APPENDIX T

WATER CORPORATION DRAFT

COMMISSIONING PLAN

28/08/2015 222
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility
Doc ID Custodian
589769 15155 Asset Delivery Manager
Version Date Accountabilities Framework
21 March 2013 Level 1 Acquire Infrastructure Assets
Next Review Date Level 2 Manage Delivery of Projects
21 March 2016

Asset Commissioning Plan

CW01564

CUNDERDIN 75 ML STORAGE
TANK FACILITY

(2 x 37.5ML Tanks)

DRAFT
NB: ignore old references to 120ML. The required storage capacity has since been
downgraded to 75ML via an approved scope change
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

DOCUMENT MANAGEMENT

Document Control
This document has been issued as a controlled document.
To maintain the integrity of both this document and the Document Control Process no part
of this document may be reproduced by any member of the Water Corporation without
first having obtained authorisation from the Author (Commissioning Manager).

Revision Status
Revision Description Approved Approval Date of
Number Date Issue
V01 Draft Issued for Review JR 28/01 30/01
V02 Draft, Incorporating Feedback from VI and TC 31/03 1/04
EVDS
V02a Draft updated to include disposal plan TC 28/04 28/04
#12647540

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 2 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

Table of Contents
1 Purpose...........................................................................................................4
2 Project / Asset Overview .................................................................................4
3 Commissioning Scope & Objectives ...............................................................5
4 Project Requirements & Performance: ............................................................5
4.1 Approved Requirements Baseline:..................................................................6
4.2 Process Control Table (PCT): .........................................................................8
4.3 Performance Criteria & Specifications: ...........................................................8
5 Commissioning Management Strategy ...........................................................8
6 Supply & Construction Verification (Inspections and Tests) ..........................12
6.1 Supply Verification ........................................................................................12
6.2 Construction Verification ...............................................................................12
7 Pre-commissioning .......................................................................................13
7.1 Pipeline .........................................................................................................13
7.2 Valves/Reg Valves ........................................................................................15
7.3 Cunderdin 37.5ML Tanks..............................................................................15
8 Performance Testing / Equipment Commissioning .......................................16
9 Integration Commissioning............................................................................16
10 Proving Period / Reliability Testing: ..............................................................16
11 Risk Management .........................................................................................17
11.1 OSH Risk Management ............................................................................................. 17
11.2 Commissioning Risk Register .................................................................................... 18
12 Schedule & Milestones:.................................................................................20
13 Communications ...........................................................................................22
14 Training .........................................................................................................22
15 Appendices / Additional Documentation .......................................................23

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 3 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

1 Purpose
The purpose of this Commissioning Plan is to describe the methodology for commissioning the
Cunderdin 75ML Storage Tank Facility (2 x 37.5ML Tanks) to a safe and fully operational state and
to verify the assets performance against design criteria. The plan is used by the Commissioning
Manager to communicate the planned commissioning arrangements to various stakeholders and as a
reference for management purposes.
The works integrate with existing operational assets and therefore the tie in of new connections and
associated interruption of supply will be scheduled during autumn and winter off peak season. The
sequence of testing and commissioning needs to be carefully considered to minimise the impact on
existing supplies and services as the new equipment is introduced.
The Commissioning Plan, associated schedules, lists, test results and verification records are all
project deliverables as required by the asset handover process.

2 Project ! Asset Overview

The Main Line conduit has a series of storages which support system outages and contingency in
supply. The reservoir at Cunderdin in its original form pre-dates the main line conduit having been
created to supply water for the steam trains to Coolgardie. It remains as an open rock and clay lined
reservoir with a common DN800 inlet/outlet. This open reservoir configuration causes Water Quality
issues for the main conduit and the most desirable solution is to replace it with suitably sized enclosed
storage. Recent planning advice has identified the need for 75ML of storage. Several options for the
site of this storage have been considered over the years. The current location 5kms west of Cunderdin
and 1km to the south of the Great Eastern Highway was selected for its ability to support a variety of
options in terms of volume and number of tanks.
The project scope is for the design, construction and commissioning of two 37.5ML storage tanks
based on DS61standards. The design considered three tank options, to a level suitable to be let for a
design and construct contract.
Construction scope includes site earthworks, site access roads, hardstand areas, overflow sump,
DN900 MSCL inlet and outlet pipelines including all valves and appurtenances, pipe supports, road
crossings and drainage.
The works also require electrical, instrumentation & control installations and SCADA integration.
Depending on the tank design selected (steel or concrete) cathodic protection and voltage mitigation
equipment will also be installed.
The new tanks change the hydraulic profile for the main line, move the location of the regulating
valves to the inlet of the tanks and provide an increased head in the suction manifolds of the A and B
Cunderdin Pump Station. There will be some minor change to the operation of the main line in the
Cunderdin area especially in terms of contingency and back feeding operations to maintain local
supplies during system outages. These will be examined and outcomes recorded as part of the
commissioning processes.
The large volume of storage being commissioned places additional emphasis on Water Quality and
Environmental consideration arising from the disposal of test water from the tanks and new connecting
pipelines. Procedures linked to this plan identify the way in which engineering quality will be verified,
the steps taken to ensure Water Quality is maintained and that the environment will be protected when
disposing of any test water arising during commissioning.
The Commissioning Plan will cover the steps required to introduce (tie in) new connections, to
transfer functionality to the new assets and to remove redundant equipment once the new systems are
working satisfactorily.

