PROCEDURE NAME PROCEDURE NUMBER

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PURPOSE
To commission and start-up new equipment and processes in a safe controlled manner. This
procedure will insure that systems operate as intended by Cargill

SCOPE
This document contains the check out procedure. The key item to remember is that we will
be commissioning systems. We need to be very clear as to what a system is defined as and be
proactive in making sure the system is complete.

PERFORMED BY
Commissioning Team (The team will be made up of production, project and maintenance
personnel.)

SAFETY, HEALTH AND ENVIROMENTAL CONCERNS

 When performing task outside the control room proper PPE is required. Hard hat,
safety glasses, safety boots, hearing protection and proper gloves.
 Permits Required: None
 All safety policies and procedures must be followed during all task’s

QUALITY CONCERNS
Quality insurance team will be involved in system approval process before systems can be
put into service.

SPECIAL CONSIDERATIONS
Hazard Analysis:
Areas that require a hazard analysis must be reviewed by the Department Team Leader or his
designate. This will require a final sign-off in the PSSR by the Department Team Leader.

Commissioning Terms:
This is a list of common commissioning terms you will find within this SOP.

Hydro Testing – Pressure testing with water.

Leak Testing – Low pressure leak test using water.
Loop Checking – Verifying that instruments are correctly installed.

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P&ID’s – Piping and identification.

PI – Pressure indicator.
Pneumatic Testing – Pressure testing with gas (air).
PRD – Pressure relief device.
Protectoseal – A pressure relief device for liquid storage tanks.
PRV – Pressure relief valve.
PSV – Pressure safety valve.
Rotation Check – Giving motors a rotational check (bumping)
Stroking – Checking operability of control valves and validating their control room
indicators.
Sub-Systems – Systems that are broken down to small tangible piece of the plant that would
be possible to isolate and complete in its entirety.
Systems – Several pieces of equipment that make up a process. The Cargill expansion is
defined by systems.
TI – Temperature indicator.

PROCEDURE
Systems:
Areas will need to be divided into manageable systems to allow for detailed checkout and
verification. Systems will need to be well defined. Each system will be chosen to be a small
tangible piece of the plant that would be possible to isolate and complete in its entirety. The
systems are process based. The system will cover peripheral equipment that are not
necessarily directly linked to the process system such as fire extinguishers, sanitation
equipment, fall protection, signage, grating, handrails, ect.

Start-up Map:
Once the systems are defined, they will be incorporated into a start-up map to show the
sequence that each system would need to be started up in.

Schedule:
Once the systems and start-up sequences are defined a check out, commissioning, and start-
up schedule will be developed. There will need to be main milestones indentified in
developing the schedule:
 Dates to start XXX
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 Dates to start XXX

 Dates to start XXX
 Dates for water run on sub system

System Checkout Books:

Each system and all check out activities that relate to the System Checkout Books are
kept in binders. The following are what are included in a binder. The person(s) that
are assigned to a system will be responsible for setting up the binders. Verification
between the instrument and equipment lists should be checked for accuracy while
assembling the books electronically, any discrepancy should be brought to the
attention of the project manager for that area. Electronic books will have the ability to
calculate percent complete and show graph. Each binder will have the following
dividers with tabs listed in the following order:

Commissioning SOP:
This will contain a copy of the Project Name Commissioning SOP. Within
this SOP, you will find the procedure of how to Commission new and/or
modified existing process equipment.

Process Narrative:
This will contain a copy of the Process Narrative. The Process Narrative will
show detailed information regarding General System Information, Operator
Interface, Process Control, Analog Instrument Ranges and Alarm Table,
Interlocks Checklist, and Graphics if available.

SOP:
This will contain a copy of the SOP. This SOP will contain the operating
parameters for the new and/or modified equipment being commissioned.

PSSR:

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This will contain the PSSR or Pre Start-up Safety Review form. The PSSR
contains a comprehensive checklist of safety related items that will be
reviewed, initialed, and dated. The PSSR will cover pre start –up safety
questions dealing with Process Hazard Analysis, Procedures, Training,
Equipment, Construction, Fire Protection, Safety Equipment, Materials
Handling, Instrumentation, DCS, and Sanitation. Checklist questions can be
answered by checking either Yes, No, or NA (non-applicable). All questions
that are answered No will be documented as a deficiency. Once the PSSR is
completed, document all deficiencies on the last page of the PSSR form
(PSSR Deficiency Summary Report). Finally, gather the “Review Approval”
signatures from the Department Superintendent, Commissioning
Superintendent, and Project Manager. The PSSR form must be completed
before equipment start-up.

