Testing and Commissioning of Submersible Pump Sets

testing and commissioning of submersible pump sets

Purpose

This describes in detail the Testing & Commissioning of Submersible Pump Sets with related accessories are executed in a safe manner and in accordance with the project requirements.

Scope

The work method was prepared for the complete execution of the Testing & Commissioning of Submersible Pump Sets with accessories.

This method ensures that all works are carried out in a safe manner in accordance with the contract specifications and approved shop drawings.

References

This method is subject to the requirements as stated in the following regulatory & statutory documents, applicable standards, specifications, and building codes:

Project Specification – Submersible Pumps
Project approved IFC drawings & materials
Approved Project HSE Plan
Approved Project Emergency Response Plan
Approved Project Waste Management Plan
Occupational Health and Safety

Definitions

MS – Method Statement
QCP – Quality Control Procedures
IFC – Issued For Construction
ITP – Inspection and Test Plan
ITA – Independent Testing Agency
HSE – Health, Safety & Environment
MEP – Mechanical, Electrical & Plumbing

Access/Egress

Works will be started or carried out only when all associated main contractors procedures are completed and by ensuring safe access to work areas will be available through hoist lifts/access ladders to carry out the work where ever main contractor site engineers & safety officers clearance are available.

Logistics

MEP subcontractor will deploy a dedicated team for the required logistics and material movement in-out of the project.

Mobile equipment- crane, forklift, etc. for material loading/offloading, transfer of materials to work locations.

Health & Safety Hazards

Extreme heat and humidity.

Extreme cold, high winds, and dusty conditions.

Temporary electrical supply for lighting, use of power tools, etc.

Improper stacking of materials: submersible pumps & accessories etc.

Manual handling/offloading & installation of submersible pumps & accessories, fittings, etc.

Damaged hand tools – submersible pumps & accessories, fittings, etc.

Uninspected power tools –drilling of holes for anchors, Installation of hangers & supports, cutting of pipes, etc. as per approved drawings.

Unsafe working on ladders.

Unsafe storage/handling/application of chemicals: sealants, solvents & cleaners.

Poor housekeeping & waste management.

MEP subcontractor will comply with all safety measures as applicable to the project’s main safety requirements and follow approved HSE plans.

Make sure all employees are Safety Inducted before they can start work on site.

Make sure employees take the right equipment with them on site. Check they have been trained and know how to use it.

Keep available, records of hazards on particular sites. Make sure all relevant people are notified.

Helmets, steel toe capped safety boots, goggles, high visibility jackets, face masks, and overalls should be appropriate and in good condition.

Assess the risks of manual handling before going to the site and look at the materials being used or stored.

Lighting devices shall be set up at the work area and ensure the required lux is available during the night shift.

The lifting area should be barricaded and appropriate signboards to be fixed to warn and avoid unauthorized entry.

Copies of drivers/operator’s license vehicle registration and security pass to be submitted to the company’s safety department before commencing the work.

All moving cranes/equipment shall have reverse indicators. All major equipment and crane shall be tested and certified by a third-party prior to mobilization to the site.

Ample and unobstructed passage shall be maintained at all times in and around the truck loading and lifting space.

All equipment movement at the job site must be controlled by a third-party certified rigger/banksman.

Trained, competent, and authorized supervision present at all times to ensure workers are safely working on site.

All site teams are to strictly follow the recommendations/instructions given in the attached risk assessment and safety analysis.

Site engineer and safety officers to ensure that all the people are wearing required PPE and following safety procedures.

All personnel is required to wear clothing appropriate for the work being performed.

Persons working near moving machinery must prevent clothing and body parts from being caught by moving components.

Only trained persons shall use the hand, air, or electrical tools.

Damaged or defective tools are to be taken out of service, tagged “Do Not Operate”, and stored in a controlled area until appropriate repairs have been made.

All working areas shall be encircled by warning tapes and sign boards in place before the commencement of work.

Access and exit routes are to be unobstructed and labeled and known to all employees at the site.

Information to personnel regarding health and safety shall be disseminated through;
HSE Site Safety Inductions.

Ensure STARTT and/or RAMS are discussed with the work group prior to work commencing.

Safety toolbox talks

Environmental toolbox talks

HSE training records / Toolbox attendance register

Training courses ( Internal and Third-party Training )

HSE Bulletin/HSE Site Notice Boards

Site Engineers, Site Supervisors, and Site Foreman

Permits and Certificates

HSE Permits and Certifications (as per activity requirements) – These should correlate with the activity

Risk Assessment

Permit To Work (Prior to starting an activity):

Ensure obtain the necessary PTW (Permit to Work), prior to allowing to work. Frequently training should be conducted by the site supervisor/foreman. Daily safety briefings should be conducted.

Hot work permit

Lifting Plan

Working at heights / Working on scaffolding or MEWP (Mobile Elevating Work Platform) – Third-party certification for workers (competency certificates), operators, and equipment.

Responsibilities

Project Manager

Construction Manager

Project Engineer

Site Engineer

QA/QC Engineer

Safety Engineer

Project Manager

The project manager shall be responsible for overall project planning, procurement, technical submissions, and drawing submissions.

The project manager shall coordinate activities within the site team and with the management for the timely completion of activity in accordance with contract requirements.

Construction Engineer

The construction manager is responsible for the work execution in compliance with the approved method statement, HSE Risk Assessment, and project specification, issued for construction drawings, sections, and details

Project Engineer

The Project engineer for each discipline shall be responsible for the execution of the complete system in accordance with project requirements. He will be responsible for the day-to-day activities on site, for materials, drawings, testing & commissioning, and allocation of departmental resources to work areas on site. The project engineer will report to MEP Project Manager.

