Professional Documents
Culture Documents
c
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
c
1. Objectives ................................ ................................ ................................ ................................ .. 4
2. Scope ................................ ................................ ................................ ................................ ......... 4
3. Definitions ................................ ................................ ................................ ................................ . 4
4. Signature responsibilities per commissioning phase................................ ................................ ... 5
5. Punch list Description................................ ................................ ................................ ................. 6
6. THE COMMISSIONING STUCTURE AND RESPONSIBILITIES ................................ .......................... 7
6.1. Commissioning Manager ................................ ................................ ................................ .... 7
6.2. General ................................ ................................ ................................ .............................. 8
7. Logistic Support ................................ ................................ ................................ ......................... 8
8. Commissioning Control ................................ ................................ ................................ .............. 8
8.1. C1 level ʹ Commissioning ͞Punch Listing͟ ʹ Contractor and/or Suppliers & Construction
Team. Pre Commissioning Checks ʹ Power Off ................................ ................................ ............... 9
8.2. C2 level ʹ Commissioning ͞Dry͟- Construction Team, Contractors and/or Supplier and
Plant. Pre Commissioning Checks ʹ Power On ................................ ................................ .............. 10
8.3. C3 level ʹ Commissioning ͞Material͟ ʹ Commissioning Team and Plant Cold Commissioning
11
8.4. C4 level ʹ Commissioning ʹ Commissioning Team and Production Process Engineer. (Hot
Commissioning) ................................ ................................ ................................ ........................... 12
8.5. C5 level ʹ Commissioning ͞Production Build-up and Optimisation͟- Production Process
Engineer and Plant Operating Personnel (performance Test) ................................ ....................... 12
8.6. General ................................ ................................ ................................ ............................ 13
9. Request for Site Modifications ʹ Construction Team ................................ ................................ 13
10. Final Handover ................................ ................................ ................................ ..................... 13
11. Commissioning team Identification and Induction................................ ................................ 13
12. Attachments Commissioning Acceptance Certificates................................ ........................... 14
C1 LEVEL ʹ COMMISSIONING ACCEPTANCE CERTIFICATE ................................ ................................ . 15
DETAILS OF WORK BEING HANDED OVER ................................ ................................ ..................... 15
RESPONSIBLE PERSON................................ ................................ ................................ .............. 15
C2 LEVEL ʹ COMMISSIONING ACCEPTANCE CERTIFICATE ................................ ................................ . 16
DETAILS OF WORK BEING HANDED OVER ................................ ................................ ..................... 16
RESPONSIBLE PERSON................................ ................................ ................................ .............. 16
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
@ p
1.1.p To define the commissioning strategy and control procedures required to allow for a
smooth transition from completion of construction by the Contractor ʹ C1 to formal hand
over and acceptance of equipment and systems by the Project Commissioning Team ʹ C3
and to final hand over to the Plant after C5 commissioning.
1.2.p To clarify and define the different phases of hand over, the different parties involved, their
responsibilities and obligations at each stage
R p
This procedure will cover the commissioning strategy that will be adopted for the
commissioning of the Flotation B-Bank i.e. Multi Cell upgrades to Enprotec Dual Cell
Technology. (Complete with it material handling sections)
i p r
The Plant refers to Plant Management who is represented by the
Construction Manager, Metallurgical Manager and the Engineering
Manager
The OMR refers to the Plant appointed operation team who will act on
behalf of the plant from commissioning stages C3 through to C5 and
ongoing plant operation
c
c! These certificate are signed by the Contractor and his Sub-contractor at
c stages C1 & C2 of the commissioning process signifying acceptance that the
" c
# equipment is ready for C3 commissioning
$
c
c These certificates are signed by the Contractor and the OMR at stage C3
c c once the construction completion certificate/s is signed off. This means the
%&
$&
plant is ready for operation by the Operations Team & Beneficial use is
Identified. At this point there is a shift in Safety Responsibility as well as
plant Operation and Maintenance from contractor to client GHC team. The
contractor is still available for support and commissioning modification
identified in the first 24 hrs of operation
c
c This certificate is signed off by the OMR and the Contractor
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
( c At stage C4 of the commissioning process signifying acceptance of plant
operations
c
c' This certificate is signed by the OMR and the Contractor and the Client
Projects Manager at stage C5 of the commissioning process signifying
acceptance of the plant performance as per design requirements
c
This takes place once all the plant equipment has met the expected
''Performance Specifications" to the satisfaction of the Plant. Exceptions
will be noted on the Final Acceptance Certificate
Page ' of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
ë p
r
*
1
Sequence for punching list sign off͛s
This deviation may affect health and/or safety of the plant personnel. The
&
deviation must therefore be rectified before signing of the Acceptance
Certificate and proceeding to the next commissioning phase
These are deviations that can be rectified while the plant is running, but
&
c
must be rectified before the Final Handover Acceptance Certificate sign off
Page 0 of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
p c
c
r
Õp Commissioning strategy.