Commissioning Deficiency Reports:

This will contain all Commissioning Deficiency Reports. Once you have
completed all deficiency reports, they will be stored here.

Equipment Program Sign-Off Sheet:

This will contain the Equipment Program Sign-Off Sheet. This sheet will
document that all spare parts have been identified, ordered, and put into the
CCN system. This sheet will also document that CCN parts tie back to the
ASAP system with detailed information. Checklist questions can be answered
by checking either Yes or No. All questions that are answered No will be
documented as a deficiency. Document all deficiencies on the last page of the
PSSR form (PSSR Deficiency Summary Report). Once checklist is
complete, collect final signature from Maintenance Team Leader. The
Equipment Sign-Off Sheet must be completed prior to equipment start-up.

Maintenance Program Sign-Off Sheet:

This will contain the Maintenance Program Sign-Off Sheet. This sheet will
document that a PM (preventive maintenance) program is in place. It also
ensures that the area around the new and/or modified equipment is safe and
accessible to perform maintenance work. Checklist questions can be answered
by checking either Yes or No. All questions that are answered No will be
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documented as a deficiency. Document all deficiencies on the last page of the

PSSR form (PSSR Deficiency Summary Report). Once checklist is complete,
collect final signature from Maintenance Team Leader. The Maintenance
Program Sign-Off Sheet must be completed prior to equipment start-up.

Non-Rotating Equipment:
This will contain the non-rotating equipment list (it also lists what type of
inspections is required). It will also contain all of the Equipment check sheets.
Each piece of equipment has a check sheet. The person in charge of the
system is responsible for checking the equipment list versus the P&ID for
correctness. If applicable, the Non-Rotating Equipment Sign-Off Sheet must
be completed prior to equipment start-up.

Rotating Equipment:
This will contain the rotating equipment list and all rotating equipment check
sheets. The mechanical group will be responsible for mechanical equipment
check out and may have a copy of the sheet for field checkout. Field sheet will
then need to be transferred into the binder by the people that did the checkout.
Rotating equipment will remain uncoupled and guard off until equipment is
commissioned to run, (coupling & coupling guard will be the permissive to
start the equipment). will The person in charge of the system is responsible
for checking the equipment list versus the P&ID for correctness. If applicable,
the Rotating Equipment Sign-Off Sheet must be completed prior to equipment
start-up.

Relief Devices:
This is a list of all relief devices. It is also a check off form. The person in
charge of the system will be responsible for checking the relief device list
versus the P&ID’s for correctness. If applicable, the Relief Devices Sign-Off
Sheet must be completed prior to equipment start-up.

Vendor Supplied Skid Unit Sign-Off Sheet:

This will contain the Vendor Supplied Skid Unit Sign-Off Sheet. It is also a
check off form. The person in charge of the system will be responsible for
checking off items on the list to ensure that Skid Unit is suitable for
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operation(s) and that all documentation is complete. If applicable, the Vendor

Supplied Skid Unit Sign-Off Sheet must be completed prior to equipment
start-up.

Motor Schedule Process Information Sign-Off Sheet

This will contain the Motor Schedule Process Information Sign-Off Sheet.
This checklist will capture all motor parameters such as MCC #, Description,
HP, Voltage, Phase, Wire Size, Fuse Size, Starter Size, and field inspection
information. This checklist will also show who validated those parameters. If
applicable, the Motor Schedule Process Information Sign-Off Sheet must be
completed prior to equipment start-up.

Motor Instrumentation Sign-Off Sheet:

This will contain the Motor Instrumentation Sign-Off Sheet. This checklist
will capture all motor instrumentation parameters such as MCC #,
Description, PCM #, Drop Card Points, and D3 Checkout. This checklist will
also show who validated those parameters. If applicable, the Motor
Instrumentation Sign-Off Sheet must be completed prior to equipment start-
up.

