01

TESTING AND
COMMISSIONIN
G IN PLUMBING

Presented by: Arch. Gabriel Bedia

UAP/FPIA/NAMPAP/ASPPI
 • What is Testing and Commissioning
in Plumbing

PRESENTATION • Basic requirements prior to

commissioning
OVERVIEW • What is Commissioning Checklist
• Documentation
• Method Statement of Installation and
Testing
• Disinfection of Domestic Water
Pipeline System
• Testing and Commissioning of Pump

K EY TO PIC S
 WHAT IS TESTING 03

AND
COMMISSIONING IN
• PLUMBING?
It is the report to be issued by an independent
Third party (Consultant) nominated by the
Employer or Project Owner for verifying the
satisfactory execution of installation, testing &
commissioning.
• It is also a diligent process of performing all
necessary quality control of Plumbing
installation.
 12
BASIC REQUIREMENTS PRIOR TO
COMMISSIONING
1.Approved Material Submittal
2.Approved Material Inspection w/ material delivery
3.Approved Shop Drawing
4.Approved Method Statement of Installation
5.Approved Material Installation & Testing (Drainage/Water Line)
 04

What is Commissioning
CheckList?
USED TO ENSURE THE SAFETY AND
FUNCTIONALITY OF A NEW PLUMBING
SYSTEM. IT ALSO VA L I D AT E S THE
PERFORMANCE OF PUMP AND PIPING
S Y S T E M . I T I S A L S O U S E D T O C A R E F U L LY
EXAMINE THE PIPING SYSTEM IN A
FA C I L I T Y AND PROVE IT WORKS
ACCORDING TO ITS DESIGN.
COMMISSIONING
14

CHECK LIST:General
• Is the work area clean, and orderly, with no leftover materials or
scattered debris?
• Is safety hazard addressed: sharp edges, low head clearance,
missing equipment, guards, etc.?
• Are name tags, nameplates, and serial numbers attached to the
equipment?
• Are instrument gauges/meter labeling correct and operating in the
normal range?
• Are valves labeled according to standard?
• Are equipment and components labeled according to standards?
 14

COMMISSIONING
CHECK LIST:General
• Are walls and floor penetration through fire rated construction have
applied fire stop sealant?
• Are walls and ceiling penetration repaired and painted with equivalent
materials?
• Does the installation meet the code compliance requirements?
• Has unapproved equipment and piping materials and accessories
removed from services?
• Does equipment meet requirements for work space clearance?
• Is manufacturer installation, operation and start-up documents
complete and verified (Operation and Maintenance Manual)?
 08

DO C U M ENTATION
• Is an equipment operation manual and
specification submitted to the
consultant and approved?
• Are as-built drawing such as Red
mark/Line drawing are submitted to the
consultant?
 08

PLUM B ING
• Are all piping materials installed has been
submitted and approved by the consultant?
• Are installed types of pipes labeled in
compliance to the standard, including
direction of flow?
• Are all drainage/sanitary piping sloped a
minimum of 2% drop per linear meter as
specified in the plumbing code?
PLUM B ING 08

• Are plumbing fixtures properly vented at the correct

location with the proper size vent line as required?
• Is the pipe properly supported according to its type
and size?
• Are sanitary accessories like faucet/flush handles
secured and properly aligned?
• Are sanitary fixtures are properly installed according
to the manufacturer’s recommendation?
• Are pumps and equipment properly installed,
aligned, and supported according to the
manufacturer’s recommendation?
METHOD STATEMENT OF 06

INSTALLATION AND TESTING

SCOPE
• This Method statement details the frequency of inspection to be carried out
in the installation and testing of PPR pipes and fittings for domestic water
supply and Low Noise PPR pipe for Drainage high level.
• This method statement gives guidelines to ensure that the work conforms to
the project specifications and to the local authorities’ requirements and to
serves the intended purposes to a satisfactory level.
MATERIAL USED: 09

