Testing and Commissioning Procedure for Water

Leak Detection System for Plumbing Works

PRO 00051 0.1

1

PRO - Procedure

03 -- Issued
04 Issuedfor
forApproval
SONO

REDCO 21/02/2019
07-02-2019

21/02/2019
07-02-2019

21/02/2019
07-02-2019

21/02/2019
07-02-2019

21/02/2019
07-02-2019

10.1 07-02-2019
21/02/2019
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SAUD I B INLAOIN GROUP laiBK
SPH-JV
GREEN LINE - ELEVATED & AT-GRADE f\edco International
Testing and Commissioning Procedure for Water
Leak Detection System for Plumbing Works
(REDCO)
RTC/082/2013
Document No.:

Document Type I PRO - Procedure

Reason for Issue 04 - Issued for SONO

T&C Engineer Signature Date

Prepared by:
Muneeb Asfaq
/~~~ 3 February 2019

T&C Manager Signature Date

Checked by:
Adnan Aslam ~~~ 3 February 2019

QA/QC Manager Signature Date

Reviewed by:
Monib Ampuan .£- 3 February 2019

Project Manager Signature Date

Approved by:
Wessam AIAhmedy .£- 3 February 2019

Revision History
Rev. No. Description of Revision Date of Revision
0.1 First Issue 3 February 2019

M009·SPH-TCH-PR0-00051 Page 1 of 18

Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
Total Number of Pages: 18 including front pages and excluding appendices

M009-SPH-TCH-PRO-00051 Page 2 of 18

Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
 TABLE OF CONTENTS
LIST OF APPENDICES .....................................................................................................4
HARDCOPY DISTRIBUTION LIST....................................................................................5
ABBREVIATIONS..............................................................................................................6
1 PURPOSE ...............................................................................................................7
1.1 General issues ................................................................................................................. 7
1.2 Purpose ............................................................................................................................ 7
2 SCOPE ....................................................................................................................7
2.1 Interdependence with Management Plans ..................................................................... 7
2.2 Revision of Procedure Documents................................................................................. 8
3 ROLES AND RESPONSIBILITIES .........................................................................9
3.1 Project Manager ............................................................................................................. 10
3.2 T&C Manager ................................................................................................................. 10
3.1 T&C Site Engineer ......................................................................................................... 10
3.2 QA / QC Engineer........................................................................................................... 10
3.3 QC Inspector .................................................................................................................. 10
3.4 HSE Manager ................................................................................................................. 10
3.5 Supplier/Manufacturer ................................................................................................... 11
3.6 Supervision Engineer .................................................................................................... 11
3.7 Supervisor/Foreman ...................................................................................................... 11
3.8 Technicians/Helpers ...................................................................................................... 11
4 RESOURCES ........................................................................................................12
4.1 Labour ............................................................................................................................ 12
4.1.1 General Tool used for this activity: ................................................................................ 12
5 QUALITY ASSURANCE/ QUALITY CONTROL ...................................................12
6 HEALTH, SAFETY, ENVIRONMENT ...................................................................13
6.1 Lockout/Tag-out Procedure .......................................................................................... 13
6.2 Hazardous Waste Management .................................................................................... 14
7 RISK ASSESSMENT ............................................................................................14
8 METHODOLOGY ..................................................................................................15
8.1 PSAT (Partial Stand Alone Test) ................................................................................... 17
8.1.1 Prerequisites for PSAT .................................................................................................... 17
8.1.2 Pre-Commissioning ......................................................................................................... 17
8.2 SAT (Stand-Alone Test) ................................................................................................. 17
8.2.1 Prerequisites for SAT ...................................................................................................... 17
M009-SPH-TCH-PRO-00051 Page 3 of 18

Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
8.2.2 Commissioning & Start Up. ............................................................................................ 18

LIST OF APPENDICES
Appendix 1 – Risk Assessment

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
HARDCOPY DISTRIBUTION LIST
This document is not controlled when printed. The controlled version is held by the Document
Controller on the Project Server’s valid Documents Folder.