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 4 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

3 Commissioning Scope " Objectives

The objectives of this plan are to:
(a) Summarise the commissioning function and performance requirements to be demonstrated.
(b) Describe the commissioning activities to be completed to determine whether the project has
successfully delivered against the agreed performance requirements. This includes:
Equipment Inspections and Tests (Supply, Construction and Pre-Commissioning);
Regulatory inspections & tests;
Control, Communications and SCADA system Tests (Factory Acceptance Tests &
Site Acceptance Tests); and
Process Performance & Reliability Tests;
(c) Provide a strategy and schedule for undertaking the above commissioning activities including
required process shutdowns and tie-ins.
(d) Identify and document the procedures necessary to ensure that commissioning activities are
carried out in accordance with corporate best practice, and ensuring the procedure documents
the impacts it will have on other operating assets.
(e) Define commissioning risks and risk management; outlining these in the categories of OS&H,
project, operational and environmental.
(f) Describe the commissioning team structure, identifying roles and defining responsibilities.
(g) Communicate the planned commissioning arrangements to the Project Team, Commissioning
Team, Regional Operating group and the Operations Centre.

4 Project Requirements " Performance:

This commissioning plan and the supporting reliability and proving tests have been developed to
ensure all new and pre-existing equipment is inspected and tested to enable demonstration of the new
assets against the criteria in:
the Approved Requirements Baseline (ARB),
the preliminary Process Control Table (PCT), and
the design reports and specifications.

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 5 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

4.1 Approved Requirements Baseline:

The table below is extracted from the Approved Requirements Baseline for the Project PM-
#9502011-CW01564 Cunderdin 120ML Storage Tank - ARB . Note that any proposed changes
to the ARB need to be addressed directly with the Project Manager rather than in an amendment to this
document (NB: ignore old references to 120ML. The required storage capacity has since been
downgraded to 75ML via an approved scope change)
Following commissioning, the commissioning manager will produce the requirements verification
report for the project. This is a table that summarises performance against the ARB with Comments on
intended verification methods at Commissioning.
Commissioning
System Requirement
ID Requirement Rationale Verification
Element Type
Comments
To replace the reservoir with tanks as
there are Water quality issues associated
with the current Cunderdin open
This determines the
The total capacity (unroofed) reservoir.
TWL and diameter of
Cunderdin for the Cunderdin
C(s) - Capacity R1 the tank. Verify as
Storage storage must be a To meet demand up to 2050.
constructed drawings
nominal 75 ML.
from survey
As per IDB recommendation
aqualink#2266203 Cunderdin 120ML
Storage - Engineering Design Report
IPB Planning advice has determined that
a minimum usable storage of 67 ML at
Cunderdin provides a sufficient volume
to meet the operating requirements of the
GAWS main conduit. Must be able to use 90%
The usable
The storage volume provide sufficient of the tank volume.
capacity for the
Cunderdin emergency storage for supplied customers Confirm that there is no
C(s) - Capacity R2 Cunderdin
Storage in meeting the objectives of adequate limitation on system
Storage must be
water quantity and water quality required operation imposed at
67 ML.
by the Water Corporations operating low levels
license.

Based on recent planning Technical

Advice #9382953

To provide for: balancing between

differing rates of inflows to and outflows
from the storage; to control valves and From an operating
The operating pumps within the system; and to provide capacity perspective this
capacity for the for high and low level alarms. would be the minimum
Cunderdin
C(s) - Capacity R3 Cunderdin required volume of
Storage
Storage must be This provides: tanks. Appears then that
19 ML. Control storage of 4 ML R1 and R2 and R4
Balancing storage of 15 ML exceed this requirement.
Based on recent planning Technical
Advice #9382953

This provides:
Failure response storage - Isolate zone,
Stop transfers 2 hr @ 80ML/d = 7 ML
Provide system warning
Reserve Storage - Provide Supply to CK,
on SCADA for when
CS, Cunderdin pipe bursts upstream for
level gets close to
The reserve 33 hours @ 18.7ML/d (worst case
equivalent volume
capacity for the scenario) 26 ML (27hr pump failure 21
Cunderdin 48ML on top of
C(s) - Capacity R4 Cunderdin ML)
Storage unusable volume 8ML
Storage must be Recovery Storage - provides Supply to
gives 56ML (75%). This
48 ML. Zone 2 while waiting full supply from
is equivalent to level
West Northam Tank 14 hrs zone demand
244.7m AHD, therefore
@ 25ML/d = 15 ML
low level alarm setting.
Based on recent planning Technical
Advice #9382953

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 6 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

To meet daily demand downstream of Confirm during

The inlet and
tank. commissioning that
outlet pipework
inflow and outflow rates
Cunderdin shall be designed
C(s) - Capacity R5 This is based on the maximum flowrate of 126ML/d are
Storage for a nominal
for the long term (2050) requirements for achievable and do not
peak flow rate of
the high growth demand scenario (most impose any operational
126 ML/d.
conservative case). constraints.

