CONTROLLED DOCUMENT

TABLE OF CONTENTS

1. INTRODUCTION

1.1 Introduction

1.2 Document Management

1.3 Permitting

1.4 Project Description

1.5 Related Documents

2. DEFINITIONS

2.1 Terms Used in Document

2.2 Acceptance Criteria

3. SAFETY & RISK APPRAISAL

3.1 Restricted Area Plan

3.2 Safety & Risk Management

3.2.1 During Equipment & Mechanical Testing

3.2.2 During Process Commissioning

3.2.3 During Plant Operation

3.3 Commissioning Risk Appraisal

3.4 Emergency & Contingency Plan

4. CONTACTS AND ROLES

4.1 Commissioning Organization

4.2 Names and Contact Details

CONTROLLED DOCUMENT

5. PROGRAMME & ACTIVITY PLAN

5.1 Programme Narrative

5.2 Pre-commissioning and Commissioning Programme

6. E&M COMMISSIONING AND COMPLETION

6.1 Constraints on Commissioning

6.2 Interfaces

6.3 Checksheets for ITP Pre-Commissioning and Commissioning

6.3.1 Pre-commissioning Checklists

6.3.1.1 Pumps 6.3.1.2 Grit Classifiers 6.3.1.3 Screens 6.3.1.4 Air Blowers 6.3.1.5 Air Diffusers 6.3.1.6 Scum Skimmers 6.3.1.7 Metal pipe works 6.3.1.8 Plastic pipe works 6.3.1.9 Penstocks 6.3.1.10 Transformer 6.3.1.11 Generator Set 6.3.1.12 Switchgear 6.3.1.13 MCC 6.3.1.14 Panel Board 6.3.1.15 Sodium hypochlorite pumps and tanks 6.3.1.16 Polymer Preparation System 6.3.1.17 Mixers and thickeners 6.3.1.18 Filter Press 6.3.1.19 Air Compressor and Air Receivers 6.3.1.20 Lifting Appliances 6.3.1.21 Potable water pumps & tanks 6.3.1.22 Reuse water pumps and tanks 6.3.1.23 Odor Control Unit

CONTROLLED DOCUMENT

6.3.2 E&M System Commissioning & Acceptance Test (SCAT)

6.3.2.1 Phase 1 – Power Supply 6.3.2.1.1 Grounding System 6.3.2.1.2 34.5 kV Utility 6.3.2.1.3 Transformer 6.3.2.1.4 LV Switchgear 6.3.2.1.5 Motor Control Centre (MCC)

6.3.2.2 Phase 2 - Inlet Works 6.3.2.3 Phase 3 - SBR System 6.3.2.4 Phase 4 - Effluent and Chlorination Disinfection

System 6.3.2.5 Phase 5 - Thickening System 6.3.2.6 Phase 6 - Dewatering System 6.3.2.7 Phase 7 - Reuse Water System 6.3.2.8 Phase 8 - Potable Water System 6.3.2.9 Phase 9 - Deodorizing System 6.3.2.10 Phase 10 – Generator 6.3.2.11 Phase 11 – Building Services 6.3.2.12 Phase 12 - Lighting Protection 6.3.2.13 Phase 13 - SCADA Alarms

6.4 Commissioning Sequence and Start Up Methodology

6.4.1 Phase 1 – Power Supply 6.4.1.1 Grounding System 6.4.1.2 34.5 kV Utility 6.4.1.3 Transformer 6.4.1.4 LV Switchgear 6.4.1.5 Motor Control Centre (MCC)

6.4.2 Phase 2 - Inlet Works 6.4.3 Phase 3 – SBR System 6.4.4 Phase 4 – Effluent and Chlorination Disinfection System 6.4.5 Phase 5 – Thickening System 6.4.6 Phase 6 – Dewatering System 6.4.7 Phase 7 – Reuse Water System 6.4.8 Phase 8 – Potable Water System 6.4.9 Phase 9 - Deodorizing System 6.4.10 Phase 10 – Generator 6.4.11 Phase 11 – Building Services 6.4.12 Phase 12 – Lighting Protection 6.4.13 Phase 13 – SCADA Alarms 6.4.14 Phase 14 – Full plant operation at 75 MLD

CONTROLLED DOCUMENT

7. PROCESS COMMISSIONING

7.1 Maintenance for off-line system (assuming all installed)

7.2 How to bring additional process tanks/ systems on-line

8. TRAINING PLAN

8.1 Process

8.2 E&M

APPENDICES

Appendix 1 IFC/As-built Drawings Appendix 2 Permits Appendix 3 Inspection & Testing Plan Appendix 4 Restricted Area Plan Appendix 5 JV’s Commissioning Organization Appendix 6 Pre-commissioning & Commissioning Programme Appendix 7 Testing and Commissioning Forms Appendix 8 Process Commissioning Plan Appendix 9 TNSTP Training Plan

CONTROLLED DOCUMENT

1. INTRODUCTION

1.1 Introduction

This document is the commissioning plan for the STP, a sewage treatment plant

providing sewage treatment to dedicated sewage collected from Taguig and Makati.