Reversible Motor Instrumentation Sign-Off Sheet:

This will contain the Motor Instrumentation Sign-Off Sheet. This checklist
will capture all motor instrumentation parameters such as MCC #,
Description, PCM #, Drop Card Points, and D3 Checkout. This checklist will
also show who validated those parameters. If applicable, the Motor
Instrumentation Sign-Off Sheet must be completed prior to equipment start-
up.

Flow Meters Sign-Off Sheet:

This will contain the Flow Meters Sign-Off Sheet. This checklist will capture
all flow meter parameters such as Tag #, Description, PCM #, Drop Card
Point, I/O Location, Field Data, I/O Room Checkout, and D3 Checkout. This
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checklist will also show who validated those parameters. If applicable, the
Flow Meters Sign-Off Sheet must be completed prior to equipment start-up.

Temperature Transmitters Sign-Off Sheet:

This will contain the Temperature Transmitters Sign-Off Sheet. This checklist
will capture all temperature transmitter parameters such as Tag #, Description,
PCM #, Drop Card Point, I/O Location, Field Data, I/O Room Checkout, and
D3 Checkout. This checklist will also show who validated those parameters. If
applicable, the Flow Meters Sign-Off Sheet must be completed prior to
equipment start-up.

Pressure Transmitters Sign-Off Sheet:

This will contain the Pressure Transmitters Sign-Off Sheet. This checklist will
capture all pressure transmitter parameters such as Tag #, Description, PCM #,
Drop Card Point, I/O Location, Field Data, I/O Room Checkout, and D3
Checkout. This checklist will also show who validated those parameters. If
applicable, the Pressure Transmitters Sign-Off Sheet must be completed prior
to equipment start-up.

Level Transmitters Sign-Off Sheet:

This will contain the Level Transmitters Sign-Off Sheet. This checklist will
capture all level transmitter parameters such as Tag #, Description, PCM #,
Drop Card Point, I/O Location, Field Data, I/O Room Checkout, and D3
Checkout. This checklist will also show who validated those parameters. If
applicable, the Level Transmitters Sign-Off Sheet must be completed prior to
equipment start-up.

Control Valve Input Sign-Off Sheet:

This will contain the Control Valve Input Sign-Off Sheet. This checklist will
capture all control valve input parameters such as Tag #, Description, PCM #,
Drop Card Point, I/O Location, Field Data, I/O Room Checkout, and D3
Checkout. This checklist will also show who validated those parameters. If
applicable, the Control Valve Input Sign-Off Sheet must be completed prior to
equipment start-up.

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Discrete Valve Input Sign-Off Sheet:

This will contain the Discrete Valve Input Sign-Off Sheet. This checklist will
capture all discrete valve input parameters such Tag #, Description, PCM #,
Drop Card Point, I/O Location, Field Data, I/O Room Checkout, and D3
Checkout. This checklist will also show who validated those parameters. If
applicable, the Discrete Valve Input Sign-Off Sheet must be completed prior
to equipment start-up.

Miscellaneous Analog Devices Sign-Off Sheet

This will contain the Miscellaneous Analog Devices Sign-Off Sheet. This
checklist will capture all miscellaneous analog device parameters such as Tag
#, Description, PCM #, Drop Card Point, I/O Location, Field Data, I/O Room
Checkout, and D3 Checkout. This checklist will also show who validated
those parameters. If applicable, the Miscellaneous Analog Devices Sign-Off
Sheet must be completed prior to equipment start-up.

Miscellaneous Digital Devices Sign-Off Sheet:

This will contain the Miscellaneous Digital Devices Sign-Off Sheet. This
checklist will capture all miscellaneous digital device parameters such as Tag
#, Description, PCM #, Drop Card Point, I/O Location, Field Data, I/O Room
Checkout, and D3 Checkout. This checklist will also show who validated
those parameters. If applicable, the Miscellaneous Digital Devices Sign-Off
Sheet must be completed prior to equipment start-up.

Drags Sign-Off Sheet:

This will contain the Drags Sign-Off Sheet. This Checklist will capture all
drag parameters such as Tag #, Description, Gear Box Checkout, and Drag
Conveyer Checkout. This checklist will also show who validated those
parameters. If applicable, the Drags Sign-Off Sheet must be completed prior
to equipment start-up.