FUNCTION
The minimum
Top of outlet flared end
operating water
is 242.05m AHD and
level under
BWL no greater than
Cunderdin F - Hydraulic normal operation Provide sufficient head for all Cunderdin
R6 243m AHD. Survey as
Storage Configurations for the Cunderdin pump stations.
Con for verification. No
Storage must be a
requirement for tank
nominal 241.90m
alarms or protection.
AHD.
OPERATIONS &
MAINTENANCE

Design will be in
accordance with To ensure compliance with existing
O-
Generic R7 IDB design design standards and relevant regulatory Addressed by design
Compatibility
standards relevant requirements.
to this installation.

Project
deliverables in
O- accordance with To verify the functionality and operability Commissioning
Generic R8
Compatibility the agreed Asset of the delivered asset. deliverables
Handover
Checklist.

Connection tapping on
The ability to
O - Control and Prevention of Falls standard has removed inlet pipework to
Cunderdin manually dose
Communications R9 access to roof need some way of facilitate connection to
Storage tanks with
Local Operation manually dosing chlorine temporary pumped
chlorine.
dosing arrangement.

The inlet and

O - Control and
Cunderdin outlet magflows Operations need to be able to view flows Functionality
Communications R10
Storage shall be monitored going in and out of tanks demonstration at SAT
Remote Alarms
remotely.

The tank level Operators need to be able to determine

Cunderdin O - Data shall be visible to level of tank as they no longer have Digital readout at site
R11
Storage Acquisition Operators from access to top of tank and there will not be cubicle
ground level. a site gauge.

CRITICA
LITY

To ensure full capacity of 75ML is Functionality

available. demonstrated
Normal operation
Cunderdin C(u) - Failure of site will be two
R12 The rationale is that both tanks are
Storage Response tanks operating in Normal operating
required to operate concurrently in
parallel. procedure outlined in
parallel in order to deliver the specified
capacity to the system O&Ms

Possible for a tank to be taken off-line for Functionality

Potable water
long time and lose residual. In this demonstrated
supplied to
Cunderdin C(u) - Failure instance customers fed directly from this
R13 customers fed
Storage Response site could be supplied un-chlorinated if
directly from the Abnormal operations
the tank was brought back online without
tanks must be outline in O&Ms.
dosing.
chlorinated.

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 7 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

LOCAL CONSTRAINTS

Provide a gravel
access track from Under normal operations, it is classified
Great Eastern as a remote site and access is not intended As constructed
Generic L - Construction R14 Highway to the to be frequent. A kerbed and drained configuration will be
entrance of the bituminous pavement is not necessarily noted.
secured tank required.
compound.

4.2 Process Control Table (PCT):

The water quality control of this asset is covered by a Water Supply Plan for the system that the tanks
will supply PM-#7030786 Cunderdin Water Safety Plan.
This plan will require updating to reflect the new storage configuration.

4.3 Performance Criteria ! Specifications:

The performance criteria and specification summary is the basis by which the Water Corporation will
manage commissioning of the assets to ensure assess the individual asset, process unit or system
against:
DDR ( 70% deliverable at time of first draft) PM-#12034927-Cunderdin 70% deliverable
Functional control (see 70% deliverable)
Drawing planset JB79
Parameter Performance
Main Conduit Operations All modes and flows remain available
Reg Valve Operation Reg Valve meets target performance
Tank level control Grass Valley/ Cunderdin A B operations
SCADA effectiveness Reliable Comms, Good data and Ergonomics

5 Commissioning Management Strategy

Specific Strategies to be employed for CW01564 include providing input to construction methodology
and sequencing to get best schedule to tie in with operational requirements, and to reduce the total
volume of water scoured to environment during commissioning processes through:
Implementing construction hygiene for pipelines and tanks to minimise scouring requirement,
Wash down disinfection for each tank prior to initial fill (0.15m) and BTEX.
Re-use of disinfection water in each section of pipework and each tank.
Storage fill diluting disinfection dose to achieve system Chlorine inventory at TWL
Periodic and staged sampling to monitor water quality during fill and provide supporting
evidence at Operation Commencement.

The logic for scheduling these activities is outlined at PM-#12307845-Cunderdin Tank

Commissioning Logic

For this project there will be a single commissioning team. The Commissioning team will be
responsible for commissioning of all new equipment installed by this project, with support provided
The Contractor personnel as required. The Commissioning Manager (CM) will be responsible for
Water Corporation Infrastructure Asset Handover Process 14/01/2014
Uncontrolled if printed Commissioning Plan Page 8 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

scheduling and coordinating commissioning sessions, and ensuring there are adequate resources with
relevant expertise provided for the commissioning process. The CM will advise the Contractor in
determining what resources are required to support Commissioning. The CM will ensure Water
Corporation personnel are available to witness commissioning activities as required. This plan
includes key commissioning milestones and hold points that will need to tie-in with the project
schedule.

The Commissioning Manager has the role of overseeing the commissioning process and ensuring the
Water Corporation’s requirements are met in all aspects of the commissioning. The CM will advise
and direct The Contractor’s job manager where necessary and advise on the commissioning
requirements set out in Water Corporation standards. The CM will assist in determining integration
requirements and ensuring that the new assets will interface successfully with existing Water
Corporation assets where required.