The purpose and objective of the Commissioning plan is to set out the procedures

by which the plant shall be tested and commissioned for all equipment, systems, and

the process.

This plan introduces the plant and equipment, defines terms, presents a safety and

risk appraisal, introduces the team and their roles, gives a program and activity plan,

sets out the commissioning procedures and documentation for each equipment and

system, and the process, and gives a training plan for training of Client’s personnel

in the equipment and process operation.

1.2 Management of the document

The Commissioning Plan is a live document and the master copy shall be

maintained and updated on site with a back-up copy retained in the partner

contractor’s office or another alternative location. It is produced concurrently with the

production of the O&M Manual, as many of the documents and activities are

common.

A copy of all permits related to the commissioning, shall be provided in the Appendix

2 of this document. Where permits are not available prior to commissioning, they

shall be provided and inserted as soon as they become available.

The plan sets out required documentation for the testing of each equipment and

system, and the process proving. Sample forms for each type of documentation are

included in this Commissioning Plan and provided in Appendix 7. Completed test

and log documents shall form auxiliary volumes.

CONTROLLED DOCUMENT

Drawings to be referred to during commissioning shall be listed in the plan and

provided in Appendix 1 and the designer should confirm that the drawings listed are

the most updated versions (either IFC or As-built) and are the correct versions for

reference.

1.3 Permitting

The following permits are required prior to or relating to the commissioning:

a.) Fire Protection

b.) Mechanical

1.) Permit to Operate Generator Sets (PTO)

c.) Electrical

1.) Meralco Permit Application

2.) Certificate of Electrical Inspection

3.) Energization Permit

d.) Environmental Permit

1.) Discharge Permit

The Discharge Permit is a permit applied for from Laguna Lake Development

Authority (LLDA) and permits the plant to discharge effluent to the receiving

water body. The Permit is applied for when the STP is ready to commence

operation, with the target date for testing of effluent compliance with

discharge standards. Following completion of the process commissioning,

inspectors from LLDA will take sample from the effluent of the STP to test for

compliance. Following testing for compliance, the discharge permit will be

issued. Quarterly reporting to LLDA on the plant performance, following

format specified by LLDA will be implemented following receipt of discharge

permit.

CONTROLLED DOCUMENT

2.) Sanitary Permit

3.) Hazwaste Disposal

4.) Emission(for Genset) from DENR

1.4 Project Description

The Sewage Treatment Plant (LKK-TNSTP) is an underground Sequencing Batch

Reactor type Sewage Treatment Facility designed to treat up to MLD of sewage

coming from the North Catchments.

Details of the process design are provided in the approved Process Design

Document with reference no.

The STP comprises of influent pumping, screening and grit and grease removal,

SBR basins for biological activated sludge treatment, chlorination disinfection, and

sludge handling and filter press sludge dewatering. Odor control facilities are

provided.

Process Flow Schematic (please also refer to Appendix 3).

A detailed process description is provided in Section 8 Process Commissioning, with

simple description as follows:

INFLUENT RECEIPT

Raw sewage enters the STP from two sources: a pressure main, which receives

up to 70 MLD average dry weather flow per day, and a gravity flow to an on-site

sump, which will receive up to 5 MLD average dry weather flow per day and the

site returns.

CONTROLLED DOCUMENT

PRELIMINARY TREATMENT

Removes debris and grit prior to entering the biological process. Comprises of

coarse and fine screening, with three sets of parallel screens (2 duty and 1

standby at design flow) and grit removal in three grit and grease chambers, again

with 2 duty and 1 standby unit at design flow.

SECONDARY TREATMENT

Uses activated sludge Sequencing Batch Reactor to removes degradable

organics and nutrients. Organics are converted to biomass, carbon dioxide and

water. Biomass is settled and treated effluent is discharged.

DISINFECTION

Uses sodium hypochlorite (NaOcl) disinfection to reduce colliforms in the treated

effluent.

SLUDGE TREATMENT

Sludge is thickened and dewatered using sludge thickeners and filter press.

Polymer is dosed during both thickening and dewatering to enhance the

thickening and dewatering processes.

The treated effluent is discharged into the adjacent creek.

1.5 Related Documents

The commissioning plan makes reference to the following drawings and

documents.