PPR Pipes and Fittings

 18

AREA OF
APPLICATION:
FOR W ET A R EA S LIK E TO ILETS,
B ATHR OO M S, K ITC H EN S, ETC .
RESPONSIBILITIES 19

• The project team consists of an experienced supervisor and foreman that

will ensure the quality of work carried out, and shall also ensure that the
work is as per the latest revision of the approved shop drawing issued for
construction.
• Ensure that materials used are as per approved material submittal.
• Site Engineers shall be responsible for the overall quality of work. He will
also ensure that the progress of works is in accordance with the project
requirements and approved program of works.
• The installation shall be properly checked and coordinated by the QA/QC
engineer.
• The QA/QC Engineer shall raise all inspection and test requests on
approved forms and carry out inspections along with the Consultant.
 12
TOOLS REQUIRED
• SCAFFOLDING WITH WHEELS • Fusion Machine
• Angle Grinder • Hand Pump
• Impact Drill • Pressure Gauge
• C u t t i n g To o l s • LADDER
• P i p e Wr e n c h • CHALK LINE
• A d j u s t a b l e Wr e n c h • SCREW DRIVER SET
• M e a s u r i n g Ta p e • NYLON STRING
• Bar level • HAMMER
• • POINTED CHISEL
Plumb Bob
• S A F E T Y WA R N I N G D E V I C E S
09
 14

SAFETY
 14
• During installation and testing, all safety
precautions shall be as per established project
Safety plan. Secure work safety permit before
commencing of work.
• All personnel shall wear proper PPE at all times
and used proper tools in a safe manner.
• The work place shall be clean, safe to work and
have proper access and egress routes.
• Ensure work areas have adequate light. Provide
additional lights if necessary.
• Provide Fire Extinguisher and pail of Sand during
hot works. Fire watchman shall be at work place
at all time.
• Electric Power tools using Octopus connection is
strictly prohibited.
MATERI AL RECEI PT A N D STO RA GE
15
• Only approved makes of pipes and fittings shall be used.
• When off-loading, pipes shall be lowered carefully and
should not be dropped to the ground to avoid from
damage.
• Pipes shall be adequately supported at all times and shall
be stacked on a flat surface free from any sharp objects.
• Pipes shall be stacked in layers and classified according to
its size as per manufacturer’s recommendation.
• All open ends of the pipes must be suitably plugged to
prevent the ingress of debris or dust.
• All materials delivered on site must have an approved
material submittal and shall submit material inspection
request upon delivery and prior to installation.
 03

PREPARATION
• Ensure that the shop drawings to be used
are marked approved and coordinated
with other services.
• The area must be properly clean and safe
ready for piping installation.
• Ensure work safety permit has been
prepared, inspected and approved by the
safety department.
• Power tools to be used must be properly
checked and in good condition to prevent
any accident.
INSTALLATION 03

• All piping works to be done shall be under the

strict supervision of a Plumbing
Foreman/supervisor & engineers.
• Anchors and fasteners shall be installed as per
the approved spacing schedule of different pipe
sizes.
• Mark required length of the pipe and cut
squarely. The edges shall be cleaned properly.
• All pipes to be installed shall be inline and
leveled as per approved shop drawings.
• Pipes and fittings are joined by means of a
fusion welding machine as per manufacturer’s
recommendations.
INSTALLATION 03

• For Low-Noise PPR pipes and fittings for

drainage system, apply approved lubricant on
pipes hub in a rubber neoprene and push inside
the fitting, wipe excess lubricant with a clean
rag.
• Appropriate sized of hangers, split clamps with
rubber neoprene shall be used for different sizes
of pipes and shall be fastened accordingly.
• Open ends of all pipes are to be plugged and
protected.
• Provide hanging support for every change of
pipe direction.
• Exposed pipe installed shall be properly labelled
for identification.
09
TESTING 06

DOM ESTIC WATER LINE

• Water tests are to be conducted to ensure and prove the tightness of joints and to
ensure that there are no leaks in the piping system.
• The pipes to be tested shall be joined, plugged, and shall have been in position for
at least 24hrs before the test is carried out.
• Pressure gauges shall be installed with isolating valve at the extremities of the
piping circuit to be tested.
• The piping shall be tested for line, gradient, and water tightness.
• Close the valves one at a time and fill the pipe with fresh clean water, leaving all
the high points open to allow purging of air.
TESTING 06