The Preliminary Commissioning Plan has been prepared by the CM and this forms the minimum
requirements to be met during commissioning. The CM will be responsible for updating the
commissioning plan as necessary, and collating commissioning documentation which has been
completed by The Contractor and MESB Specialist. Documentation will be tracked using a
Commissioning Activity Master Equipment List (CAMEL) which details what documentation is
required for which items of equipment, including any checks that are to be carried out prior to the
commencement of commissioning (i.e. during supply, construction and pre-commissioning).

5.1 Commissioning Team Roles and Responsibilities

The Commissioning team roles and members are anticipated to be as follows. Staff will be required to
assist during on-site commissioning as detailed below.

Role Who
Commissioning Manager Tim Cross
Mechanical Inspector Adam Graham
Civil Inspector TBA
Electrical & Controls Inspector Robert Van-Tiel
Materials and Coatings Geraldine Pederson
SCADA Inspector Erik Van Der Zwan
Operations Staff Christine Lowther
Asset Delivery Representative Chas Allardice

Contractor’s Staff:
Role Who
Contractor’s Job Manager TBA
Construction Supervisor TBA
Electrical Supervisor TBA
Mechanical Supervisor TBA
Engineering Design Manager TBA

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 9 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

The Commissioning Manager (CM) is responsible for:

Preparing the preliminary Commissioning Plan, Commissioning Activity and Master Equipment List
(CAMEL) and inspection and test plans and report templates. Reviewing and revising the preliminary
Commissioning Plan and CAMEL as necessary throughout the life of the project

Ensuring that commissioning planning and scheduling minimises commissioning risks (as
identified in the commissioning plan) as much as possible. Engages with Contractor’s Job
Manager (CJM) on discussions on how to adequately mitigate commissioning risk
Collating documentation provided by the contractor for inclusion in the CAMEL
Liaising with the CJM to ensure that the Principal’s mechanical, electrical, control and other
specialist inspectors are available to witness commissioning tests (and record results where this
has been agreed).
Advising The CJM where required to schedule commissioning inspections and tests.
Managing integration testing of the new equipment/assets following energisation to ensure that
it is successfully integrated with existing assets.
Liaise with the Water Corporation’s SCADA Maintenance Group (SMG) and Operations Centre
to ensure their requirements are met for SCADA testing, integration and commencement of
remote operation & monitoring.
Produce the Requirements Verification Report
Conduct Commissioning Progress Meetings
Advise on Water Corporation commissioning requirements and monitor commissioning to
ensure Water Corporation requirements are met.
Assist wherever necessary to ensure that commissioning activities run smoothly and are carried
out to an acceptable standard.
Ensures JSAs/JHAs are in place for commissioning sessions.

The Contractor’s Job Manager is responsible for:

Managing commissioning inspections and tests in line with the Commissioning Plan provided
by the CM.
Ensuring that scheduling minimises commissioning risks (as identified in the commissioning
plan) as much as possible.
Scheduling commissioning inspections and tests in line with the Commissioning Plan and
communicating this as necessary to both internal and external stakeholders. The CM will assist
in determining scheduling as necessary.
Providing resources where necessary to address faults or issues that relate to the contracted
scope of work during the commissioning and proving period.
Attend commissioning meetings held by the CM.
Promote safety during the commissioning phase and assist the CM in determining ways to
minimise risk to personnel during commissioning activities.
Produce a Commissioning Report detailing the outcomes of commissioning activities.
Complete JSA/JHA as required for commissioning tasks.
Conduct Site Toolbox and Safety Meetings for commissioning activities.

Commissioning Inspectors, (Mechanical, Electrical, Materials and Civil) are responsible for:

Creating commissioning procedures to document planned testing and consulting with

stakeholders on the planned testing where required. This includes the creation of FAT/SAT
procedures for testing of control systems.
Ensuring that adequate resources are provided to carry out testing on the new assets, as well as
completing any documentation that is associated with these items (documentation requirements
are covered in the CAMEL – see section 15.2).
Water Corporation Infrastructure Asset Handover Process 14/01/2014
Uncontrolled if printed Commissioning Plan Page 10 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

Submission of all commissioning documentation to the CM progressively as it is completed.

Documentation requirements are discussed in this plan and set forward in the CAMEL (see
section 15.2)
Assist the CM in the witnessing of commissioning activities on site and recording of
information.
Provide technical advice and assistance to the CM if required
Ensures commissioning is carried out in a safe manner and advise, report any issues to the Site
Safety Officer.
Completes JSA/JHA as required for commissioning tasks.
Provide input to Toolbox and Safety Meetings.

5.2 Commissioning Work Packages:

The commissioning process will consist of:
100 System Tie Ins
a) System shut down to install new isolation valve, tank inlet and tank outlet
b) Work completed with new isolation valve fully open allowing normal flow down main conduit
and new tank inlet and outlet valves shut and blanked.
200 Pipeline and Isolation Valves Inspection, Disinfection and Testing (procedure TBA)
a) Inspection of pipework and valves.
b) Fill and pressure test pipework (in parallel with c))
c) Flush, scour and disinfect pipework PM-#367317-Disinfection of Water Mains.
d) Bacto test.