CONTROLLED DOCUMENT

Single Line Diagram for MCC-2 E-WW-MP-TG-10-003a-4000-E005-2 E

Single Line Diagram for MCC-2 E-WW-MP-TG-10-003a-4000-E005-3 E

Single Line Diagram for Socket E-WW-MP-TG-10-003a-4000-E004-2 B Outlet Maintenance Panel Single Line Diagram E-WW-MP-TG-10-003a-4000-E002-1 E MV Switchgear

Document Schedule:

Document

Inlet Works

Drawing Nos.

E-WW-MP-TG-10-003a-4000-P003-2

Rev.

F

SBR System E-WW-MP-TG-10-003a-4000-P003-3 F

Effluent & Chlorination

Disinfection System E-WW-MP-TG-10-003a-4000-P003-4 F

Thickening System E-WW-MP-TG-10-003a-4000-P003-5 F

Dewatering System E-WW-MP-TG-10-003a-4000-P003-6 F

Reuse Water System E-WW-MP-TG-10-003a-4000-P003-7 F

Single Line Diagram for LV

Switchgear Room E-WW-MP-TG-10-003a-4000-E004-1 E

Single Line Diagram for

MCC-1 E-WW-MP-TG-10-003a-4000-E005-1 E

CONTROLLED DOCUMENT

2. DEFINITIONS

2.1 Terms Used in Document

Pre-commissioning Carry out all tests checks, and inspections on

individual plant systems and equipment prior to plant

operation.

Commissioning Design, planning and application of activities required

to bring an item of plant or process into full operation

and provide adequate support and training to the end

user to safely run it.

FAT Factory Acceptance Test

P&ID Process and Instrumentation Diagram

Handover The transfer of ownership and responsibility for the

operation and maintenance from the Contractor to the

end user.

SCADA System Control and Data Acquisition

MCC Motor Control Centers

Functional Tests Test used to measure all individual components of the

plant are ready for operation in accordance to the

product specification and Contract requirements.

Trial Operation Test used to demonstrate the quality of the functions

of the system and satisfactory operation of the Plant.

It shall be run for a continuous period of 28 days.

CONTROLLED DOCUMENT

2.2 Acceptance Criteria

The JV shall monitor plant performance and ensure that it meet the the quality

standards defined in the Contract Performance Specification. Such shall be

documented and included in the Contractor’s report. If the plant fails to meet any

of the Performance requirement for plant reliability, functionality and hydraulic

performance, the JV shall undertake necessary measures for improvement.

See attached Appendix 3. “Inspection & Test Plan”

3. SAFETY AND RISK APPRAISAL

3.1 Restricted Area Plan

See attached Appendix 4. “Restricted Area Plan”

3.2 Safety and Risk Management

This section applies for the management of HSE at Sewage Treatment Plant

throughout the Testing and Commissioning process and eventually the process

proving. The Safety Officer is responsible for the proper implementation of HSE

throughout the commissioning process. The preparation and improvement of the

safety plan, identification of hazards and its controls.

CONTROLLED DOCUMENT

All personnel involved on the Testing and Commissioning works shall undergo

Safety Training / Induction

Safety Trainings

Safety Training / Induction shall include the following topics, but not limited to:

– Brief description of the Sewage Treatment Plant

– Safety features of the plant

• Gas detectors and alarms

• Fire fighting equipment

• Emergency exits, assembly area and routes

• Emergency back-up system

– Chemicals used in the plant and chemical safety

– Frequency of trainings

– Required Personal Protective Equipment per area

– Area Zoning and Restricted Access

– Signage and Warning Signs

– Plant Facilities

– Safety Rules and Regulations and Permit to Work System

– Key Personnel and Organizational Chart

All personnel involved in the Testing and Commissioning Works shall undergo the Safety Training / Induction before commencing work on site

Client and visiting personnel shall undertake a Safety Briefing and be escorted at all times while visting the plant

All personnel, client representatives and visitors shall have their attendance at the Project Induction Program recorded in the Safety Training Attendance and shall be kept by the Safety Officer for safekeeping

CONTROLLED DOCUMENT

Permit to Work System

Permit to work has been established to maintain control of hazardous work being

carried out on the worksite and to ensure that all necessary safety precautions

are carried out. It should be noted that a work permit does not guarantee safety;

an accident can occur at any time and safety rules must be always followed.

It identifies conditions and limits potentially harmful effects on the person carrying

out the work by specifying safety precautions to be followed during work activity.

It gives a comprehensive and detailed record of all ongoing work, control of the

work situation and avoids conflicting or incompatible work being carried out

simultaneously.

Safe Work Permits shall be issued for the following activities:

- Hot Works

- Cold Works

- Lifting Operation

- Confined Space Entry

- Excavation Works

- Electrical Works

- Energizing / Isolation / Lock Out Tag Out

STARRT card shall also be utilized in conjunction with the above mentioned Safe

Work Permits

Personal Protective Equipment

PPE means all equipment and clothing which is intended to be worn or held by a

person at work and which affords protection against one or more risks to health

or safety. This includes clothing designed to protect against adverse weather

conditions.