Belt Conveyer Sign-Off Sheet:

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This will contain the Belt Conveyer Sign-Off Sheet. This Checklist will
capture all belt conveyor parameters such as Tag #, Description, Gear Box
Checkout, and Belt Conveyer Checkout. This checklist will also show who
validated those parameters. If applicable, the Belt Conveyer Sign-Off Sheet
must be completed prior to equipment start-up.

Screw Conveyer Sign-Off Sheet:

This will contain the Screw Conveyer Sign-Off Sheet. This Checklist will
capture all drag parameters such as Tag #, Description, Gear Box Checkout,
and Screw Conveyer Checkout. This checklist will also show who validated
those parameters. If applicable, the Screw Conveyer Sign-Off Sheet must be
completed prior to equipment start-up.

Manual Valve Sign-Off Sheet:

This will contain the Manual Valve Sign-Off Sheet. This Checklist will
capture all manual valve parameters such as Tag #, Description, and Manual
Valve Field Verifications. This checklist will also show who validated those
parameters. If applicable, the Manual Valve Sign-Off Sheet must be
completed prior to equipment start-up.

Heat Trace Sign-Off Sheet:

This will contain the Heat Trace Sign-Off Sheet. This checklist will capture
all heat trace parameters such as Plant Location, Panel #, Circuit #, Circuit
Breaker Amps, Temp Settings, and Pipe Size. This checklist will also show
who validated those parameters. If applicable, the Heat Trace Sign-Off Sheet
must be completed prior to equipment start-up.

Hydro Testing Sign-Off Sheet:

This will contain the Hydro Testing Sign-Off Sheet. This checklist will
capture all the piping Hydro testing completed for that area. The process for
this to be accomplished is outlined in a separate SOP. If any hydro testing
was done in the area then the SOP for this testing should also be attached
inside the checkout book along with this commissioning SOP.

Master P&ID’s:
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There needs to be (1) set of neatly unmarked P&ID’s in the binder that has all
the items in that system.

P&ID Worksheet:
This is where you will put the P&ID worksheet. As you perform you final
walk down, use a highlighter to check off the new and/or modified system
against the P&ID. We want to ensure that what is in the field matches what is
on the P&ID.
You can use any color of highlighter you choose for this task except for red. If
you come across anything in the field that does not match what is on the
P&ID, use a red marker to capture the on the P&ID. Capture all
“INFIELD”/P&ID mismatches as a deficiency.

Commissioners Responsibilities:

INSTRUMENT CHECK OUT

 Check out crew will be responsible for the check out of all valves (both control and
digital) in their area.
 During the line walk, air should be turned on to all valves
 If valves are fused, they can be checked during the walk through. The check should
encompass all aspects of the loop from field verification to the DCS graphics.
 Technicians are required to do the calibration on all control valves
 Technicians are required to check the fail position on all valves
 Technicians are required to open and close the valve and make sure it works as
planned
 Any problems with the valve should be listed on a valve checkout sheet in the field
notes section and logged into the PSSR Deficiency Summary Report.
 In addition, the valve should get a red dot attached, which makes it easier for the
Instrument technicians to find it. Be very specific regarding the problem and the
location on the valve check out sheet.
 All instruments and valves with a red dot, initialed and dated when they work
properly.
 Fail position on valves must be confirmed both electrically and pneumatically.
 Only people properly trained can do any final checkout!!
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E & I Checkout Flow

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EQUIPMENT
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 Needs to be clean.
 Internal inspections, visual inspections, etc.
 Piping needs to be blown clear with air, flushed with water, visually inspected or
some other means to verify we do not have junk in the system.

LEAK TESTING
 Need to do low pressure leak tests on all piping systems where applicable.

FILTERS
 If there is a filter in your system, you need to make sure the elements are installed.
 Filters in bag houses are also part of this.

TANKS
 On all tanks you need to make a note to pull manways after commissioning on water
to verify no junk has been flushed into the system.
 If you can verify that it is indeed in clean condition, you don’t have to open it.
 If we flush a bunch of stuff into vessels, we need to open the man ways prior to
introduction of water to make sure we have not flushed debris into the vessel.

VENDORS
 Identify all vendors that need to come on site.
 You will need to review your equipment and see if we have adequate vendor
representation.