DOM ESTIC WATER LINE

• The piping shall be hydrostatically tested at a pressure of 344kpa (50psi) or 1.5

times the system working pressure, whichever is greater. ( Ref. IPC section 312.5)
• Keep piping undisturbed for 4 hrs. check for leakages at joints. A drop in pressure
to the order of 10 kpa (1.5 psi) is considered acceptable.
• The pressure gauge calibration certificate & Hand pump test certificate must be
duly signed by the consultant.
• Inspection request to raise for consultant’s approval.
09
 13

DRAINAGE HIGH LEVEL

THE PIPING OF THE PLUMBING, DRAINAGE,
AND VENTING SYSTEM SHALL BE TESTED
W I T H WAT E R O R A I R E X C E P T T H AT P L A S T I C
PIPE SHALL NOT BE TESTED WITH AIR. THE
A U T H O R I T Y H AV I N G J U R I S D I C T I O N M AY
R E Q U I R E T H E R E M O VA L O F A N Y
C L E A N O U T S , E T C . , T O A S C E RTA I N W H E T H E R
T H E P R E S S U R E H A S R E A C H E D A L L PA RT S O F
THE SYSTEM. AFTER THE PLUMBING
F I X T U R E S H AV E B E E N S E T A N D T H E I R T R A P S
F I L L E D W I T H WAT E R , T H E Y S H A L L B E
S U B M I T T E D T O A F I N A L T E S T.
DRAINAGE LEAK TEST
15
The water test shall be applied to the drainage and vent systems
either in its entirely or in sections. If the test is applied to the
entire system, all openings in the piping shall be plugged and
tightly closed, except the highest opening, and the system filled
with water to point of overflow. If the system is tested in sections,
each opening shall be tightly plugged, except the highest opening
of the section under test, and each section shall be filled with
water, but no section shall be tested with less than a ten (10) foot
(3048mm) head of water. In testing successive sections, at least
the upper ten (10) feet (3048) of the next preceding section shall
be tested, so that no joint or pipe in the building (except the
uppermost ten feet of the system) shall have been submitted to a
test of less than ten-foot head of water. The water shall be kept in
the system, or in the portion under test, for at least fifteen (15)
minutes before inspection starts. The system shall be then being
tight at all points
 DISINFECTION OF 03

DOMESTIC WATER
PIPELINE SYSTEM

PR OCESS OB JEC T IVE S

The primary goal of the disinfection process in drinking water

treatment is the inactivation of microbial pathogens. These
pathogens comprise a diverse group of organism which serve as the
etiological agents of waterborne disease. Included in this group are
bacterial, viral, and protozoan species.
GENERAL DESCRIPTION 12

The disinfection process for the pipe network of the domestic water
system shall be implemented through the following steps:

• Scheduling the commencement time of the disinfection process to

avoid difficult processes or many corrections after the process.
• -Preliminary correction by which the sensitive equipment is
protected during the disinfection process and the process operation
will be done troubles free.
• Before being chlorinated, the main should be completely filled
with potable water to eliminate air pockets and then flushed to
purge the line of dirt and debris.
• Preliminary flushing should be accomplished at a rate of at least
1.5m/sec. Fittings and valves should be thoroughly cleaned before
applying chlorine to the main.
 12

GENERAL DESCRIPTION
All process steps will be achieved properly by
the followings:
• Detailed process step description
• Process schedule
• Risk assessment
• Responsibility matrix
 09

MATERIAL USED
• C ALC IUM HYPOC HL OR I T E
– DOSAGE 0 .2 KGM
C HEMIC ALS / 1 .0 C U.M .
WATER
• Po t a b l e wa t e r q u a l i t y
 22