300 Tank Commissioning

a) Clean, wash down and initial disinfection of tank. Disposal of arisings.
b) Initial fill for hydrocarbons and Bacto (BTEX)
c) Disinfection, staged fill, settlement pins and leak testing of tank in accordance with PM-
#365544-Working on Storages and Bringing New Storages On-Line
d) If required, disposal of de-chlorinated water using Disinfection Water Disposal Plan in
accordance with BWW-024-2 “Guidelines for the Disposal of Disinfected Water” PM-
#1082608-Disposal of Highly Chlorinated Disinfection and Alkaline Water Guideline

400 Instrumentation and SCADA

a) Conduct SCADA/PLC FAT with optimal controllers and control cubicles to confirm logic,
screens and functionality.
b) Following issue of notice of completion, energise site, communications and instrumentation
transducers. Prove field devices
c) Integrate new control screens with main GAWS microscada.
d) Calibrate and set to work valve controls, instrumentation and sensors
e) Carry out pre SAT/ SAT of SCADA system

500 System Commissioning, PRV operating with new 37.5 ML Tanks

a) Configure valves for supply to PRV manifold
b) Scour water
c) Isolate old reservoir
d) Bring new tank on line, adjust main and standby PRVs as required.
e) Complete SAT
f) Record valve performance at full range of possible flows.

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 11 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

600 System de-commissioning, Old Reg Valves and Cunderdin Reservoir

a) System shut down to remove old Reg valves and replace with new section and blank reservoir
connection.

6 Supply ! Construction Verification (Inspections and

Tests)
The objective of supply and construction verification is to ensure that equipment (typically
mechanical, electrical, control systems, valves and pipework) as defined in this plan and the project
Commissioning Activities and Master Equipment List Camel TBA has been:
Supplied undamaged and according to the specification, and
Installed according to design and manufacturer’s specifications.

6.1 Supply Verification

6.1.1 PIPELINE
a) Dimensional checks prior to installation ( ie ovality, wall thickness)

6.1.2 VALVES and REGULATING VALVES

a) Use the Supply Verification ITR WC-SV-M-001-R Valve (Appendix 3) as the guide for the
inspection and to document the inspection and test results.

6.1.3 TANK MATERIALs

a) Use the Factory Verification 5822792 and Supply Verification ITR, 3671135 recommended by
MESB to verify that materials comply with the design and water corporation standards.

6.1.4 INSTRUMENTATION AND SCADA

a) Use the Supply Verification ITR WC-TBA and record inspections and verification of all
instrumentation and communications devices.
b) Conduct Factory Acceptance Testing of best possible arrangement of controllers and devices,
testing against functional control description.

6.2 Construction Verification

6.2.1 PIPELINES, PIPE MANIFOLDS AND SPOOLING.
a) Verify that the manifolds have been fabricated as per drawing dimensions and required
standards
b) As constructed survey and documentation shall be completed in accordance with the Procedure
for pipelines and tanks. Refer Section 19 ‘Constructed Survey and Documentation, Design
Standards DS60, Pipelines - Other Than Reticulation.’

6.2.2 VALVES AND REGULATING VALVES

a) Verify that the valve(s) have been installed to the manufacturer’s instructions and with the
correct orientation (direction of flow and position of valve operating gear).
b) Manually operate the valve to check operation.
c) Use the Construction Verification ITR WC-CV-M-001-R Valve (Appendix 3) as the guide for
the inspection and to document the inspection and test results.
d) Use the CV 3671141 for the Regulating Sleeve Valve

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 12 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

6.2.3 TANK CONSTRUCTION

a) Verify that the tanks construction complies with Water Corp standards

6.2.4 SCADA AND INSTRUMENTATION

a) Verify that the switchboards have been manufactured to Water Corp standards

The Supply and Construction Verifications (completed and signed ITR’s) for specific equipment are to
be submitted and approved by the person nominated in 5.1 above before pre-commissioning (as
outlined in section 7) for that specific equipment can commence. This hold/check point applies to all
inter related equipment energised as part of that pre-commissioning.

7 Pre-commissioning
The objective of pre-commissioning is to ensure each item of equipment or component of a system
functions safely and to specification in a standalone environment after the system is energised
electrically and physically (hydraulically or pneumatically).
Pre-commissioning is to be undertaken in a planned and coordinated manner following the
commissioning schedule and commissioning work breakdown structure outlined in this plan. It will
include control system SAT, including end to end testing of I/O and alarms from field device to the
OC via the SCADA system.

7.1 Pipeline
PM-#12032774-Cunderdin Tanks Cleaning disinfection and fill procedure

7.1.1 TESTING PREPARATION

a) The Region’s Operations Manager is to be made aware of the intended testing time for the
pipeline as soon as possible after determining when that will occur. In addition the Region’s
Operations Manager is to be contacted at least five working days prior to commencing filling of
the pipeline for testing, to ensure efficient scheduling of operational changes required to ensure
that customer supply is not impacted.
b) The pipeline will be cleaned of all debris and physically isolated from the ‘live’ system. The
testing will take place at least 48 hours after thrust or anchor blocks have been poured.
c) The testing will include all valves and appurtenances to the pipeline.
d) For the section of pipeline to be tested, the difference in elevation between any two points on
the main shall be less than 30 metres. The pressure test gauge shall be located as close as
practicable to the lowest point of the test section.
e) All manholes shall be exposed during testing.
f) Filling of the main shall be completed at least 24 hours prior to the commencement of the
pressure test. For cement mortar lined steel pipes the pipeline shall be charged with water for a
period of 48 hours prior to the pressure test to allow for the absorption of water by the lining.
Before the commencement of the pressure test the pipeline shall be held under pressure for one
hour and make-up water added as required.
g) The filling water will be disinfected in accordance with the pipeline disinfection procedure
described below.