CONTROLLED DOCUMENT

Protective clothing includes - for example - gloves, safety shoes, safety helmets

and high visibility jackets. Protective equipment includes eye protectors, safety

harness, and respirators.

As a minimum, all Testing and Commissioning operatives must wear safety

helmet and safety shoes.

As per area requirements or as per Risk Assessment other items may be

required (refer to PPE requirement table)

The Risk Assessment will take account of:

The PPE - is appropriate for the risk(s) involved and the conditions at the place

where exposure may arise;

Takes ergonomic considerations into account, be capable of being fitted to (and

used by) that employee where applicable;

So far as is practicable, prevent or adequately control the risk of exposure

without increasing the overall risk;

Is designed and manufactured to an approved standard.

Where more than one sort of PPE has to be used simultaneously, each must be

compatible with the other and full effectiveness must be maintained.

PPE must be maintained by the user - e.g. cleaned, repaired or replaced - in an

efficient state.

Suitable storage arrangements should be made to prevent damage to the PPE,

including that which has already been issued.

CONTROLLED DOCUMENT

PPE INSPECTION

It is the responsibility of the PPE user to carry out a visual inspection and

functional check (if applicable) prior to every use. General inspection shall be

done every three (3) months to be conducted by Safety Officer. If any PPE is

defective or damaged, it must be immediately reported to Safety Officer to

assess and for replacement as necessary.

CONTROLLED DOCUMENT

Waste Management

Joint Venture are committed to implement the project environmental plan so that it is

effective, accurate and economical and ensure that the procedures put into place are

working and are maintained. This is to ensure that all waste materials are:

• Reduced, reused and recycled as far as possible;

• Properly categorized for correct collection, storage, handling, treatment and

disposal;

• Traceable from production source through to final disposal.

Restricted Areas

Sewage Treatment Plant Facilities shall have restricted access particularly in areas

where hazard criteria based from risk assessment would fall from medium to high.

Special training including PPE is required prior to entry to such areas with restrictions.

Primarily, the entire Sewage Treatment Plant shall be an all restricted area.

Visitors shall only be allowed on two (2) locations, one is the visitors parking area and

the other one is the admin area. Visitors can only access restricted area given the

following conditions:

- They have an appointment with the plant management with at least two (2)

working days advance notice

- They have undergone the required safety briefing conducted by authorized

personnel

- They are equipped with the appropriate PPE

- They are accompanied by a duly authorized plant representative

Visitors shall only be allowed on certain restricted areas even with the presence of all

the above mentioned requirements since special trainings shall be required for further

access on highly restricted areas

CONTROLLED DOCUMENT

Emergency Response Procedure

Required Emergency Response Procedures shall be defined and developed by

the Testing and Commissioning and Design team.

Emergency Escape Routes and Emergency Devices

Emergency escape routes together with emergency contact numbers and contact

persons shall be verified and made available during the commissioning works.

For the initial layout of emergency devices, refer to appendix **

DEFINITIONS AND PROVISIONS

HAZARDOUS LOCATION

The National Electrical Code (NEC) defines hazardous locations as those areas

"where fire or explosion hazards may exist due to flammable gases or vapors,

flammable liquids, combustible dust, or ignitable fibers or flyings."

HAZARDOUS WORKPLACES

OCCUPATIONAL SAFETY AND HEALTH STANDARDS

(As Amended, 2006)

Department of Labor & Employment Philippines

RULE 1010

OTHER SAFETY RULES

1013: Hazardous Workplaces:

For purposes of this Standards, the following are considered "hazardous

workplaces:"

a. Where the nature of work exposes the workers to dangerous environmental

elements, contaminants or work conditions including ionizing radiation,

chemicals, fire, flammable substances, noxious components and the like;

b. Where the workers are engaged in construction work, logging, fire fighting,

mining, quarrying, blasting, stevedoring, dock work, deep-sea fishing and

mechanized farming;

CONTROLLED DOCUMENT

c. Where the workers are engaged in the manufacture or handling of explosives

and other pyrotechnic

products;

d. Where the workers use or are exposed to power driven or explosive powder

actuated tools;

e. Where the workers are exposed to biologic agents such as bacteria, fungi,

viruses, protozoas, nematodes, and other parasites.

CONTROLLED DOCUMENT

3.3 Commissioning Risk Appraisal

The principal risks associated with Commissioning of the STP have been assessed

and included into HAZCOM study assessment. The outcome of these risks during

commissioning should be recorded and included in O&M Manuals. Information

should be provided on risk to health and safety, preventative measures and

emergency procedures associated in Commissioning.