BELT CONVEYERS
 There are several things you need to ensure that are in place before running a belt
conveyer.
 First check that the gear box is filled with correct type and amount of oil.
 Also check that the Breather Cap is installed and that gearbox is aligned.
 Check for rotation before motor is coupled.
 After rotation is verified, move on to check that the coupler is on and the all guards are
in place.

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 Next check that the greasers are in place, the conveyer belt is properly tensioned and
that the belt is properly tracking.
 Finally, check that all motion sensors and limit switches are working and in place.
 Purge belt conveyer to remove any debris that might be left over from installation.

SCREW CONVEYERS
 There are several things you need to ensure that are in place before running a screw
conveyer.
 First check that the gear box is filled with correct type and amount of oil.
 Also check that the Breather Cap is installed and that gearbox is aligned.
 Check for rotation before motor is coupled.
 After rotation is verified, move on to check that the coupler is on and the all guards are
in place.
 Next, check that the greasers are in place and that the hanger bearings are installed
correctly.
 Finally, check that all motion sensors and limit switches are working and in place.
 Purge screw conveyer to remove any debris that might be left over from installation.

DRAG CONVEYERS
 There are several things you need to ensure that are in place before running a drag
conveyer.

 First check that the gear box is filled with correct type and amount of oil.
 Also check that the Breather Cap is installed and that gearbox is aligned.
 Check for rotation before motor is coupled.
 After rotation is verified, move on to check that the coupler is on and the all guards are
in place.
 Next check that the greasers are in place, the drag chain is properly aligned, and that the
drag chain is properly tensioned.
 Finally, check that all motion sensors and limit switches are working and in place.
 Purge drag conveyer to remove any debris that might be left over from installation.

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pH PROBES
 You are responsible to note on the instrument check out sheets that we cannot install
the device until we are complete with water commissioning and we are ready to start-
up.

LEVEL SWITCHES
 We need to physically check the level switch to make sure it goes off before it hits the
overflow or the empty mark.
 This needs to be captured on the instrument check out sheet.

INSULATION
 Verify insulation with P&ID’s.
 Is the proper type and thickness installed?
 Is the outer covering in good shape, weather tight and have adequate bands

HEAT TRACING
 If there is heat tracing shown on your P&ID’s you need to make a note that it must be
functional and turned on. Need to identify devices that have heat tracing
 Verify the circuits are labeled
 Verify the circuits are operational and at set-point with no faults showing
 Verify Software installed and operational if required.

INSTRUMENTS
 Are physically located in the correct position and tagged accordingly. This is for
transmitters only – control valves, discrete valves and manual valves.
 Once a transmitter with I/O going back to the D3 has been verified in the field, you
must go to the Instrument check out sheet and sign “Field location verified”. This
gives the E/I persons permission to do the loop check. Panel wired, field wired and
air installed. E&I contractor should update this.
 Have correct flow direction
 Shipping stops removed [Control Valves]
 During the walk through, turn on the air to all control valves
 Flow Orifice Plates oriented correctly

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GAUGES
 Local Gauges: (The main intent is not to have a plant full of broken gauges. We will
install on an as needed basis)
 TI's will need to have wells.
 For TI’s with out wells, you are required to label the gauge “No Well”. This will need
to be logged in commissioning punch list data base

TI's WITH WELLS

 The Thermo wells will be installed by construction. If gauge is installed, verify the
well is also installed.

PI'S
 All gauges will have a supply valve. The valve will be installed by Construction.
Verify that the valve is installed. The P&ID’s do not indicate a root valve for all
gauges, so the P&ID’s will need to be marked up accordingly.
 The gauge will not be installed initially. These will be installed by operations as
required.
 The check out crew will plug the "Instrument Valves" as part of line walks.

RELIEF DEVICES: THERE ARE (2) ITEMS WE NEED TO CHECK ON RELIEF

DEVICES.
 Location and Correct Installation
 Correct Set Pressures
 These are columns in the Relief device check sheet (that will be issued to everyone as
part of the line walk). Once the criteria for these have been completed, Initial and
date the sheets.