COMMENCEMENT
TIME OF THE
FLUSHING
PROCESS

TH E CH E MIC A L FL U SH IN G
SH A LL B E STA RT E D A S TH E
PRO JEC T SC H E D U L E B U T TH E
FO LLO W I N G PR E - C A U TIO N
SH O U LD B E TA K E N I N TO
C O N SID E R AT IO N .
 20
• The chemical flushing process shall commence immediately after the system hydro
testing, and shall be reflected in the Commissioning Plan and commissioning
schedule. The maximum amount of time that a loop can be untreated or loaded
without water is 48 hours. If cleaning and flushing of the system cannot be
accomplished immediately after the hydro-test, the water used for hydro-testing shall
be charged with the pre-treatment/ Passivation chemicals to avoid corrosion.
• Any installation or maintenance works shouldn’t be done during or after the
treatment process to avoid contaminations or losing of treated water.
• It is highly recommended to flush whole water distribution network as one circuit to
avoid contamination or loss of treated water during reconnection.
PRELIMINARY PREPARATION
06

Purpose

• Provide sufficient operating parameters such as water velocity as well

as all requirements during the process
• Provide the flushing process free of troubles and unscheduled
shutdown.
• Provide a smooth re-connection after the process to avoid water re-
contamination.
 04

Disinfection Procedures (In

accordance w/ AWWA
Standard, C 601 & C 652)
 12

• Empty the pipelines which shall be disinfected for internal inspection

and following the attached procedure.
• All scaffolding, planks, tools, rags, and any other material not related
to the structural or operating facilities of the tanks shall be removed.
• The surfaces of the walls, floor, and operating facilities of the storage
facilities shall be cleaned thoroughly using high-pressure water,
sweeping, scrubbing, or equally effective means.
 12

• All water, dirt and foreign material accumulated in this cleaning

operation shall be discharged from the storage facility or otherwise
removed.
• The vent screen, overflow screen and any other screened opening shall
be checked and put in satisfactory condition to prevent birds, insects and
other possible contaminants from entering the facility.
• Removing-by flushing or other means- those materials that may have
entered the water main after the hydraulic pressure test of the
distribution network.
• Safety meeting to be arranged before starting the disinfection.
 10

Disinfection
Steps
• Fill all storage facility with potable water. 12
• Add the disinfectant solution to get free chlorine not less than 50mg/lit and samples
shall be taken from different points of the storage facility to ensure that free chlorine is
more than 50 ppm in all samples.
• Let the transfer pump run, pumping water through all the piping system to ensure that
the water with the disinfection solution reaches the internal surface of the piping
system. By getting samples from different points and allowing water to run until the
heavy concentration of the disinfection solution 50 ppm free chlorine reaches all
openings, especially the ones at the end of each line.
• After getting 50 ppm min. free chlorine in all storage facilities and in all open outlets,
the level of the water in all storage facilities must be up to Min 5% close to outlets,
keeping it in the same condition for a period of 24 hrs. During this period all valves in
lines must be open and closed to be internally disinfected.
 12
• Measuring the free chlorine after 24 hours, this value shall be 10 ppm of
free chlorine min. In all outlet.
• Then lowering the chlorine content by flushing with fresh water (or let
the chlorinated water for 4-5 days) and adding chlorinating agent until
getting free chlorine of max 1 ppm.
• After the disinfection procedure is completed and before the system is
placed in service, samples for bacteriological analysis shall be collected
and tested for coli form organisms.
• If the test for coli form bacteria organism is negative, then the system
may be placed in service.
• Then disinfection certificate shall be issued.
 05

TESTING AND
COMMISSIONING
OF PUMP
Pre-commissioning
check

P R I O R TO START- UP
• Check and inspect the installation of water pump is complete, verify the 12

