Quality Department Quality Management System

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TESTING AND COMMISSIONING PLAN

MEP SYSTEM WORKS

PROJECT : JOTON Project – Phase II, 10th of Ramadan, Cairo, Egypt.

CLIENT : El Mohandes Jotun S.A.E

MASTER
: N\A
DEVELOPER

PMC : N/A

LEAD CONSULTANT : COSMOS-E Engineers & Construction

SUB-CONSULTANT : Sub-consultants

MAIN CONTRACTOR : HAC- HASSAN ALLAM Construction.

SUB-CONTRACTOR : PERFECT

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TABLE OF CONTENTS
1. REVISION RECORD ...................................................................................................................................... 4
I. INTRODUCTION ............................................................................................................................................ 5
I.1. Overview of the commissioning process .............................................................................................. 5
I.2. Systems and assemblies included in commissioning authority’s scope of work ............................. 5
I.3. Commissioning team and its responsibilities ....................................................................................... 6
I.3.1. Owner (El Mohandes Jotun S.A.E) ......................................................................................................... 6
I.3.2. Commissioning Authority (Production Team “JOTUN” & Quality Team “HAC”) .............................. 6
I.3.3. Design / Technical Control Consultants (COSMOS) ............................................................................. 7
I.3.4. Contractor / Sub-contractor / Supplier (HAC)........................................................................................ 7
I.4. Description of management, Communication and Reporting of Commissioning Process ...... Error!
Bookmark not defined.
I.5. Commissioning Plan ............................................................................................................................... 8
I.6. Commissioning Process Milestone, Schedule...................................................................................... 8
I.7. Commissioning Check-Lists and Testing Procedures ....................................................................... 10
2. SCOPE ......................................................................................................................................................... 11
3. REFERENCES ............................................................................................................................................. 11
3.1. References / Code of Practices ............................................................................................................ 11
3.2. Contract documents .............................................................................................................................. 13
3.3. Contractors Submittal ........................................................................................................................... 13
4. DEFINITIONS / ABBREVIATIONS .............................................................................................................. 14
5. Completion Phase .........................................................................................Error! Bookmark not defined.
6. Commissionig Phase ...................................................................................Error! Bookmark not defined.
7. HandOver Phase ..........................................................................................Error! Bookmark not defined.
8. Documentation For Completion , Commissionig & HandOver. ....................Error! Bookmark not defined.
9. FORMS......................................................................................................................................................... 19
10. ANNEXES
1. ANNEX 01: T & C for HVAC System
19
2. ANNEX 02: T & C for .............................................................................................................................. 19
3. ANNEX 03: T & C for .............................................................................................................................. 19
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1. REVISION RECORD
This page is a record of all revisions of the document identified below by number and title. All
previous revisions are hereby superseded and are to be destroyed.
Rev. Date By Checked. Approved Description of Revisions

0 16-Aug-22 A.Fekky M.Refaat A.Atteia First issue

0 27-Dec-22 A.Fekky M.Refaat A.Atteia Second issue

0 06-April-23 A.Fekky M.Refaat A.Atteia Third issue

Signature field
Rev. Number→ Rev.No. Revision Date→ 16-Aug-22
Position Name Signature Date
QA/QC
Prepared by→ Engineer
Sub-
contractor N\A N\A N\A
QA/QC
Checked by→
Manager
QA/QC
Segment
Reviewed Construction
By→ Manager
Technical
Manager
Project
Approved By→
Manager

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I. INTRODUCTION
The commissioning plan is the reference document that identifies the strategies, aspects and outlines
the overall process, schedule, organization, responsibilities and documentation requirements of the
commissioning process for all commissioning team members.
Required commissioning plan components:
1. Brief overview of the commissioning process.
2. List of all systems and assemblies included in commissioning authority’s scope of work.
3. Identification of commissioning team and its responsibilities.
4. Description of management, communication and reporting Of commissioning process.
I.1. Overview of the commissioning process
The Commissioning authority will verify the installation and performance of the systems to be
commissioned, and will complete a commissioning report as part of the Fundamental commissioning
process.

The commissioning authority will document all commissioning review process, submittals, system
manual, verify O&M as a part of the commissioning report and final acceptance.