The principal risk associated with the Testing and Commissioning of the STP have been assessed to be

the following:

CAUSE EFFECT RISK LEVEL & MITIGATION

Handling and Spillage of

Chemicals

� Environmental Hazard (soil,

water and air pollution)

� Chemical reaction and

contamination

� Skin contact / irritation

� Respiratory irritation

� Ingestion

Medium

- Provide PPE for handling of

chemicals

• Safety eye goggles

• Chemical Gloves

• Chemical Respirators &

Breathing Apparatus

• Apron

• Safety Shoes / Boots

- Provide chemical spill cleanup

kit and cleanup procedure

training

- All liquid chemical containers

and tanks should be contained

within a bunded area

- Check proper storage of

chemicals to avoid cross

contamination and reaction

- Check storage area for

sufficient ventilation

- Provide MSDS of all chemicals

present

- Provide training for chemical

handling and storage

- Provide safety eye wash and

shower station

- Provide first aid kit

Electrical � Electrocution resulting to Medium

CONTROLLED DOCUMENT

- Extension leads

- Faulty wiring / grounding

- Arcing

personnel injury or death

� Equipment damage

- All electrical and control

equipments including but not

limited to wires and cables

should be checked and punch

listed prior to testing

- Check all grounding / earthing

systems

- Check all connections,

isolations and fail safe devices

prior to testing

- PTWS and LOTO

- Area restriction to authorized

personnel only

Equipment damage due to:

- Misuse

- Factory defect / Malfunction

� Equipment damage

� Personnel injury

Medium

- All equipments should be

checked and punch listed prior

to initial testing

- Only trained personnel should

be involved in the

commissioning, testing and

operation of equipments

- Testing and commissioning

procedure should be in

accordance with the O&M

manuals and all submitted

documentation

Falls from elevated level /

reservoir due to:

- Slips

- Trips

- Unprotected / barricaded

levels and floor openings

� Personnel injury / Death

� Drowning

Low

- All walkways, aisles, stairways

and catwalks should be clear

from debris, water, oil and

grease

- Ramps or catwalk with non-slip

surface should be installed on

walkways with pipes crossing

- Permanent railings complete

with top rails, mid rails and toe

boards should be installed

prior testing and commissioning

works. In any cases where work

should be done outside such

barriers, fall protection system

should be used

- Life vest should be used in

addition with fall protection

system when working outside

the safety barrier particularly

on the SBR and holding tanks

CONTROLLED DOCUMENT

- Indicate emergency shutdown

button / call point

- Area restriction to authorized

personnel only

Excessive Noise � Hearing Damage Low

- Provide suitable hearing

protection (ear plugs / ear

muffs)

- Provide demarcation for sound

level around genset room

Moving vehicles / Traffic � Vehicular collision resulting to

property damage

� Pedestrian struck by moving

vehicles resulting to injury

Low

- Provide traffic man if necessary

- Indicate traffic route inside

plant area

- Provide pedestrian lines and

safety bollards

- Specify parking, waiting/stand

by and loading area

CONTROLLED DOCUMENT

4. CONTACTS AND ROLES

4.1 Commissioning Organization

See attached Appendix 5. “JV’s Commissioning Organization”

4.2 Names and Contact Details

NAME COMPANY POSITION PHONE NUMBER

Commissioning Director 0917-55806xx

Project Manager 0917-59278xx

Head, Testing & Commissioning

Electro-Mechanical

0917-59585xx

Instrumentation & Control

Engineer

0908-59412xx

Head, Testing & Commissioning

Building Services Manager

0949-95949xx

Head, Process Commissioning 0917-79113xx

Commissioning Co-ordination

Manager

0917-80806xx

Head, Commissioning Safety 0932-84804xx

Process Engineer 0917-81071xx

CONTROLLED DOCUMENT

NAME

COMPANY

POSITION

PHONE NUMBER

Control & Instrumentation

Supervisor

0917-53953xx

Head of Mechanical (Testing &

Commissioning)

0915-13347xx

Mechanical Commissioning

Supervisor, Auxillary

0915-68977xx

Mechanical Engineer, SBR &

Auxilliary

0915-61830xx

Mechanical Commissioning

Supervisor, SBR

0919-22084xx

Scheduler/Planner 0932-84819xx

CONTROLLED DOCUMENT

Commissioning Team Terms of Reference

CONTROLLED DOCUMENT

Commissioning Director

- Overall-in-charge of the testing and commissioning.

- Develop overall project planning, master program on testing and commissioning.

- Single point of contact to JV member, consultant, client, suppliers and

subcontractors.

- Act as JV Representative in project meetings with consultants and clients.

- To chair all the internal project team meetings.

- Ensure development of the quality culture on site by delivering training to internal

staff.