Õp Commissioning procedure.
Õp Initiation of audits and monitoring activities to ensure compliance to the
commissioning procedures and safety standards.
Õp Commissioning structure and functions.
Õp Identification and appointment of personnel on the commissioning structure.
Õp Identification of infrastructure requirements and ensuring availability ahead of
commissioning.
Õp Development of the commissioning program and monitoring of progress with the
assistance of the Project Planning Co-ordinator.
Õp Ensuring that the required operational parameters are identified and met before the
plant is handed over to the Plant.
Õp Manage and control the commissioning and hand over to the Plant.
Õp Ensure compliance with laid down procedures.
Õp Ensuring all documents, drawings and ͞as-build͟ drawings are available for Final
Handover to the Plant at the C5 Commissioning stage.
The commissioning package for each Commissioning Manager will typically contain the
following:
R p
Õp Other key members of the Commissioning Team shall be selected from mining
personnel or representatives as required.
Õp The relevant Discipline Engineers shall assist the Commissioning Managers in
compiling procedures and check lists. These will be handed over to the
Documentation controller for filling and issuing as required.
Õp All Commissioning planning will be co-ordinated by the project planning co-
ordinator.
£ p
The project has included where necessary, maintenance and training requirements in the
relevant contract document. These requirements have been identified in conjunction with
Goedehoop and the Contractor/Supplier. In the event of additional commissioning requirements
this shall be arranged directly by the Commissioning Manager in conjunction with the
Contractor/Supplier taking cognizance of the time and cost involved for the supplier to present
themselves on site.
The logistic support work typically involves liaising with Contractors to identify specifics such as;
the maintenance frequency for specific equipment, recommended and strategic spares
requirements, tools, personnel training, potential maintenance contracts and al related
documentation.
On completion of commissioning a Flotation technician from Enprotec will be on site for six
months thereafter. This will ensure adequate training to the relevant plant operators.
The responsibilities for the various stages of commissioning and handover shall be as follows:
c From the Contractor and/or supplier to the construction Engineer, technical punch list
completed5
c c
#6 7
c From the Contractor and/or supplier to the Construction Engineer, no Process involvement,
technical punch list completed and Contractor and/or Supplier5
c c
#6
7
Page 4 of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
c From the construction Engineer and Plant Engineering staff to Process Operational staff and
process punch list completed.
*
c c
%&
6$&
7
$!$ 7
c Operational staff introducing limited process material and checking process functionality
and safety5( c
c' Operational staff introducing plant/equipment functionality for throughput, volumes and
flow rates as specified in compliance with the test on completion contractually.
The Construction Electrical, Mechanical and C & I Engineers shall be responsible for their specific
discipline throughout all the various stages of commissioning in conjunction with the Plant
Process and Engineering staff on a modular basis.
This means Punch Listings of discrete parts of equipment of systems By Contractors and/or
suppliers before handing over to the Plant/Process Engineers.
The Commissioning manager will sign off this stage of commissioning when following have been
achieved:
testing without endangering life of the safety of the works. He shall clear any
uncertainties with the Construction Manager if in doubt.
Õp C1 ʹ Commissioning shall be considered complete when all the above including the
entire Category A punch list items have been addressed and all the documentation
has been handed over to the Documentation Controller.
Õp C1 Document Package consists of;
op Acceptance Certificate.
op Contractors punch list.
op Construction Team punch list.
op Note pertaining to acceptable punch list items that may be carried to the
next stage of commissioning.
op After all safety checks have been completed.
op All certifications must be identified by Commissioning Manager.
The C1 Commissioning Acceptance Certificate must be signed of before proceeding to the next
stage of commissioning.
º R pcRc rc
c
c c
This involves running the equipment or module dry to test or perform relevant checks on the
equipment or system, all equipment such as motor etc. are run for short periods under the
supervision of the Commissioning Manager, Contractor and/or Supplier in accordance with the
running test and procedures provided by the Commissioning Manager, Contractor and/or
Supplier.
All witnessing certificates such as Megger test, loop checks, pressure test, rotational speed test
etc.
Page 9 of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
The Plant/Process Engineer shall be present during these test to familiarise himself with
equipment.