Hardcopy Distribution List*

Copy No. Name Company Position Signature

001 Qatar Rail Project Owner

002 Qatar Rail Employer’s Personnel

003 SPH Project Director

004 SPH Construction Director

005 SPH Station Manager

006 SPH QA / QC Manager

007 SPH HSE Manager

008

010

011

012

* The final distribution may be modified after consultation with Main Contractor.

** It is the responsibility of the Station Manager to provide this Procedure to the respective
Project or Site Engineers and obtain sign off that they have received and understood the
document. Please refer to the communication protocol.

M009-SPH-TCH-PRO-00051 Page 5 of 18

Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
ABBREVIATIONS

ARCH Project Archive

BS British Standard
HSE Health, Safety and Environment
IFC Issued for Construction
IT Information Technology
MS Method Statement
MSDS Material Safety Data Sheet
NCR Nonconformity Report
PD Project Director
PMC Project Management Consultant
PPE Personal Protective Equipment
SPH Joint Venture of Saudi Binladin Group, PORR and HBK
QA / QC Quality Assurance / Quality Control
QCS Qatar Construction Specification
QMS Quality Management System
QS Qatar Standard
SONO Statement of No Objection
QND Qatar National Datum
IRE Inspection Request
T&C Testing and Commissioning.
MES Method Statement
NFPA National Fire Protection Association
MAR Material Approval Request
IRN Installation Release Note
PRO Procedure

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
1 PURPOSE
1.1 General issues
This document is to present the Procedure as required by subcontract documents for Green Line
Elevated & At Grade Project.

This document was composed exclusively for the Qatar Railway ‘Green Line Elevated & at
Grade’ Project. All the requirements listed in the above referred tender document were taken into
account. The company has Quality Management System Certificate of ISO 9001: 2008,
Certificate of ISO 14001: 2004 of Environmental Management System. Furthermore, it applies
the BS OSHAS 18001: 2007 on Occupational Health and Safety Management System.

1.2 Purpose
The purpose of this Procedure is to explain step by step method for Testing and
Commissioning of Leak Detection System for Plumbing Works guidelines contained herein so
as to ensure that the job execution complies with project requirement and serves the intended
function to satisfactory level. The aim is to carry out the Testing & Commissioning in a safe
manner to an approved and controlled methodology. To determine the results in accordance
with applicable standards, codes of practice and project specifications.

2 SCOPE
Scope of this Procedure is the Testing and Commissioning of Leak Detection System for
Plumbing Works.

This document includes the following either in the main body or in the Appendices:

x Methodology for Testing and Commissioning of Leak detection System

x Equipment and materials used.
x HSE Assessment & Risk Assessment.
NOTE: For Check List Refer to ITP (M009-SPH-MEP-ITP-00087)

2.1 Interdependence with Management Plans

Standards Relevant to Docum

ent & Information Management are:

x NFPA 130 Standard for Fixed Guide Way Transit and Passenger Rail Systems
x Qatar Construction Specifications 2010 (QCS 2010)

The following documents are referred to either to support the implementation of the
Procedure or are a pre-requisite to its implementation:

M009-SPH-TCH-PRO-00051 Page 7 of 18

Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
x DWG:
Document No. Document Name
M009-SPH-MEP-DWG-GWST080-CL-11203 Concourse Level Partial Plan Part 3 of 6 Plumbing

x MAR:
Document No. Document Name
Material Approval Requisition for Leak Detection System for Plumbing wroks -
M009-SPH-MEP-MAR-00337
dann Teat / Denmark

x ITP:
Document No. Document Name
Inspection and Test Plan for Testing and Commissioning of Water Leak
M009-SPH-MEP-ITP-00087
Detection for Plumbing Works

x PLANS:

Document No. Document Name

M009-SPH-MEP-PLN-00003 Project Testing & Commissioning Plan
M009-SPH-QMS-PLN-00005 Project Quality Plan
M009- SPH-PRJ-PLN-00003 Project Controls Plan
M009- SPH-HMS-PLN-00009 Health and Safety Plan
M009- SPH-PRM-PLN-00002 Information Management Plan
M009- SPH-DCM-PLN-00002 Electronic Document Management Plan (EDMS)
M009-REI-RSK-PLN-00001 Risk Management Plan (Issued for approval)
M009- SPH-SHM-PLN-00003 Interface Management Plan
M009-SPH-EMP-PLN-00026 Construction Waste Management Plan

2.2 Revision of Procedure Documents

The revision of this Procedure shall be done when:

x New information becomes available.

x Main Contractor requires modifications.
x The Project Director requires modifications of Procedure.
x There is a significant change in the works methodology.
x The revised Procedure shall be submitted to DVE for SONO and PMC for Review and
Approval.

