally balanced
heaMg,
Set earth leakage and overload relays as per motor name plate rattng.
Poor VentJIIatJon.
Check the tnterface of fan wtth fire alarm & BACS system
Poor Coordination
• Check the tdenttficallon & labelling of fan & ductworl<
Poor illumination,
• All area should be evacuated, prtor to start of acttvtty
Falling Materials/ Personels.
• Post awareness & wam1ng signages prior to start1ng of activity to wam others.
Heat exhaustion etc.
• Do not lean your body during worlmg on ladder or scaffold.
Over-reaching,
• Job rotallon and adequate supply of drinking water
Repetitive work.
• Working area should be Illuminated
Trailing cables,
• Proper coordtnatton wtth team WO<king near by acllvity
• Task fans shall be provided at worl<place
• Dust Mask must be worn before start of dust Cleantng
• Proper hand protection gloves shall be worn
• Mandatory PPE must be worn all the ttme on Stte

Page ~ of 6
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llmr.Jir!ll Responsibility

briefing for operatives prior to start work.

Do • Notice to SPH prior to the testing.
• Competant and trained operative required to carry out the work
• Ensure there 1s valid permit to work IS issue.
Ensure the PCC is Available.
• Duct access doors are securely closed
• MCC panels are 1nstalled and commissioned.
Ensure sample of test pack has been Approved
Ensure that lock out tag out in place.
All equipments must have valid calibrated certificate
Ensure that approved as build have been provided.
Ensure approved Procedure IS on the site.
• Ensure that all the pre-commissioning checks are carried out successfully.
Start the fan for a moment & check the direction of rotation of the fan/motor is correct.
Upon ensuring correct direction of rotation start & run the fan for 5 minutes tn normal condit ion.
Check for any undue vibration or noise
Ensure that all the PSAT checks are earned out successfully
Carry out the final visual inspection.
Start the fan by inducing a fire signal from the F ire alarm control panel.
Check all the fire dampers in shaft in all the floors close completely and the shaft is totally ISOlated.
Measure the airflow & inlet static & the static pressure in the shaft & record the values.
Check whether the fan speed ts property controlled by the VFO vide the signal from the pressure sensor in the shaft
Clear the fire signal & check the fans tops & all the motonzed dampers in the shaft are opened
Record all readings 1n the final performance checklist.
All area should be evacuated, prior to start of activity.
Post awareness & warning signages prior to starting of activ1ty to wam o thers.
post watchman to keep unauthorized persons away.
Ensure safe access & egress.
Ensure proper illumination.
Site Engineer fT&C
Coordinate with other team working in the area.
7 4 Engineer/ HSE
4 16 I • Proper Communication system shall be provided.
Representative I
Adequate superviosion and monitoring by the foreman .
Foreman /
Extreme care when work1ng in wet and slippery areas.
Personnel should never run on worksite
Keep worl<s ite 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.
To ensure that the fans are operating automatically as reqwred for system application
To ensure that the fans perform according to design and specifications reqwrements
Fans shall be tested only on their performance. Controls and sequence of operation shall from part of BMS commission1ng.
Air Balancing shall commence after approval and acceptance of the comm1ssiomng of all fans.
While performing the commissioning procedure check the fan and motor at full load by measuring the following
Flow in liters/second
Static Pressure
Revolutions per minute.
Full load running amperes.
Voltage across all phase.
Compare these Values against rated performance.
Should any parameter fall short of acceptable range rectify and reset until that part•cular parameter has met or exceeded
performance.

Page 5 of 6
 • Adequate Pr>E should be used.
Extreme care when work1ng 1n wet and slippery areas
Tnp. Fall. Enwonmentat Effect
Personnel should never run on W011<s1te. Slle Eng~neer I
handling. protruding sharp
Housekeeping
dust, poor illumination,
3 6 I· Keep workSite clean and tidy at allt1mes. General Foreman I
All materials to be secured by suitable chocks, sandbags Of other means. HSE
surfaces. heavy load.
All p1pes no~ laid during the course of a day are to be returned to the stockpile and secured appropriately.
Store/park plant & eqUipment off site & in a secure area

Page 6 of 6
APPENDIX 2

CHECK LIST
 PSAT/ PRE-COMMISSIONING
CHECKLIST FOR CHEMICAL DOSING
SYSTEM
DESCRIPTION DATE
STATION IRE REF NO
DWG REF
LOCATION
MES/ITP
MANUFACTURER SYSTEM

MODEL NO COUNTRY OF ORIGIN

SERIAL NO TYPE
CHECKED BY
NO. DESCRIPTION SPH Supervision
T&C Engineer Date REMARKS
T&C Engineer
1 Documentation
1.1 Permits to work
1.2 Procedure is Approved
Ensure that all the installation inspection is done and all IRE related to the Installation
1.3
and mechanical completion are approved.
1.4 Review Factory Acceptance Test Reports.