All individual interlocks are completed and the control room to then take ownership of the
completed interlocks system for sequential testing.
It is essential that all the construction activities, in the applicable area, are complete at this
stage.
All equipment that forms a module or stream shall be run together to allow balancing and to
check all the interlocks and process control.
Material shall only commence once a discreet piece of equipment or system is ready to run
sequentially.
The purpose of wet commissioning is limited running of discreet piece of equipment or system
with water to essentially check pump ,pipes, shuts, cells, pumps, etc, confirm instrument
calibrations and confirm sequences and interlocks.
The Commissioning Manager must ensure that all outstanding C1 and C2 punch list items are
complete or progressing as planned before handing over.
At this stage, no ͞modification requests͟ shall be accepted until proven during the next phase of
commissioning i.e. if a pump does not perform as expected during this phase, for example, it is
essential to establish that the pump will not behave entirely differently under normal operating
conditions.
It is essential that the Plant/Process Engineer and plant Operation Team be involved at this stage
of commissioning in order to facilitate a seamless progression to the next stage of
commissioning.
The C3 Commissioning Acceptance Certificate must be signed of before proceeding to the next
stage of commissioning.
At this stage prior to the start of C4 commissioning; the plant or sections of the works must be
handed over and accepted by the Plant Operations team from the commissioning team. All
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
safety, plant operations and maintenance of the works is the responsibility of the plant
operations.
The Production Process Engineer shall take over full operational, safety and maintenance
responsibility for the water/ore commissioning on the discreet piece of equipment or system.
The purpose of this stage of commissioning is to introduce material to the equipment or system,
starting at low rates and building up progressively until rated capacities are achieved.
The Commissioning Ma anger and his team will be available to assist the Production Process
Engineer during this phase. The two Managers, Engineers and their respective teams will work
together until the discreet piece of equipment or system is running with material at the rated
capacity.
Once the equipment or system is fully commissioned with material, the Senior Process
Metallurgist/Plant Process Engineers shall commence with the optimisation of each relevant
piece of equipment. The equipment and/or system shall be manned and run for at least eight
hours during the optimisation process. This optimisation process is to optimise the process in
line with the plant design parameters only.
The C4 Commissioning Acceptance Certificate must be signed off before proceeding to the next
and final stage of the commissioning stage.
º ë pcëc
The Contractors and/or Suppliers where deemed necessary may be asked to be available during
optimisation of their equipment to assist the team and ensure that process/performance
guarantees are met. This would also provide an opportunity to reinforce training of operators
and artisans.
Once the process/performance guarantees and the operational efficiencies are met by a specific
piece of equipment, a C5 Commissioning Acceptance Certificate will be filled in and signed by
the Construction Engineer who shall then arrange for the Plant representative to observe the
process and accept on behalf of the plant
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
Once all the C5 Certificates have been signed off, the equipment or system shall be run at full
production as per the requirements of test on completion before official hand over to the Plant.
The Construction Manager shall submit the Final Hand over Certificate to the relevant Plant
representative.
º p
[ p
c
The Request for Site Modifications, Procedure PPP-RSM shall apply to all modifications. These
are generated by the Construction Team and/or Plant personnel and reviewed and
approved/rejected by the Construction Manager.
The cost implication for such a modification determined prior to completing such a request.
After the final handover to the Plant, the following activities may remain to be completed and
are the responsibility of the Project and Construction Engineers.
Õp Updating of operating manuals, flow sheets and P & Ids to reflect any modifications,
which have been made during commissioning.
Õp The completion and forwarding to production of as-build drawings resulting from
modifications during commissioning.
Õp Compilation of a post completion audit and report.
All personnel to undergo commissioning induction understand the lockout procedure and
adhere to the lockout procedure
Stickers on hard hats and different ID cards are to be utilized to identify the commissioning
team.
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
,-%)$$-
*
: ;;;;;;;;;;;;;;;;;;; *
: ;;;;;;;;;;;;;;;;
$
: ;;;;;;;;;;;;;;;;;;; $
: ;;;;;;;;;;;;;;;;
%
: ;;;;;;;;;;;;;;;;;;; %
: ;;;;;;;;;;;;;;;;
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
c@c
cccc
Ô
c
Form No. ENP C1 REF DATE: 13/01/2011 REV. NO.:00
CONTRACTOR/SUPPLIER
CONTRACT NUMBER
DESCRIPTION OF EQUIPMENT
PUNCH LIST NUMBER
This is to certify that the Equipment/System as described below has been tested and punch list to
the satisfaction of the Construction Engineer.