M009-SPH-TCH-PRO-00051 Page 8 of 18

Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
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3 ROLES AND RESPONSIBILITIES

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M009-SPH-TCH-PRO-00051 Page 9 of 18

Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
3.1 Project Manager
Project Manager is responsible and accountable for delivering the project, with authority
and responsibility from the project board to run the project on a day to day basis. He shall
also be the authority to apply final changes to the methodology process if needed, after the
approval. Project manager is also responsible to allocate resources to maintain good
Occupational Health & Safety standards, during every stage of the project, according to
local and international standards and RAK health and safety plan.

3.2 T&C Manager

The T&C Manager is responsible for Verifying the testing work carried out in accordance
with the requirements of the contract. And ensuring the quality standards set for the Testing
work are achieved and the work team adhere to the QA/ QC and HSE requirements of the
contract.

3.1 T&C Site Engineer

T&C Site Engineer is responsible for Ensuring that the works are being carried out in
accordance with contract requirements and this Procedure. He will manage the testing
activities to ensure that the team carries out the works in time with the delivery schedule.
Implementation of and adherence of the team to the QA/ QC and HSE policies and
procedure.

3.2 QA / QC Engineer
He is responsible and accountable for conducting surveillance and inspection duties at
various stages of the project delivery to ensure compliance to contract requirements and to
QA / QC requirements. He will ensure that the necessary corrective action is undertaken
against any recorded non-conformance. He will work in close coordination with all the inter-
related disciplines and stakeholders of the project. He is responsible for preparation of all
QA/QC related documents/procedures etc. Work in close coordination with Supervision
Engineer and Main Contractor’s QC Engineer to fulfil the QC requirements and reports to
QC Manager.

3.3 QC Inspector
He is responsible and accountable for checking the compliance of works to the design,
carrying out Inspections of all relevant construction works. He will be responsible for
inspecting the installation on the checklist and responsible for controlling /verifying, detailed
activities for on-site installations. Work in close coordination with Supervision Engineer and
Main Contractor’s QC inspectors to fulfil the QC requirements and reports to QC Engineer.
Report quality problems or findings to QC Engineer.

3.4 HSE Manager

He is responsible and accountable for developing, implementing and monitoring H&S
strategies, policies and programs that prevent injury and promote safe methods of working.

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
 He shall also be responsible for developing, implementing and monitoring environmental
strategies, policies and programs that promote sustainable development. He will be the one
to communicate and direct the HSE team, HSE Engineers/HSE Supervisors, to be
responsible for site activities regarding to check, to review and to make sure that all crew
members use appropriate PPE, all machinery, equipment and vehicles are appropriate for
HSE Requirements, work area clean and tidy.

3.5 Supplier/Manufacturer
Supplier/Manufacturer is responsible that check all power connection and equipment
installation as per manufacturer requirements then he will start the equipment.

3.6 Supervision Engineer

He is responsible and accountable for checking the compliance of works to the design,
carrying out comprehensive supervision of all construction works and final approving that
the work executed complies with the approved design and be responsible for checking the
construction works. He will be responsible and accountable to take reasonable care of
himself and the safety of others working nearby. He will make sure that all the workforce is
briefed about the task related hazards, control measures and availability and use of the
relevant PPEs.

3.7 Supervisor/Foreman
He will be responsible and accountable for supervising all the activities on site and has full
control over the use of the labour, plant equipment, leading, monitoring and overseeing a
team of foremen to ensure they produce quality work. He shall provide technical guidance
regarding the installation and maintenance of MEP systems and to ensure that the required
work is completed according to the shop drawings and is ready for inspection. He will be
responsible and accountable to take reasonable care of himself, his team members and the
others working around him. He will deliver start briefing prior to the job. He will be
responsible and accountable to receive PTW for the daily activities. He will make sure that
required PPE’s are available at worksite and are being used.