Project Manager

- Monitor the performance of the Quality Management Systems to comply with the

JEC Quality Procedures.

- Responsible for the deployment of suitable project team member and facilities.

- Develop and maintain the project organization chart for commissioning phases.

- Delegation of work to each project team member (including JV member).

- To maintain the integrity of the project team (including JV member).

- To seek resources to solve technical, commercial and contractual issues.

- Manage and control resources, cost and time.

- To arrange all necessary reports to clients.

- To arrange all commissioning reports and analysis to Commissioning Director.

- To report project risk and propose mitigation measures to Commissioning

Director.

- Oversee project administration, procurement, sub-letting and document control.

Commissioning Coordination Manager

- Liaison between installation and commissioning stages.

- Liaison between construction and safety / environmental.

- Attending all testing and commissioning co-ordination meetings.

- Assisting in the preparation of the 2 week lookahead programmes. - Advising on any proposed actions which require input from design and

construction activities. - Assisting the Project Manager in co-ordination of site activities. - Preparation and input into Progress Reporting on Commissioning. - Informing the project manager on all relevant aspects of construction works in

terms of planning, progress, quality, safety and subcontractor performance

CONTROLLED DOCUMENT

Head of Testing & Commissioning (Electro-mechanical)

- Liaise with external suppliers and client to ensure that the Quality Management

System is compliant with contract requirements.

- Assist in the conduct of Supplier Evaluation activities, including auditing and

document vetting.

- Design, implement & maintain the quality assurance program audit for ISO

compliance.

- Ensure corrective Reports are submitted after each audit and followed up for

implementation and compliance.

- Ensuring project execution in accordance with the project quality control plan and

quality requirements in the contract.

- Execution of testing and commissioning activities.

- Ensure the optimization and operation of subcontractors bespoke process plant

and all associated proprietary equipment such as control systems, instruments,

valves and pumps etc at various sites.

- The ability and willingness to undertake ‘hands on’ work whenever necessary.

- Compilation of detailed formal site reports and other documentation to support JV

activities including office administration forms such as timesheets, expenses, risk

assessments etc.

- When necessary and practical provide support to clients by e-mail or telephone.

- Multi skilled installation, commissioning and troubleshooting of all associated

proprietary equipment such as control systems, instruments, valves and pumps.

Head of Testing & Commissioning (Building Services)

- Resolving structural/civil matters concerning project execution, planning and site

queries in cooperation with the project team.

- The ability to supervise and manage other personnel with regards to building

services.

- Person-in-charge with the fire fighting and building services.

- When necessary and practical provide support to colleagues in relation to

general project work etc.

- Operate at all times within the guidelines of the company’s and clients

procedures regarding quality, health, safety and environmental issues.

CONTROLLED DOCUMENT

- Undertake office based activities as necessary, including but not limited to

preparation of O&M manuals, commercial proposals and technical advice to

clients and colleagues.

- Be aware and take account of commercial and contractual issues in relation to

project timescales and budgets etc. concerning building services.

Head of Testing & Commissioning (Process)

- Liaise with client to develop solutions to requirements of process commissioning.

- Person-in-charge in the preparation and updating of process commissioning

plan.

- Be a technical point of contact both internally and externally when it comes to

process commissioning.

- Liaising with other departments within the JV Commissioning team.

- Undertake both formal ‘classroom’ and ‘hands on’ training of client’s personnel

and prepare appropriate training documentation whenever required.

Process Engineer

- Concept and development of the process design and commissioning.

- Working within a team to ensure co-ordination of the testing and commissioning.

- Liaise with construction team, and other JV Design team members to ensure

feasibility of the design.

- The multi skilled installation, commissioning and troubleshooting of the JV

process plant.

Electrical Commissioning Supervisor

- Concept and development of the testing and commissioning of electrical

components.

- Liaising with other trades within the JV Commissioning Organization.

- Liaise with construction team to ensure feasibility of the electrical design.

- Be a technical point of contact both internally and externally in regards with

electrical commissioning.

Mechanical Commissioning Supervisor

CONTROLLED DOCUMENT

- Concept and development of the testing and commissioning of mechanical

components.

- Liaising with other trades within the JV Commissioning Organization.

- Liaise with construction team to ensure feasibility of the mechanical design.

- Be a technical point of contact both internally and externally in regards with

mechanical commissioning.

Scheduler/Planner

- Determining critical / key logic when producing commissioning programme.

- Producing and sending out testing and commissioning progress up-dates weekly.

- Determining site loading to suit programme demands and staff/resource levels to

suit programme requirements.

- Prepare all programmes as required by the commissioning team.

- Attending progress meeting with the client.

- Providing current position reports for board level presentations by the

Commissioning Director.

Commissioning Safety Head

- Responsible of overall project safety.