Upon signing this certificate the Construction Engineer undertakes to carry out the next stage of the
commissioning process namely C2 level ͞Dry͟ Commissioning.
It is the responsibility of the Contractor/Supplier to address the attached Punch List as per the
programme agreed with The Construction Manager.
r
Ô!
rr
(PER DISCIPLINE)
Page ' of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
cRc
cccc
Ô
c
Form No. ENP C2 REF DATE: 13/01/2011 REV. NO.:00
CONTRACTOR/SUPPLIER
CONTRACT NUMBER
DESCRIPTION OF EQUIPMENT
PUNCH LIST NUMBER
This is to certify that the Equipment/System as describe below has been ͞Dry͟ Commissioned to the
satisfaction of the Construction Engineer.
Upon signing this Certificate the Commissioning Engineer undertakes to carry out the next stage of
the commissioning process, namely C3 level ͞Wet͟ Commissioning.
It is the responsibility of the Contractor/Supplier to address the attached Punch List as per the
programme agreed with the Construction Manager
r
Ô!
rr
(PER DISCIPLINE)
Page 0 of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
cic
cccc
Ô
c
Form No. ENP C3 REF DATE: 13/01/2011 REV. NO.:00
CONTRACTOR/SUPPLIER
CONTRACT NUMBER
DESCRIPTION OF EQUIPMENT
PUNCH LIST NUMBER
This is to certify that the Equipment/System as described below has been successfully ͞Wet͟
Commissioned tested and that all outstanding C1 and C2 Punch List items are completed or
progressing as planned.
Upon signing this certificate the Commissioning Process Engineer undertakes to carry out the next
stage of the commissioning process, namely C4 level ͞Material͟ Commissioning.
r
Ô!
rr
(PER DISCIPLINE)
Page 3 of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
c½c
cccc
Ô
c
Form No. ENP C4 REF DATE: 13/01/2011 REV. NO.:00
CONTRACTOR/SUPPLIER
CONTRACT NUMBER
DESCRIPTION OF EQUIPMENT
PUNCH LIST NUMBER
This is to certify that the Equipment/System as described below has been successfully commissioned
with MATERIAL and the rated capacities of the Equipment/System were achieved.
Upon signing this certificate the Maintenance and Commissioning Process Engineers undertake the
responsibility to out the next stage of the commissioning process, namely C5 level, Production Build-
up, Maintenance, Operation and Optimisation.
It is the responsibility of the Contractor/Supplier to address the attached Punch List items as per the
programme agreed with the Commissioning Process Engineer & Construction Manager.
r
Ô!
rr
(PER DISCIPLINE)
Page 4 of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
cëc
cccc
Ô
c
Form No. ENP C5 REF DATE: 13/01/2011 REV. NO.:00
CONTRACTOR/SUPPLIER
CONTRACT NUMBER
DESCRIPTION OF EQUIPMENT
PUNCH LIST NUMBER
This is to certify that the Equipment/System as described below has been successfully commissioned
with Material at the rated production capacities of the said Equipment/System.
Upon signing this certificate the Maintenance and Commission Process Engineers undertakes the
responsibility to carry out the next stage of the commissioning process, namely FINAL HANDOVER
TO THE PLANT.
r
Ô!
rr
(PER DISCIPLINE)
Page 8 of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
CONTRACTOR/SUPPLIER
CONTRACT NUMBER
DESCRIPTION OF EQUIPMENT
PUNCH LIST NUMBER
&
-<
=$&
>
>
7 >
&
?
(PER DISCIPLINE)
Page 9 of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
CONTRACTOR/SUPPLIER
CONTRACT NUMBER
DESCRIPTION OF EQUIPMENT
PUNCH LIST NUMBER
&
=$&
>
>
7>
&
?
(PER DISCIPLINE)
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
Commissioning Punch
List
Form No. ENP-PL REV Date: 13/01/2010 REV No.:00
Item No. Description of Defect Type Due Date Actual Date Responsibility
Defect
Legend
DEFECT: D= Design S = Safety Required M = Modification O =Outstanding
Required Required Item
TYPE: A = Equipment/System is not handed over or approved for "Dry" B = "Dry" commissioning is authorized
commissioning
C = Equipment/System is handed over subject to the attached
punch list programme
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011
c
Form No. ENP-RSM REV Date: 13/01/2011 REV NO:00
Ô
r
%
*
$
%
c
Commissioning Eng.
Process Eng.
Construction Eng.
Project Eng.
Project Manager
Design Manager
Page of
Revision
Enprotec 01 Approved By: Date:
Commissioning
Procedure 10/01/2011