7.1.2 TEST PROCEDURE

a) Reference IDB Design Standard DS60 “Water Distribution – Pipelines Other than Reticulation”
b) The test section shall be subjected to a hydraulic pressure equal to the designated maximum
working pressure of the pipeline (DN900 PN 12 to be tested to 120m (1200kPa))
c) The maximum working pressure is defined as the maximum internal working pressure which
may be applied to the pipeline either as a continuous or transient peak pressure.
Water Corporation Infrastructure Asset Handover Process 14/01/2014
Uncontrolled if printed Commissioning Plan Page 13 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

d) The test pressure is that pressure which would be measured at the lowest point of the test
section.
e) The duration of the test for all pipelines shall be two hours.
f) For a pipeline to satisfactorily pass a pressure test there shall be no leakage for the duration of
the test.
g) If a pipeline fails a pressure test, additional water added for further testing shall be disinfected in
accordance with the disinfection process for pipelines.
h) After a satisfactory pressure test, the pipeline shall remain full with the disinfection water for as
long as the disinfection strategy allows. The pipeline shall then be completely drained of the
disinfection water and filled with potable water.
i) Following satisfactory bacteriological tests the pipeline will be drained as necessary to make the
required connections to existing mains in accordance with the Disinfection Water Disposal Plan.
j) The details of all official pressure tests shall be recorded on the Pressure Test Record Sheet.
Further tests, if required, shall be carried out until the results are accepted by the Corporation’s
Representative.
k) An example of a Pressure Test Record Sheet is contained in Appendix 1

7.1.3 DISINFECTION
a) This filling and disinfection procedure draws on BWW 024-1 “Disinfection Guidelines for
Water Mains” .
b) Approximate volumes of water required for the commissioning operations are tabulated below.

Pipe-work Item Length X Section Volume(m3)

(m) Area(m2)
PN12 DN900 MSCL 1000 0.636 636
PN12 DN900 MSCL 1000 0.636 636
Total volume of pipework 1272
Flushing volume needed 2 vols 2544

c) The pipeline will be physically isolated from the “live” system it is to be cleaned of all debris
and dirt before filling with water. The disinfection will include all valves and appurtenances to
the pipeline.
d) Water will be supplied from the Main Line and a certified (installed and tested by a licenced
plumber) back flow prevention device supplied by the contractor must be used.
e) Disinfection utilising the Water Corporation chlorination trailer available from Engineering &
Construction Services Branch.
f) Method of chlorine dosing will use sodium hypochlorite.
g) The lowest level of disinfection shall be 20 mg/L and the main shall be allowed to sit for 24
hours before scouring. The minimum time that the main shall be left to sit is 3 hours at a
concentration of not less than 10 mg/L.
h) The procedure identifies the calculated amount of sodium hypochlorite required for disinfection
i) The length of time the highly chlorinated water will be in contact with the pipe-work for 24
hours
j) After the appropriate detention period the disinfection water will be flushed in to the next
section of pipework or tank to be disinfected. The pipeline will be back filled with potable
water. The pipeline water will then be tested for bacteriological content and pH value.
k) The form BWWF024-1-1 “Request for Main to be Tested – Pre-commissioning quality check”
is to be completed and sent to the Regional Water Quality Officer to request the appropriate
testing. Seven (7) days notice is to be given of the requirement for bacteriological testing.
l) Scouring of highly chlorinated water will be minimised by re-using each disinfection dose. Final
disinfection doses will either by diluted and re-used or scoured to the sump. Expected volume
around 1000 to 2000m3. Hay bales will be used for de-chlorination if required.

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 14 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

m) Disposal of chlorinated water will be carried out in accordance with the projects test water
disposal plan PM-#12647540-Cunderdin 75ML Storage Tanks and Pipeline test water disposal
plan SIGNED

7.2 Valves/Reg Valves

7.2.1 INSTALLATION.
a) Use the Pre-Commissioning ITP WC-PC-M-001-P Valve (Appendix 3) as the guide for the
inspection and the Pre-Commissioning ITR WC-PC-M-001-R Valve (Appendix 3) to document
the inspection and test results.

7.2.2 DISINFECTION
a) On delivery to site spray all internal surfaces with a 1% solution of sodium hypochlorite. Flush
with potable water and wrap the valve in plastic until installed.