I.2. Systems and assemblies included in commissioning authority’s scope of work

The scope of services for the commissioning authority is based on the owner’s project
requirements. Thus, as requested by the owner, the mission will cover the following base
building systems:

▪ Ventilation systems (Supply air, Return air, Exhaust air)

▪ HVAC and associated control systems
▪ Air Handling Unit
▪ Air Cooled Chiller Equipment and Accessorise
▪ Chilled water
▪ VRV system
▪ VOC Extraction system
▪ Compressed Air System
▪ Process Piping
▪ Domestic water heating
▪ Water distribution systems
▪ Domestic, Industrial & Storm Sewage Systems
▪ Standpipe and Hose Firefighting System
▪ Sprinkler Water Firefighting System
▪ High and Low Expansion Foam Firefighting System
▪ Clean Agent FM-200 Firefighting System
▪ Electrical power generation and distribution systems
▪ Meduim Voltage Switchgear Panel and Transformer
▪ MCC and Auxiliary Equipment Control Panel
▪ Cable Routing, Mangement, Ladders and Distribution Panel Board
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▪ Lighting and lighting controls

▪ Earthing System
▪ Heat Tracing System
▪ Online UPS
▪ Building Management System BMS
▪ CCTV System
▪ Fire Alarm system
▪ Telephone and Data System
▪ Boom Barrier System
▪ Access Control and Biometric System

I.3. Commissioning team and its responsibilities

“Commissioning team”; it’s “Those people responsible for working together in carrying out the
commissioning process”.

Below are the commissioning team members, along with their individual responsibilities in the
commissioning process during project phases.

I.3.1. Owner (El Mohandes Jotun S.A.E)

A. Include a statement regarding commissioning responsibilities in request for design
services.
B. Develop and commit to the Owner’s Program for the facility and its use.
C. Assign operations and maintenance personnel and schedule them to participate in
the various meetings, training sessions, and observations/inspections.
D. Review and approve any changes made to design intent.
E. Review and accept the commissioning report.
I.3.2. Commissioning Authority (Production Team “JOTUN” & Quality Team “HAC”)
A. Organize and lead the commissioning team.
B. Develop the Commissioning Plan, which details the extent and activities of the
commissioning process including commissioning team organization, schedule and
documentation requirements and all related testing, verification, and quality control
procedures.
C. Execute the commissioning process through attending meetings, tests,
demonstrations, training events, and performance verifications.
D. Review the plans and specifications with respect to their completeness in all areas
relating to commissioned systems. This includes ensuring that the design phase
Commissioning Plan has been followed and that there are adequate devices included
in the design to ensure the ability to properly test, verify, and adjust the systems. Any
items required but not shown shall be brought to the attention of the Owner.
E. Receive and review the operations and maintenance (O&M) manuals as submitted
by the contractor. Ensure that they follow the specified outline and format. Insert
systems description as provided by the design professional in the Systems Manual.
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F. Witness equipment, subsystem, and system start‐up and testing. Ensure the results
are documented, including a summary of deficiencies, and incorporated in the O&M
manuals.
G. Supervise the commissioning team members in the functional performance tests. The
test data will be part of the commissioning report.
H. Ensure that the O&M manuals and all other as‐built records have been updated to
include all modifications made during the construction phase.
I. Prepare the final commissioning report and the systems manual.
I.3.3. Design / Technical Control Consultants (COSMOS)
A. Provide system design parameters and revisions to the initial design intent document
as necessary, obtaining approval of the owner.
B. Prepare contract documents, including the commissioning specification and
description of the commissioned systems.
C. Attend construction‐phase coordination meeting.
D. Specify and verify adequate maintenance accessibility for each piece of equipment in
shop drawings and actual installation. Periodic inspections are part of the design
professional’s construction administration duties.
E. Develop an overview of system design and operation concepts for the Systems
Manual.
F. Review and accept as‐built records as required by contract documents and turn them
over to the commissioning authority.
I.3.4. Contractor / Sub-contractor / Supplier (HAC)
A. Include costs for commissioning requirements in the contract price.
B. Ensure cooperation and participation of specialty subcontractors and controls
contractors.
C. Ensure coordination, installation, and operation of interfaces between commissioning
team.
D. Prepare necessary preliminary schedule for commissioned system orientation and
inspections, O&M manual submission, equipment and systems’ testing, for use by
the commissioning authority.
E. Notify the commissioning authority when equipment and system start‐up and testing
can be witnessed.
F. Provide written notification to the construction manager and commissioning authority
that the following work has been completed in accordance with the contract
documents and that the equipment, systems, and subsystems are functioning as
required and ready for commissioning.
G. Demonstrate the operation of each piece of equipment to the commissioning
authority.
H. Schedule subcontractors as may apply to demonstrate the operation of the
equipment and systems.
I. Provide services of an engineer to participate in verification tests.