1.5 Ensure that the equipment are as per specification and as per approved drawings

2 General Installation
2.1 Check installation of Manual & auto dosing system is done properly.
2.2 Check availability of power at Dosing system.
Check electrical connection to the dosing pumps, Water Treatment Controllers,
2.3
solenoid Valve & Other electrical accessories.
Check Installation of Water Treatment Controller is done as per manufacturer’s
2.4
recommendations
2.5 Ensure the dosing pump discharge & suction is connected appropriately.
Check Dosing Tank Installation is done according to the manufacturer’s
2.6
recommendations
Check the low-level float switch is connected to water treatment controller as per
2.7
recommendations.
2.8 Check Isolation valves & by pass are provided in the system.
3 Water Treatment Controller:
Turn on the Water Treatment Controller after connecting all the accessories &
3.1
equipment
3.2 Open the inlet valve and allow water to flow through

3.3 Check the Conductivity reading on the screen of the water treatment controller.

3.4 Cross check the readings with manual testing of water by pocket Conductivity meter.

3.5 Calibrate the controller if it needs to be based on the reading.

Activate all the relays of water treatment controller manually and ensure they are
3.6
functioning properly.
3.7 Set point for the chilled water system conductivity is 2000 us/cm.
The Corrosion Inhibitor dosing pump will be working when the conductivity is lower
3.8
than 2000 us/cm.

3.9 Timer setting for Chilled Water Biocide will be once a month (4-week biocide Timer).

4 Tank & Level Switch:

4.1 Fill the dosing tank with 100Ltr of potable water.
Remove the discharge end and also make sure that the suction line is below the water
4.2
level.
4.3 Start the dosing pump by activating the controller relay manually.
Use the measuring cylinder to measure the amount of water is being feed by Dosing
4.4
pump. Keep the stroke of pump 100%.
Take the float switch out and make sure that relay is getting activated in case of low
4.5
level.
4.6 Register the readings.
4.7 Cheack Water leakage if any
4.8 Conductivity range should be as per supplier's recommendation

Description T&C Engineer Specialist/ Vendor* Supervision Engineer SPH T&C / PMC

Name

Position

Signature

Date
1- All relevant Drawings and Document must be attached with it
* Where Applicable
Form No M009-REI-QMS-FRM-00118 Revision 1 06-02-18
 SAT/ COMMISSIONING CHECKLIST
FOR CHEMICAL DOSING SYSTEM

DESCRIPTION DATE
STATION IRE REF NO
DWG REF
LOCATION
MES/ITP
MANUFACTURER SYSTEM
COUNTRY OF
MODEL NO
ORIGIN
SERIAL NO TYPE
CHECKED BY
NO. DESCRIPTION T&C SPH Supervision
Date REMARKS
Engineer T&C Engineer

Conductivity Set Point is 2000 us/cm. Change this set point to less than the reading on
1 controller.

2 The corrosion Inhibitor dosing pump should start feeding chemical automatically.

Take the float switch out, the pump should stop working as this float is to provide dry
3 run protection.

The monthly timer for biocide can be changed according to the commissioning time
4 and the pump should work based on the new timer automatically.

Take the float switch out, the pump should stop working as this float is to provide dry
5 run protection.

Close the inlet valve and the pump will not work as the flow switch is provided to avoid
6 any malfunctioning of the unit in the case of no flow through system.

Description T&C Engineer Specialist/ Vendor* Supervision Engineer SPH T&C / PMC

Name

Position

Signature

Date
1- All relevant Drawings and Document must be attached with it
* Where Applicable
Form No M009-REI-QMS-FRM-00119 Revision 1 06-02-18