installation as per approved shop drawings. Verify compliance to the attached

manufacturer’s installation instructions. Obtain installation certification from
manufacturer or their authorized representative. Check and ensure adequate
clearance available for service and maintenance of water pumps and motor.
• Check the installation is coordinated with other services. Ensure the shipping
bolts/ chambers are removed. Check all nuts, bolts, screws, fasteners, etc., are
fixed and tightened as required. Ensure the piping is pressure tested. Verify
test certificates. Check all piping connections are complete at pumps, flow
meter and pressure relief line including flexible connections where applicable.
• Check and ensure the domestic water piping is flushed and cleaned. Check the pump 12
alignment is completed as per manufacturer’s instructions. Check and verify the water
level in the water tank is full. Check and ensure safety guards are in place and secure.
Adjust desired cut-in and cut-off pressure as per requirements.
• Rotate the pump manually and ensure free and smooth rotation. Ensure the pumps are
cleaned prior to start up and all identification labels and tags are in place.
• Check all power cabling and control wiring is completed and dressed neatly. Check the
power isolator is fixed close to the pump motor for emergency stop and power isolation,
as per approved drawings/details. Check all terminations are completed and tightened as
required. Check the grounding connections are completed and tightened as required.
Ensure the overload protection are set correctly as per the pump motor load current.
 05

TESTING &
COMMISSIONING
PROCEDURE
 12

• After satisfactorily installation and static checks

for domestic water Booster Pumps,
commissioning shall commence.
• Ensure system is full and vented including the
water tanks.
• Power shall be available at the MCC and tested
by electrical team as per MCC Approved
Commissioning Method Statement Record shall
be available.
 12

• Start the Water Booster Pumps with the system

discharge valve 50% open or as instructed by
the consultant.
• Established that there is no excess vibration and
the pump is running satisfactorily.
• Slowly open the discharge valve to fully open
while monitoring running currents.
• Record the Water Booster Pumps running
current, speeds, and pressure & check for
smooth pump operation.
 12

• Check tank float switch interlocks operates to prevent

dry running of Water Booster Pumps and that the
correct level/ pressure is set.
• Simulate the following faults & test output with
multimeter for the following points: Run, Trip Low
Level Alarms for Water Booster Pump & Run, Trip,
Low Level Alarms and auto Status / BMS enable for
the transfer pumps.
• After successful commissioning of domestic water
pump set, the results will be recorded on the test
sheets & shall be verified & accepted by the
consultant.
 05

TESTING &
COMMISSIONING
OF PUMP SET
Confirm that the system is completely filled with 12
water:
• Tighten the foundation bolts properly. Check the
suction line connection in order to avoid drawing
of air into the pump.
• Open the suction valve slowly, and start the pump
by opening the discharge valve. Observe any
leakage in the pump.
• After a few minutes of operation note the pressure
reading at both suction and discharge sides.
• Measure the RPM / speed of the pump motor using
the tachometer.
 12

• Note down the amperes of the motor on both load

and off load positions.
• Check and record the motor temperature and make
sure the motor is not heating up and values are in
acceptable limits.

Contractor shall provide all suitably qualified

personnel to assist as required to perform Functional
Performance Tests.
 04
• Activate pump start using control system

Functional Performance Test: command.

• Verify pressure drop across strainer, verify strainer
is clean. Verify pump inlet/outlet pressure reading,
compare to test and balance report, pump design
Contractor shall demonstrate conditions, and pump manufacturer’s performance
operation of pump(s) per data. Operate pump(s) at shutoff 50% and 100%
flow. Plot test reading on pump curve, verify
specification including the specified flow is obtained.
following: • Verify motor amperage per phase and voltage
phase-to-phase and phase-to- ground.
• Check and report any unusual vibration, noise, etc.
 04

RESULTS
If specified equipment performance is not
verified, the General Contractor shall see that
corrections are made and reschedule functional
performance test as soon as possible after
corrective work is completed.
 04

Reports
S U B M I T R E P O RT O F F I N A L F U N C T I O N A L
P E R F O R M A N C E T E S T F O R A C C E P TA N C E B Y
T H E C O N S U LTA N T E N G I N E E R .
 04

Inspection & Testing Plan

A L L T H E W O R K S S H A L L H AV E I N S P E C T E D I N
ACCORDANCE TO THE INSPECTION &
TESTING PLAN AND INSPECTION
C H E C K L I S T. R E S U LT S O F I N S P E C T I O N &
TESTING SHALL BE RECORDED ON THE
INSPECTION CHECKLIST FORMS.
 01

THANK YOU!

Presented by: Arch. Gabriel Bedia

UAP/FPIA/NAMPAP