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J. Turn over a set of as‐built records to the commissioning authority. (Hard and soft
copies).
K. Provide filled checklist data sheets to document verification tests for the
commissioning authority.
L. Submit verification test data to the design team and the commissioning authority for
review.
M. Conduct tests and verifications including opposite season tests, as required.
N. Retest if performance deficiencies are found and corrected and additional testing is
requested.

I.4. Commissioning Phase &Plan

The commissioning plan is implemented to verify and document that the system / subsystem is built
to fulfil its purpose and specified requirements and that each functional unit can be tested by
commissioning to confirm its suitability for operation.

The commissioning Phase take place when mechanical completion is completed for a
commissioning package.

The commissioning Phase can be divided into three main activities :

• Pre Commissioning .
• Commissioning Execution .
• Commissioning Documentation and Handover to operation

1.5.Commissioning Process Milestone, Schedule

Commissioning milestones and schedules cannot be determined exactly for the time being, but will
be integrated to this report during future revisions.

The startup and testing of systems may proceed prior to final completion of systems. However, the
commissioning authority shall not perform checkout services that are the primary responsibility of the
contractor vendor in advance of their testing and checkout, whom in return are responsible to inform
the commissioning team once their systems are ready to be verified and tested.

Problems observed will be addressed immediately, responsible parties will be notified.

The following table including all systems to be commissioned can be updated during commissioning
process .

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Systems to be commissioned
Pre‐functional Equipment Functional Sample
System: Target
checklists startup testing size
date:
Chilled Water System Y/N Y/N Y/N % N/A
Air Cooled Chiller
Equipment & Accessories Y/N Y/N Y/N % N/A

Air Handling Unit Y/N Y/N Y/N % N/A

HVAC and Associated
Control System Y/N Y/N Y/N % N/A

VRF System Y/N Y/N Y/N % N/A

VOC Extracting System Y/N Y/N Y/N % N/A
Compressed Air System Y/N Y/N Y/N % N/A
Domestic water heating
& Distribution Y/N Y/N Y/N % N/A

Sewer System Y/N Y/N Y/N % N/A

Standpipe & Hose
Firefighting System
Firefighting Sprinkler
System Y/N Y/N Y/N % N/A
High & Low Expansion
Foam Firefighting System Y/N Y/N Y/N % N/A

Clean Agent FM200 System Y/N Y/N Y/N % N/A

Process piping Y/N Y/N Y/N % N/A
Electric power generation
and distribution Y/N Y/N Y/N % N/A
Switchgear Panel Y/N Y/N Y/N % N/A

Transformer Y/N Y/N Y/N % N/A

MCC & Auxiliary
Y/N Y/N Y/N % N/A
Equipment Control Panels
Distribution panel board Y/N Y/N Y/N % N/A
Lighting and related
Y/N Y/N Y/N % N/A
controls
Earthing System Y/N Y/N Y/N % N/A
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Heat Tracing System Y/N Y/N Y/N % N/A

Online UPS Y/N Y/N Y/N % N/A

CCTV Y/N Y/N Y/N % N/A

Fire Alarm System Y/N Y/N Y/N % N/A

Telephone and Data Y/N Y/N Y/N % N/A

Boom Barrier Y/N Y/N Y/N % N/A

BMS Y/N Y/N Y/N % N/A

Access Control & Biometric
System Y/N Y/N Y/N % N/A

1.6.Commissioning Check-Lists and Testing Procedures

Commissioning check‐lists and systems’ testing and verification procedures shall be filled by the resident
consultant engineer and the concerned subcontractor.

The commissioning authority will direct and witness some verification operating tests and checks.

The testing contractor’s technician will inspect and verify the position of each device and interlock that is
identified on the checklist. Each item shall be signed off as acceptable or failed.

Operating checks shall include all safety cutouts, alarms, and interlocks with smoke control and life safety
systems during all modes of operation of the system.

If, during a test, an operating deficiency is observed, appropriate comments shall be added to the checklist
data sheet.