PSV’s:
 Verify Correct Location
 Verify there is a seal attached

Protectoseal:
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 Verify the holders are installed in the correct position. (Typically and arrow is
installed)
 Verify the disks are installed correctly in the holders (Vent side is typically labeled )

PRV:
 Verify Correct Location
 Most of these devices have been installed with the packing supports installed.
 The access plates to the weights will have to be removed. Typically, the weights are
secured with a rubber band and a piece of cardboard is installed on the sealing seat
between the weights and the seat.
 Remove the weight assembly and verify no additional obstructions are located around
the inlet and outlet nozzles
 Correct Set Pressures
 Record all nameplate data:
 Be sure to accurately record all information and the appropriate units along with the
device tag number:

For PSV’s there could be:

 Model Number
 Set Pressure PSIG
 Cold Differential Set Pressure PSIG
 Relieving Temperature
 Orifice Size

For Protectoseal there could be:

 Burst Range (PSIG or in. w.c.)
 Burst Temperature
 Type
 Material of Construction
 Holder Model or Number

For Protectoseal valves there could be:

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 Model Number
 Pressure Set Point (in.w.c. or oz./sq. in.)
 Vacuum Set Point (in.w.c. or oz./sq. in.)
 Materials of Construction
 Compare the name-plate data to the Relief device Specification Sheet that is
maintained in the Relief Device Binder (Brian has in his area). Once all tag data has
been verified, the Correct Set Pressure Column can be initialed and filled out.

STRAINERS
 If strainers are listed on the rotating equipment list, they need to be verified in the
field. They also need to be pulled after water flushing. The pump sheet lists if a
strainer is required or not.
 Verify Direction
 Verify Strainer Elements have been installed

MCC’S
 Assign bucket #’s
 Order locks, apply color band, apply lock numbers, put on the bucket
 Verify single lines and elevations
 Verify motor HP
 Verify rotation
 Verify FLA
 I/O checkout

OTHER ELECTRICAL EQUIPMENT

 Lights and outlets properly labeled and functioning
 Panels properly labeled inside and out
 Transformers and other switchgear properly labeled.

INSPECTIONS

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 On the equipment list for your area, there is an indication of the type of inspection
required for each vessel. You are responsible to review this decision versus what is in
the field and make sure it is adequate. The main things we are looking for are:
 Vessel are internally clean
 Vessels with internals have the correct internal and they are tight, fastened, supported,
etc.
The goal is to minimize work, so if we can use a scope or do a visual from the man-
way, instead of going in, we will do this.

INTERNAL INSPECTIONS
 If you have an internal inspection in your area, you are required to :
 Do all paper work associated with entering a confined space.
 Identify any additional requirements and materials needed (i.e. blinds, gaskets, etc.)
 Take care of all aspects of entry (air movers, compressors, hoses, LEL monitors, etc.)
 Pull vessel drawings and inspect vessel versus fabrication drawings. (Also check that
the P&ID is correct )

SPECIAL SYSTEM CHECKS

 Any special system checks that have been identified, you will be responsible for
executing and developing procedures for execution.

VENDORS
 You are there full time escort the entire time they are here and responsible for them.
 If they need millwright, pipe fitting or electrical assistance, you will be responsible
for communicating these needs prior to the visit.

LABELING
 You are responsible for labeling your system. This needs to be neat, thorough and in
compliance with site standards.
 Equipment standard is Black lettering on White in a large print and applied in a
manner so it is able to be distiguished from every direction. It shall be marked with
the equipment number.
 Need to make sure all systems are completely labeled prior to turn over.
 Pipe marking standard is as follows.
Print Date

11/8/2023
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PROJECT NAME COMMISSIONING SOP

DEPARTMENT ORIGINATION DATE CURRENT REVISION DATE PAGE NUMBER
COMMISSION Page 20 of 24

PIPE MARKING GUIDE

Guide to the ANSI A13.1Standard for the Identification of Pipes

Material Properties Letter Color on Field Color

Hazardous liquid or gas Black on Yellow

Steam Black on Yellow
Condensate Black on Yellow
Chemical Black on Yellow
Hot Oil Black on Yellow
Natural Gas Black on Yellow
Non-hazardous liquid White on Green
Cooling Water Supply (CWS) White on Green
Cooling Water Return (CWR) White on Green
Nitrogen White on Green
Chilled H2O White on Green
Potable H2O White on Green
Air White on Blue
Fire H2O White on Red
Process Equipment Black on White