The project engineer shall coordinate all related MEP system activities with all other trades for progress monitoring.

Site Engineer

The site engineer is responsible to carry out the work as per approved shop drawings and method statements. He is also responsible to ensure adequate tool kits required for the works are in place prior to the starting of work. The site engineer reports to the Construction Manager.

The site engineer is responsible to ensure work has been done as per the specification and drawings; inspections are carried out based on ITP and quality control procedures and coordinated with QA/QC department inspections.

The site engineer is responsible to ensure that all safety precautions are ensured in place and that all personnel on site are using the required personal protective equipment like helmets, gloves, shoes, and reflective jackets.

The site engineer in coordination with safety officers will ensure all relevant permissions are taken prior to the commencement of works.

QA/QC Engineer

QA/QC Engineer will be responsible for overseeing the quality requirements and quality control measures for the project in coordination with the project engineer and construction manager.

Safety Engineer

The safety engineer will be responsible for the safety, health, and environmental aspects on site as per the project safety and environmental requirements/safety standards in coordination with the project engineer and construction manager.

Methodology

Material Handling & Storage

The pump sets and accessories received at the site shall be carefully off-loaded using adequate manpower and equipment if necessary under close supervision such that no damage shall be caused to the materials. Manufacturer’s recommended storage guidelines to be followed.

The materials received at the site will be inspected to ensure that they are as per the approved material submittal.

The pumps will be protected from direct sunlight by covering them with tarpaulin/polythene sheets.

All the pump fittings and other accessories will be stored in the boxes as supplied by the manufacturer.

Any discrepancies, damages, etc., found will be notified and reported for further corrective action.

Preparations/Pre-installation checks

Ensure that the Method Statement is approved and the material delivered is inspected & approved by the consultant representative.

Confirm all approvals such as layout/detailed shop drawings, MEP coordination drawings, and Material Submittals are available.

Ensure the materials/accessories available/ received from the store are free from damages during transportation.

Ensure the area for installation of pumps & accessories is cleared from Civil Dept. for proceeding with installations.

Obtain work permit prior to commencement of works.

Installation

Installation shall be carried out with the manufacturer’s installation, prior to installations ensure all invert levels are marked/made transferable in near to locations as per approved drawings.

Prior to installation, check that the work area/sump pit is free from debris or foreign materials that could obstruct the work.

Ensure that the access ladder/scaffolding is safe to use or cleared by the safety department.

The pumps will be positioned and installed manually or by using light mechanical means similar to pulleys/chain block set/hoist etc.

Discharge piping shall be supported by approved brackets as per approved shop drawing details.

Installation of check valves and isolation valves are followed as per approved valve pit details.

All installations shall be ensured for easy removal/maintenance/replacement of related accessories.

Electrical and control wiring shall be completed as recommended by the pump manufacturer’s installation manual and be verified by the supplier/manufacturer representative prior to the start-up of pumps.

Level/float switches installations shall be coordinated/followed as per each type of sump detail shown in approved drawings.

Labeling/name plates for equipment to be provided complying with specifications and material approvals.

Startup/ Testing & Commissioning procedures

All equipment startup-test and commissioning procedures and related method/forms shall be submitted as per the test and commission plan general procedure for the startup as follows:

Start-up/commissioning of all sump pump units will be carried out by the manufacturer’s service protocols & applicable procedures ref. attachment and updates shall be submitted in due course/along with various material/model submittals and revisions.

Prior to energization power, cable sources/distributions are verified for strict adherence to electrical drawings, and all termination points are identified.

Sump pump start-up protocol shall be followed only as per the manufacturer/service representative in his presence.

Verify and record all sequences as per control panel settings for dual or single pump configurations.

RUN/FAIL/HIGH LOW-Alarms, indications are verified &Record data as per supplier provided filled up pre-commissioning forms.

Start-up/commissioning of all sump pump units will be carried out by the manufacturer’s service protocols& applicable procedures ref. attachment and updates shall be submitted in due course/along with various material/model submittals and revisions.

Prior to energization power cable sources/distributions are verified for strict adherence to electrical drawings and all termination points are identified.

Sump pump start-up protocol shall be followed only as per the manufacturer/service representative in his presence.

Verify and record all sequences as per control panel settings for dual or single pump configurations.

RUN/FAIL/HIGH LOW -Alarms, indications are verified &Record data as per supplier provided filled up pre-commissioning forms.

Training

All Required training for stipulated installation activities is provided to all contractor’s technical staff for ensuring a quality workmanship

Working Hours

Site operational time shall be followed as per project progress requirements, and all relevant local authority schedules of holidays are to be observed.

Housekeeping

Working areas will be kept clean by disposing of the waste materials in the designated areas. At the end of the day’s work, the installation supervisor will ensure that the debris is disposed of on regular basis.

Manpower

Subject to main contractors programmer and scope/area available for MEP activities, but not limited to below:

MEP Supervisor
Foreman
Chargehands
Plumbers
Pipefitters
Assistant fitters
Helpers

Material

Ensure materials being used are of the approved manufacturer from the project vendor list and of quality as specified.
Submersible pump sets and accessories

Plant & Equipment

Hacksaw and blades
Chalk line/chalk powder
Portable hand tools- Grinder/hammer-drill
Brush and cleaning waste/cloth
Spirit level & water level pipe
Standard tool box set with tools
Flood lights (for night works)

Supporting Documents

This “testing and commissioning of submersible pump” is to be read in conjunction with the below-referenced documents:

Contract Specification & Approved drawings
Approved Value Engineering
Project Quality Plan
Project HSE Plan

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