The proper response of monitoring and control system controllers and sensors shall be verified.

Final verification:

JOTON Engineer will direct and witness the field verification of the final testing report.

JOTON Engineer will select at random percentage of the report data for verification.

• Failure of an item is defined as the following:

− For all readings other than sound, a deviation of more than 10%.
− For sound pressure readings, a deviation of 3 decibels.
− A failure of more than 10% of the selected items shall result in the failure of acceptance of
the final testing report.
All these deviations are to be followed, unless otherwise referred to or specified.

• Failure of the final testing and balancing report shall require contractor to complete the
following work.
− Any system failing the verification procedure must be rechecked and corrected.
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− New total system testing and verification reports must be provided.

− Field verification of the new testing and balancing report must be performed.
• If deficiencies are identified during verification, the construction manager will be notified and
action taken to remedy the deficiency. Once verification is completed, the commissioning
authority will provide a verification report to the owner.
Check‐lists and testing procedures are found in the annexes of this report.

2. SCOPE
2.1. To define the Preliminary Steps, principles and structures of mechanical completion ,
commissioning and Handing over for provisions of MEP Systems for JOTUN New solvent &
water Based factory Project – Phase II , 10th of Ramadan , Egypt , for Jotun paints
2.2. This plan is a general plan providing Direction for the commissioning process, providing
resolution for issues such as scheduling, roles and responsibilities, lines of communication and
reporting, approvals, and coordination ,explain on-site procedures and methods of testing and
commissioning for the different components of the MEP Systems, including the installation of
Main Systems, Sub-main Systems, Accessories, and all other components,
2.3. A separate detailed commissioning plan for each system shall be submitted in separate
annex

− .
3. REFERENCES
3.1. References / Code of Practices
1. (ECP) Egyptian Code of Practice.

2. (ASTM) American Society for Testing and Material.

3. (ES) Egyptian Standard Specifications.

4. (ECPE) Egyptian Code of Practice for External Networks.

5. API Standard 650 Welded Steel Tanks for Oil Storage.

6. API Standard 2000 Venting Atmospheric and Low-Pressure Storage Tanks.

7. (ASME) Boiler and Pressure Vessel Codes.

8. EN13480 Code for Pressure Piping.

9. EN 12215 Coating plants.

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10. EN 13445 Unfired pressure vessels.

11. EN 13480 Metallic industrial piping.

12. IEC 60079 Explosive atmospheres. All standards under the 60079 series.

13. IEC 62305 Protection against lightning All standards under the 62305 series.

14. NFPA 10 Standard for fire extinguishers, portable and mobile.

15. NFPA 11 Standards for Low-, Medium-, and High-Expansion Foam.

16. NFPA 12 Standards on Carbon Dioxide Extinguishing Systems.
17. NFPA 13 Standard for installation of sprinkler system.
18. NFPA 14 Standard for the installation of standpipe and hose systems.
19. NFPA 15 Standard for Water Spray Fixed Systems for Fire Protection.
20. NFPA 16 Standards for the Installation of Foam-Water Sprinkler and Foam-Water
Spray Systems.

21. NFPA 20 Standard for the Installation of Stationary Pumps for Fire Protection.
22. NFPA 22 Standard for Water Tanks for Private Fire Protection.
23. NFPA 24 Standards for the Installation of Private Fire Service Mains and Their

Appurtenances.
24. NFPA 25 Standard for the Inspection, Testing, and Maintenance of Water-Based Fire

Protection Systems.
25. NFPA 30 Flammable and Combustible Liquids Code.

26. NFPA 33 Standard for Spray Application Using Flammable or Combustible Materials.

27. NFPA 35 Standards for the Manufacture of Organic Coatings.

28. NFPA 68 Standards on Explosion Protection by Deflagration Venting.

29. NFPA 69 Standards on Explosion Prevention Systems.

30. NFPA 70 National Electric code.

31. NFPA 72 National Fire Alarm Code®.

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32. NFPA 77 Recommended Practice on Static Electricity.