Outside Pipe Diameter Height of Label to use Height of lettering to use

including covering in inches in inches
in inches
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Less than ¾ NA NA
¾ to 1 ½ 1 ¾
Over 1 ½ to 6 2½ 2
Over 6 4 3½
All equipment 4 3½

PLACE MARKERS
 Near valves, flanges and changes in pipe direction
 At both sides of ceiling, wall or floor penetrations
 At any line entry point
 At frequent intervals on straight pipe runs (every 20 feet is typical)
 Locate pipe markers so they are visible from the point of normal approach
 Provide arrows at one or both ends of the label to indicate direction of flow

COMMISSIONING DEFICIENCY REPORT

During the process of commissioning, chances are you will encounter deficiencies of one sort
or another. The term deficiency is defined as “the quality or state of, being deficient or
inadequate”. With that being said, a new or modified system can not be given the “green
light” unless the following requirements are met:

 A System Checkout Book is made.

 All required components of the System Checkout Book is completed. All required
components are either to be filled in as “YES”, “NO”, or “NA”. If any of the required
Checkout Book components are answered “NO”, that would be a deficiency.
 All commissioning deficiencies will be hand written on the PSSR (Pre Start-up Safety
Review) form. The form is the last page of the PSSR. Deficiencies will be
documented as you find them. Never commit a deficiency to memory.
 All deficiencies must be assigned to an owner. The owner will usually be the
designated Checkout Book component approver.
 The deficiency will then be given a resolution due date that will be agreed upon by
the Commissioning Technician and the deficiency owner. If a resolution due date
cannot be agreed on, the Commissioning Superintendent will assign one.
 Once the above items are completed, you must get your final PSSR signatures from
the:
Print Date

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DEPARTMENT ORIGINATION DATE CURRENT REVISION DATE PAGE NUMBER
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1. Project Manager
2. Department Superintendent
3. Commissioning Superintendent
 After giving the new or modified system a “green light”, you can now create the
Commissioning Deficiency Report.
 To create the Commissioning Deficiency Report, please see the Commissioning
Deficiency Report SOP.

P&ID’S
 You are responsible to walk the system versus the P&ID worksheet. Any
discrepancies between what are in the P&ID and what is in the field needs to be
marked-up in red on your P&ID worksheet set in the binder. These need to be very
neat, in red using straight edges, etc.
 Get a copy of the most recent master P&ID’s.
 While walking down the system, take a colored highlighter (besides red) and
highlight the P&ID worksheet if what is “infield” matches what is shown in the
P&ID.
 Once you have identified any changes on the P&ID’s, document as a deficiency in the
PSSR (see PSSR question 4a.) and notify Brian Combs immediately to get these
captured on the AS-BUILT Prints. We want our final P&ID set to represent exactly
what is in the field.
 Follow the P&ID worksheet carefully.
 Do only one piece of equipment or line at a time. Do not criss-cross for convenience
 Mark deficiencies as you go . Do not try to develop a deficiency list based on
memory

WALK LINE VERSUS MASTER SET OF P&ID’S:

General Piping
 Flow direction of all bi-directional devices
 Correct size and fittings
 Valves
 Install all plugs for open-ended valves.
 Install plugs in open-ended nipples, ect…
Print Date

11/8/2023
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PROJECT NAME COMMISSIONING SOP

DEPARTMENT ORIGINATION DATE CURRENT REVISION DATE PAGE NUMBER
COMMISSION Page 23 of 24

 Type (Globe, Gate, ball etc.)

 Correct valve vs. pipe spec material code. [See reference document]
 Packing Gland in place [No adjustment]
 Open and close valve to ensure it operates
 Place Valves have locks affixed.
 Drain valves checked and plugs are installed
 Correct Gaskets installed.
 All flanges and bolts are tight. And flanges square [Visual only]
 Temporary supports removed (No wood, wire, etc.)
 Verify expansion joint rod supports are removed
Note: On large duct work that does not have a line number, we must pull the fabrication
drawings and look for plugs, etc. This is primarily on the evaporator systems.

SUPPORTING MATERIAL

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DEPARTMENT ORIGINATION DATE CURRENT REVISION DATE PAGE NUMBER
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Team Leader Approval: _____________________________________________ Date:________________

Department Supervisor Approval: _____________________________________ Date:________________

Print Date

11/8/2023