- Prepare and up-date commissioning safety plan.

- Prepare risk assessments for all site activities and review sub-contractor method

statement and risk assessments.

- Carry out weekly project safety audits.

- Provide safety training for site staff and operatives prior to testing and

commissioning.

- Provide briefings for operative toolbox talks.

- Prepare weekly, monthly safety reports

- Monitor and control testing and commissioning safety.

CONTROLLED DOCUMENT

5. PROGRAMME AND ACTIVITY PLAN

5.1 Programme Narrative

The interrelationship between and sequence of events for testing and

commissioning activities are schematically set out in Figure 1, and are defined in

Section 2.

Figure 1: Testing and Commissioning Activities

Commissioning has two distinct phases, separated by the introduction of

sewage. Prior to the introduction of sewage all testing shall be of individual

systems and shall be dry or wet testing with clean water.

Following the completion of individual systems testing, the system shall be

seeded with sludge (biomass) and sewage shall be introduced to the plant. The

commissioning activities shall be focused on systems integration testing and

process biological start-up and stabilization. Following process establishment,

the 28 day trial operation shall commence to demonstrate the process

performance. Successful completion of Trial Operation shall be followed by the

process proving period.

Phase Pre-

Commissioning

Trial operation Process proving

period

Installation checks Dry tests West tests Functional tests Process establishment 28 day test 2 year period

Visual inspections Rotation/electrical

checks

Pumps run on clean

water

Interaction of plant Seed sludge introduced No modifications to

operation of plant

Detailed monitoring

periods within this time

Check interlinks of

equipment work

Software checking Feed with sewage,adjust,

calibrate, generally settle

plant and build biology to

correct operating

position.

Inputs only as the

allowable levels in the

operation and

maintenance manual

Calibration - of

whatever can be

calibrated

Monitor and adjust until

effluent parameters

achieved

Influent Sewage

Characterisation Study

Operating

Commissioning

All relevant permits need to

be in place - effluent

discharge commences

Ha

nd

ov

er

Ind

ica

tive

act

ivit

ies

Intr

od

uce

wa

ter

Intr

od

uce

se

wa

ge

Live flow present to be managed

CONTROLLED DOCUMENT

The testing and commissioning activities shown in the pre-commissioning and

commissioning program prior to the introduction of sewage are categorized by

systems, i.e. inlet work, each SBR, air blower for SBR, effluent disinfection &

reuse water system, sludge thickening & dewatering system, deodorization

system, power system, process start up, trial operation and the other services.

For each system in the program, the appropriate activities, such as the pipework

hydraulic test, air pipework pneumatic test, electrical cable insulation test,

instrumentation and control cable insulation test, equipment functional test, pump

functional test, switchgear test, etc., will be indicated.

The schedules of the testing activities are staggered for reasonable manpower

arrangement of testing and inspection.

Pre-commissioning will be conducted before the commissioning for each system.

However, there may be both pre-commissioning and commissioning activities

ongoing for different systems at the same time. Each activity shown in the

program includes pre-commissioning and commissioning.

Before the permanent power on, i.e. end January 2013, those tests not requiring

permanent power such as the pipework hydraulic test, air pipework pneumatic

test, electrical, instrumentation and control cable insulation test will be

conducted. Testing will commence from mid Dec 2012.

After the completion of testing of transformer, MV switchgear and LV switchgear,

the permanent power supply will be switched on. i.e. end Feb 2013, by Meracle.

Following the permanent power supply being on, the clean water functional test

of equipment and pumps, SCADA and the other services, as appropriate, will be

conducted. For the MLR pumps, WAS pumps, effluent pumps and the other

pumps, clean water will be filled in for functional tests. The dates of clean water

filling in shall be referred to the program.

Once the tests of pipework, cables and equipment of inlet work, SBR no. 2, 3, 4,

6, 7 and 8, blowers, effluent system and deodorization system are finished, the

process start up will commence, i.e. mid Feb 2013, with the seeding of the target

operational SBR basins with biomass (activated sludge from other STP), and the

acceptance of influent sewage.

CONTROLLED DOCUMENT

For the influent flow of 51 MLD only 6 SBRs are required for process start up.

These basins will be seeded and the process startup, as detailed in Section 7

(Process Commissioning) shall be followed.

The process start-up is estimated to take 15 days, and the initial tests and

systems integration will be completed during this time, which shall be early March

2013. A four (4) day influent sewage characterization shall also be performance

once a consistent inflow of sewage to the STP has been established.

Following process startup and when the process is stable and producing

consistent effluent quality meeting the required discharge standards, the 28 days

trial operation will commence.

51MLD incoming sewage is assumed to be received for the process start up and

trial operation.

The disinfection system, reuse water system and deodorization systems will be

tested during the process start-up, i.e. early March 2013.