33. NFPA 101 Life Safety Code®.

34. NFPA 110 Standard for Emergency and Standby Power Systems.

35. NFPA 170 Standards for Fire Safety and Emergency Symbols.

36. NFPA 204 Standards for Smoke and Heat Venting.

37. NFPA 291 Recommended Practice for Fire Flow Testing and Marking of Hydrants.

38. NFPA 329 Recommended Practice for Handling Releases of Flammable and
Combustible Liquids and Gases.

39. NFPA 432 Codes for the Storage of Organic Peroxide Formulations.

40. NFPA 484 Standards for Combustible Metals, Metal Powders, and Metal Dusts.

41. NFPA 650 Standard for Pneumatic Conveying Systems for Handling Combustible
Particulate Solids.

42. NFPA 654 Standards for the Prevention of Fire and Dust Explosions from the
Manufacturing, Processing, and Handling of Combustible Particulate Solids.

43. NFPA 730 Guides for Premises Security.

44. NFPA 780 Standards for the Installation of Lightning Protection Systems.

45. NFPA 5000 Building Construction and Safety Code®.

46. UL 142 Standard for Steel Aboveground for flammable and combustible liquids.

47. UL 58 Standard for Steel Underground Tanks for flammable and combustible.

3.2. Contract documents

1. Project Specification
2. Contract Drawings
3. Project Contract – Chapter 5 – Mechanical completion & Commissioning.
4. Project Contract – Clauses 9.1 , 9.2 & 10.1

3.3. Contractors Submittal

5. Project Quality Plan
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6. Project Safety Plan

7. Material approvals
Sr.
Description Material Sub. No. Rev No. Date Remarks
No.

8. Shop Drawings
Sr.
Description Shop Drawings Rev No. Date Remarks
No.

9. Related method Statements

Sr.
Description MET no. Rev No. Date Remarks
No.

4. DEFINITIONS / ABBREVIATIONS
1. Commissioning Package : A practical scope of work unit within a system or subsystem
commissioning
2. Carry Over work register (COWR) : Register of incomplete items.
3. C : Commissioning .
4. CC : Commissionig certificate .
5. MC : Mechanical Completion .
6. MCC : Mechanical Completion Certificate .
7. RFCC : Ready for Commissioning Certificate .
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8. MUD : Marked out Drawings

9. Status “ NA” : Not Applicable.
10. Status “OK” : Means the item is completed
11. Status “ PA” : Means that checked items are incomplete and that remaining works is category
(A) that shall be completed prior to commissioning.
12. Status “PB” : Means that checked items are incomplete and that the remaining works is
category (B) may be completed prior to or after commissioning.
13. TOC” : Signed off take over certificate .

5. Completion Phase

• Mechanical completion means that the work is finished according to project specifications ,
Suppliers’ requirements and is ready to commissioning .
• Documentation for work completion include inspection requests & Test result submittals.
• MCC : Shall be issued by the executer and signed by the engineer prior the commencement
of commissioning.

6. Commissioning Phase

• Commissioning take place when mechanical completion is completed for a

commissioning package.
• Commissioning can be divided into three main activities :
- Pre commissioning .
- Commissioning Execution.
- Commissioning Documentation and Handover to operation
7. Handover Phase
• Handover of systems from executer to project client shall be according to formal
documented procedure consists of :
- Mechanical Completion Certificate (MCC)
- Commissioning Certificate ( CC)
- Marked up drawings. ( MUD )
- Signed Off Original Take Over Certificate (TOC)

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8. Documentation for Completion, Commissioning & Handover

1- Inspection Requests , Test Results & material submittals are the evidence
Documents for mechanical completion.
2- MCC shall be issued and signed by all parties prior the commissioning.
3- RFCC shall be issued and signed by all parties once the MCC is signed and
the system is ready for commissioning ( start up & testing ).
4- CC shall be issued and signed by all parties after finishing the
commissioning of each system .
5- TOC shall finally be issued and signed attached with it all the above
mentioned documents and MUD

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9. Forms

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10. ANNEXES
10.1. ANNEX 01: T & C for HVAC System.
10.2. ANNEX 02: T & C for
10.3. ANNEX 03: T & C for
10.4. ANNEX 04: T & C for
10.5. ANNEX 05: T & C for
10.6. ANNEX 06: T & C for
10.7. ANNEX 07: T & C for
10.8. ANNEX 08: T & C for
10.9. ANNEX 09: T & C for
10.10. ANNEX 10: T & C for
10.11. ANNEX 11: T & C for
10.12. ANNEX 12: T & C for
10.13. ANNEX 13: T & C for
10.14. ANNEX 14: T & C for

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