7.2.3 TESTING and SETTING TO WORK see PM-#12280433-CW01564 Cunderdin New

Storage Reg Valve Test Procedure
a) Reg Valves will require data loggers and appropriate instrumentation ( TBD) to establish valve
performance and system characteristics meet the design requirements.
b) Pre-commissioning documentation 3671152 will be used

7.3 Cunderdin 37.5ML Tanks

7.3.1 TESTING PREPARATION

PM-#12032774-Cunderdin Tanks Cleaning disinfection and fill procedure

a) Inspection of pipework and valves.

b) Clean and wash down tank.
c) Disinfection and leak testing of tank in accordance with PM-#365544-Working on Storages and
Bringing New Storages On-Line
d) Disposal of de-chlorinated water using Disinfection Water Disposal Plan in accordance with
PM-#12647540-Cunderdin 75ML Storage Tanks and Pipeline test water disposal plan SIGNED
e) Re-fill test for hydrocarbons and Bacto.
f) Staged fill, settlement pins and leak testing.

PM-#3069762-C-CONCRETE TANK-PC-R Or Steel Tank equivalent ITR

7.4 SCADA and Instrumentation

7.4.1 TESTING PREPARATION
a) Perform SCADA SAT, i.e. set up levels, check alarms verify magflows and confirm valve
control.

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 15 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

8 Performance Testing " Equipment Commissioning

Equipment commissioning tests the full operation of all equipment supplied by the project under
specific conditions and operational modes in isolation from the main line system

The following equipment commissioning sessions will be undertaken:

A shutdown process where the new tank inlet, new tank outlet and isolating bypass valve can be
‘cut in’ in accordance with the drawings and specification as agreed by the Superintendent.
Charging and scouring the new inlet and outlet pipelines via RPZ connections.
System operation across full range of mainline operating configurations. Testing and recording
of regulating valves. Demonstration of abnormal operating procedures. Recording of
instructions. Field crew training.
Specific procedures will be prepared for each of the sessions to ensure they are performed in a safe
and controlled manner. These will be prepared following the Water Corporation’s Commissioning
Procedure / Session – Typical Format , AquaDoc # 5595017 or in a format that at minimum meets the
criteria specified in this document.
With satisfactory completion of pre-commissioning activities, the following steps represent a
minimum standard to be used to commission the new pipeline into service:

9 Integration Commissioning
Integration commissioning tests the full operation of the assets delivered by the project as part of the
larger water system under specified conditions and operational modes.
The integration requirements will include:
System operation across full range of mainline operating configurations.
Testing and recording of regulating valves performance.
Demonstration of abnormal operating procedures.
Recording of instructions and field crew training.
These will be considered in greater detail at a later stage of the project and specific procedures will
be prepared to cover the commissioning sessions required and ensure they are performed in a safe
and controlled manner. These will be prepared following the Water Corporation’s Commissioning
Procedure / Session – Typical Format , AquaDoc # 5595017. These will be prepared by the
Principal’s Commissioning Manager prior to the tests.

10 Proving Period " Reliability Testing:

Proving Periods:
(a) New 37.5ML Tanks, 30 days including 7 day leak test.
(b) New Regulating Valves and standby regulating method, 30 days of continuous operation
(c) SCADA and communications
Minimum 1 week proving period in stable operation
Comply with specified frequency and duration of system faults or outages (number of
outages per 24hr period, frequency of individual outages, sum total duration of outages
per 24hr period)
Compliance with SCADA handover guidelines
All data displayed in correct units of measure in accordance with the Water
Corporation’s Data Collection Standards.
Water Corporation Infrastructure Asset Handover Process 14/01/2014
Uncontrolled if printed Commissioning Plan Page 16 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

11 Risk Management
This section identifies commissioning risks, assesses these for significance based on likelihood
and consequences and then outlines the planned mitigation (including contingency plans).
These can be particularly important and complicated where brownfields installations or direct
on-line commissioning is concerned.
The identified commissioning risks & mitigations are to be included and managed in the Project
Risk Register PM-#9595844-CW01564 Cunderdin 75Ml Storage Risk Register

11.1 OSH Risk Management

Procedures:

The Water Corporation’s Safe Job Planning process will be followed for specific pre-
commissioning and commissioning activities. All Job Safety Analyses and/or Job Hazard
Assessments will follow these. As required, these will be checked/verified by the project /
Construction OSH representative. Ref Aqua DOC # 2289406 and # 2289407.

It is planned that the following OS&H processes and procedures will apply in the project for the
purposes of pre-commissioning & commissioning (others may apply during construction –
please refer to the constructors OSH Plan for these):
(i) Incidents to be managed in accordance with Water Corporation OSH Incident
Process.(Refer WC-OSH-010)
(ii) Water Corporation Clearance to Work procedures (Refer WC-OSH-23)
(iii) Water Corporation Isolation and Tagging procedures (Refer WC-OSH-109)
(iv) Water Corporation Confined Space procedures (Refer WC-OSH-108)
(v) Electrical work: to be completed in accordance with the Water Corporation Electrical
Safety Procedure S-133
(vi) Water Corporation Protective device (RCD) testing

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 17 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