3.8 Technicians/Helpers
They will be responsible and accountable for the safety of themselves and the others who
can be affected by their work activities and shall be responsible for installing the equipment
at the exact location marked by the surveyor and according to the shop drawings, to
perform safely physical installation, handling the material and required equipment,
positioning and installation of materials shall ensure quality installations. Duties include
using, supplying or holding materials or tools, and cleaning work area and equipment. They
will make sure that required work permit has been received from the relevant authorities
and the control measures mentioned in the permit are being adhered to.

All the workforce is responsible and accountable to take reasonable care of their safety and
safety of the others working nearby them. They will be responsible and accountable to

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
 adhere to all the HSSE rule and regulations told to them in Induction trainings, TBTs and
STARRT briefings. They will also be responsible to use the PPE’s provided to them for their
safety and also not to alter with them.

4 RESOURCES
4.1 Labour

Sr. No. Description

1 Project Manager
2 T&C Manager
3 T&C Engineer
4 Supervisor
5 Foremen’s
6 QA/QC Inspector
7 Technician
8 Helper

4.1.1 General Tool used for this activity:

Sr. No. Tool

1. Mechanical Tool Box
2. Electrical Tools Box
3. Measuring Tape.
4. Torque Wrench
5. Mobile Scaffolding

Note:
x All Instrument should valid calibration Certificate and certificate should be available on site
at the time of testing
x Equipment may be substituted subject to availability and actual requirements on the day.
x The type and quantities of equipment are subject to change to suit the site requirements
and to meet the construction program.
.

5 QUALITY ASSURANCE/ QUALITY CONTROL

Package Project Director is responsible of pre-working control and shall provide specific
resources to the work to be performed and have to determinate the verification, validation,
monitoring, inspection to the work as well as criteria for product acceptance and quality record
needed.

Items which are a part of, or intended to be used permanently on, any of the systems of the
project shall not be used as an element of the testing setups for the purposes of testing.

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
The concerned Site Engineer or General Foreman will be responsible to ensure compliance for
these operations and the site QA / QC Engineer will carry out quality control checks and report
the inspection results.

6 HEALTH, SAFETY, ENVIRONMENT

The Health and Safety Plan will be strictly adhered to at all times.

x All workers will receive a site induction and be issued with PPE (hard hat, safety glasses,
safety vest, safety shoes) including hard hat with a SPH Inducted sticker before entering
to site to work.
x Regular Tool Box talks are held and attendance logged.
x The Emergency Response Plan is in place and will be strictly adhered to.
x In the event of any accident the HSE Incident Escalation Matrix will be followed at all
times.
x Specific HSE Hazards are mitigated in the Risk Assessment.
x To prevent accident during the implementation of the above activities, all relevant safety
measures shall be strictly implemented by the site engineers and the HSE team.

6.1 Lockout/Tag-out Procedure

The locking off procedure shall only be performed by trained and authorized personnel and
it shall be carried out in the following order:

1. Prepare for shutdown. This will include:

x Identify the equipment that needs to be locked off and the energy sources used to
operate the equipment.
x Identify the potential hazards of that energy
x Identify the method to control the energy – electrical, valve etc.
2. Inform all affected employees and let them know who is locking off the equipment and
why they are doing it.
3. Turn off the equipment following agreed procedures.
4. Isolate all energy sources in the equipment and ensure all stored energy has been
removed from the equipment.
5. Lock off energy device controls such as switches, valves and circuit breakers using an
appropriate lockout device and secure with safety padlock
6. Tag-out the lockout device using an appropriate tag

x Tags used must be highly visible with prominent warning to warn employees of the
danger of reenergising the equipment
x Tags must be durable and be securely fastened to the lockout device
x Tag details must be completed in full

7. Test the energy device controls to ensure equipment is de-energized and locked out.
8. Place key of safety padlock in Group Lockout Box and secure Group Lockout Box with
their own personal padlock.
9. Each person working on the equipment should put their own personal padlock on the
Group Lockout Box prior to commencing any work.