The sludge thickening & dewatering system will be process commissioned when

there is sufficient sludge available from the process. This may be during the 28

day trial operation, or later, depending on the loading to the STP.

For the building services and the lifting appliances, the tests will be completed

before construction completion milestone date, i.e. 3 April 2013.

CONTROLLED DOCUMENT

6. E&M COMMISSIONING AND COMPLETION

6.1 Constraints on Commissioning

The main constraints on commissioning shall be identified by JV at a later part of

Installation works.

6.2 Interfaces

The interfaces with each discipline (Electrical, Mechanical, Process,

Instrumentation and Control) will be required. The Commissioning Co-ordinator

shall be responsible for the co-ordination of the works to be carried out during

testing and commissioning.

As the Commissioning stage progresses, the operating parameters may require

adjustment and where modifications are required, the JV shall liaise closely with

all parties involved to secure an agreed course of action.

CONTROLLED DOCUMENT

7. CHECKSHEETS FOR ITP PRE-COMMISSIONING AND

COMMISSIONING

These check lists showing the check points be submitted for information as a

complete package. The individual check lists items will be inspected and signed

off by the JV and where appropriate, and requested by a Work Inspection Report,

the Engineer as the pre-commissioning and commissioning is carried out. The

master file of the completed and partially completed check lists will be maintained

and controlled by the JV. Once any given checklist is fully complete, it will be

submitted to the Engineer for final signature and the option is available for the

signature of the Client also as an indication of a review of the check list form. The

signed form shall be returned to the Contractor. On completion of the Trial

Operation and Reliability Tests a copy of all the completed check lists will be

submitted as part of the Commissioning Report along with the test data and

operational conditions during the Take-Over.

7.1 Pre-Commissioning Checklists

In this section, JV shall provide all records and tests carried out in preparation for

the pre-commissioning works.

The following should be included:

1. CABLE TEST SCHEDULE – this needs to demonstrate that all cables have

been tested and checked to confirm that cables are correctly connected to the

correct terminals and / or drives.

2. PLANT TEST AND DETAILS – this needs to demonstrate that plant is

correctly set up and is safe to commission.

CONTROLLED DOCUMENT

3. CIVIL WORK TESTS – this needs to demonstrate that the structure have

been properly constructed and tested, all connections in place and is safe to

commission. All results to be recorded in this section of the commissioning

plan.

Tests should include:

• Pipeline pressure tests

• Water retaining structure tests

• Certificates of tests for tank cover materials

4. Test Certificates for permanently installed monitoring equipment such as Gas

Detection Systems – to be placed in O&M manual.

5. Test to be carried out on lifting equipment, davit posts and pressure vessels,

tests to be recorded and certificates placed in O&M manual.

6. PRESSURE TESTING – details of sources of water for commissioning to be

recorded in plan and confirmation of agreements with both parties for use of

water for testing and method of disposal after testing.

See attached Appendix 7 “Testing and Commissioning Forms”.

7.2 E&M System Commissioning & Acceptance Test (SCAT)

In this section, JV shall provide all records and tests carried out during the

commissioning works.

CONTROLLED DOCUMENT

7.3 Electrical & Mechanical Commissioning Sequence and

Start Up Methodology

Each system will be dry and wet tested as part of the functional tests prior to

overall process commissioning. All structures should be demonstrated to be free

of leakage or excessive cracking or any other indications of potential structural or

service failure during commissioning. Checklists for the pre-commissioning and

commissioning of elements and systems are to be enumerated.

Once the dry functional tests are complete and the tank systems (SBR, Inlet,

chemical dosing) have been tested with water to ensure their correct

functionality, process commissioning prior to the Trial Operation and Reliability

Tests will commence. The overall sequence and procedures can be referred to

section the procedures outlined.

8. PROCESS COMMISSIONING

See attached Appendix 8 for the approved “Process Commissioning Plan”.

9. Training Plan

Training requirements shall be established as specified in the Contract. As a

minimum, management, supervisory, process, operations and maintenance

personnel shall be trained. JV shall provide a syllabus of the training to be

provided. A comprehensive training plan shall also be developed by the JV in

conjunction with the Operation and Maintenance manual.

See Appendix 9 “TNSTP Training Plan”.

CONTROLLED DOCUMENT

It would be helpful if Client could confirm the names and positions of the individuals who will form part of the Operations and Maintenance Team at LKK. As well as formal classroom training required for certain elements it is intended that the majority of the training will be of a “hands-on” type working alongside the JV’s commissioning team. The relevant Client staff will need to be full time available at the plant from the start of commissioning. Furthermore it is recommended that operational staff are made available for pre-commissioning testing which will be witnessed by the Engineer in order to maximize their understanding of how the systems work.