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
 10. Perform activity and do not bypass the lockout. The activity shall be done in
conjunction with and as set out in a ‘Permits to Work’ document.
11. On completion of activities, follow the agreed procedures to reactivate the equipment.
x Remove any blocks put in place and re-install any safety guards.
x Remove personal padlock from Group Lockout Box
x Once all personal padlocks have been removed from the Group Lockout Box,
keys to the safety padlocks are removed and used to remove all lockout devices
and tags.
x Re-start the equipment and test to ensure all is ok.
x Cancel the ‘Permits to Work’ and sign off the work.
x Let the relevant employees know that the equipment is ready for use.

6.2 Hazardous Waste Management

The SPH JV ultimately responsible for all hazardous waste storage activities. The SPH JV
will store hazardous waste as follow:

x Fire prevention systems and pollution control equipment will be provided for
storage facilities where necessary, to prevent fires or the releases of hazardous
materials to the environment;
x Containers intended for hazardous waste disposal will not be used for other
purposes unless they are specifically labelled for that purpose. Rusty, dented or
defective containers for waste accumulation or storage will not be used;
x Hazardous waste will be retained in a secure area with an impervious bunded
base;
x Secondary containment is required for liquid hazardous waste or other waste that
might be released into the environment, such as dusts, powders, and shavings.
x The conceptual design for the hazardous waste storage facility is part of the
CWMP.
x Hazardous waste will be disposed of in the area designated by municipality.
Incompatible hazardous wastes will not be transported together.

7 RISK ASSESSMENT
The Risk Assessment for this work is attached in Appendix 1.

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
8 METHODOLOGY

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
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M009-SPH-TCH-PRO-00051 Page 16 of 18

Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
8.1 PSAT (Partial Stand Alone Test)

8.1.1 Prerequisites for PSAT

Leak Detection commissioning will not commence until the installation mechanical and
electrical IRE signed off.

1. Ensure there is valid permit to work is issue.

2. Ensure that IRN had been submitted by construction and approved by all parties.
3. Electrical power wiring is complete.
4. Equipment schedules provided to show design parameters.
5. Ensure that as build / red line drawing provided.
6. Ensure sample of test pack has been prepared.
7. Ensure that civil work completed Ensure that lock out tag out (LOTO) in place.
8. Ensure approved Procedure is on the site.
9. Ensure HSE in place.

8.1.2 Pre-Commissioning

1. Ensure that no damage occurs between mechanical completion & PSAT (partial
stand-alone test).
2. Check that the Water leak detection system installation and connection to the
controller is as per the Installation & Operating Instructions.
3. Ensure that all the PSAT checks are carried out successfully
4. Ensure that pipe alignment is done
5. Switch on the electricity supply.
6. Check current, voltage record the value.
7. When the piping system has been filled with liquid, slowly open the valve until
it is completely open.
8. For the water leakage detection system setting refer to manufacturer
recommendation

After a successful completion of this stage, Pre-Commissioning Certificate

(PCC) will be released.

8.2 SAT (Stand-Alone Test)

8.2.1 Prerequisites for SAT

1. Ensure there is valid permit to work is issue.

2. Ensure the PCC is Available.
3. All piping installation work completed, inspected and approved including valve
package.
4. Electrical cable installation is completed, inspected and Approved
5. Ensure sample of test pack has been prepared.
6. Ensure that lock out tag out in place.
7. Ensure HSE in place.

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
 8. Ensure that approved as build have been provided.
9. Ensure approved Procedure is on the site.

8.2.2 Commissioning & Start Up.

8.2.2.1 Mechanical Checks

1. Check Piping and valve/ accessory installation.

2. When the Leak detection system is installed in the system check whether there is
sufficient suction pressure demand for water.
3. Make sure that the availability of water is sufficient enough to start and operate
the system.
4. Check all Joints of water leakage detection system.

8.2.2.2 Electrical Checks

1. Check the power supply

2. Check for the functionality of main fuses, earthling cable, isolator,
3. Check and inspect if the control key pad is working properly as per its
application.
4. Check the cables interconnection are properly tightened

After a successful completion of this stage, Partial Acceptance Certificates

(PAC) will be released.

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Testing and Commissioning Procedure for Water Leak Detection System for Plumbing Works (REDCO)
 APPENDIX 1

RISK ASSESSMENT
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