11.2 Commissioning Risk Register

OSH Hazards and Risks: Commissioning OSH Hazards, Risk and Mitigation Measures Residual After Mitigation
Item Commissioning Issue Cause Likelihood Consequence Impact Mitigation Likelihood Consequce
Impact
O1 Commissioning Safety Incident or Poor Communication with District and CTW UNLIKELY MODERATE MODERATE Commissioning Plan includes safety procedures and
unacceptable impact on operations. not followed. Commissioning activities references. CTW permit required only for tie-ins RARE MODERATE
HV/LV Electrical undertaken in an unsafe manner.
Pressurised pipelines LOW
Chlorination Systems
O2 Pressure to commission tanks and reg Time constraints due to off-site demands UNLIKELY MODERATE MODERATE Ensure program takes into account Treatment plant
valves before assets are proven safe upgrade. Keep SDR and Regional Customer & Business
RARE MODERATE
to operate. Administration Manager informed of progress
Tie ins – time constraints due to A safety inspection with Principal’s commissioning manager
impact on town supply. is to be carried out onsite before energisation.
All construction & pre-commissioning verifications are to be
LOW
presented to the Principal’s commissioning Manager before
system energisation.
Environmental Risk Management: Commissioning Hazards, Risk and Mitigation Measures Residual After Mitigation
Likelihood Consequce
Item Commissioning Issue Cause Likelihood Consequence Impact Mitigation
Impact
E1 Discharge of highly chlorinated Disinfection dose inadvertently scoured to UNLIKELY MINOR LOW Valve and system operation controlled by procedure and
disinfection water to the Environment the environment without de-chlorination tag out system. Environment Management plan in place to RARE MINOR
processing either due to valves being left treat and monitor the water being discharged to the
open or incorrectly operated environment.
LOW
E2 Discharge of scour water to the Large volumes of scoured water discharged UNLIKELY MINOR LOW Valve and system operation controlled by procedure and
Environment causes erosion of beds in an uncontrolled manner or Water Quality tag out system. Flows to be monitored, potential high RARE MINOR
and banks issues dictate that a full tank is to be erosion areas to be protected by geo fabric or similar. Limit
scoured to the environment. scouring rates to minimise impact LOW

Asset Risk Management - Performance and/or Reliability: Commissioning Hazards, Risk and Mitigation Measures Residual After Mitigation
Likelihood Consequce
Item Commissioning Issue Cause Likelihood Consequence Impact Planned Mitigation
Impact
Pressure main or pressure pipework Pipe blockage, compressed air in pipe, UNLIKELY MODERATE MODERATE Formal staged pressure test of ALL pressure pipework to
burst or leak during commissioning closed air valves, poor construction, closed be completed before any pumping. Pipe route is to be UNLIKELY MINOR
A1 valves. walked and all valves checked before pumping.
LOW

Assets unavailable for operation in Hand-back of assets to operations for

emergency contingency events. Contractor fails to FAT testing of control switchboard. Provide contingency in UNLIKELY MINOR
A2 handover. Emergency operation required case of PS poor performance or inability to bring PS on-line
and not possible and town water supply maintain existing temporary pump station in operable state
runs out. Lack of contingency planning. LOW
UNLIKELY MODERATE MODERATE for 2 weeks following commissioning.
A3 Poor Commissioning Information Inadequately prepared commissioning plan UNLIKELY MINOR LOW Preliminary Commissioning Plan prepared and provided to
Provided to Constructor and CAMEL for constructor Project Manager (for forwarding to constructor) prior to UNLIKELY MINOR
contract award.

LOW

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 18 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

Asset Risk Management - Performance and/or Reliability: Commissioning Hazards, Risk and Mitigation Measures Residual After Mitigation
Item Commissioning Issue Cause Likelihood Consequence Impact Planned Mitigation Likelihood Consequce
Project delays or rejection of Tank Site Tanks and Valves do not perform to meet POSSIBLE MINOR MODERATE Test Reg valves before delivery to site(FAT to be witnessed
by client system requirements by WC) UNLIKELY MINOR
A4
LOW

A5 Lack of Commissioning Water Supply Use disinfection water for hydrostatic test. POSSIBLE MINOR MODERATE Consider arrangements for Hydrostatic test
UNLIKELY MINOR

LOW

A6 Commissioning & Handover Delays Commissioning and handover is not UNLIKELY MINOR LOW Commissioning Plan prepared in accordance with
Business Requirements not met undertaken in accordance with WC Guidelines and to address Handover Requirements. WC RARE MINOR
guidelines Commissioning Manager to deliver and describe these to
the Constructor before construction commences. Asset
Handover check-list prepared and SDR to arrange regular
LOW
review of this to track progress during the project delivery
phase.
A8 Commissioning Delays, project Commissioning Strategy incorrect, UNLIKELY MINOR LOW
delivery delays – Poor planning of impractical, or not properly planned.
RARE MINOR
activities Commissioning team not given enough
information to write the draft plan.
Lack of communication with District Preliminary Commissioning Plan Prepared by in-house
operating staff. (WC) commissioning manager in advance of construction
Systems & equipment not tested contract award. LOW
adequately before Commissioning plan provided to Customer for comments
energisation/commissioning and to include in District operations planning
A9 Commissioning Delays - Operational Unplanned high system demands, UNLIKELY MODERATE MODERATE Ensure that tie-ins are arranged with District well ahead of
imperatives prevent commissioning Lack of planning & communication with time (involve in site meetings during commissioning tie-in RARE MODERATE
being able to occur as scheduled. District. period). Ensure bypass-pumping is available during
Lack of /or poor reliability of pumping commissioning / tie-ins
arrangements / existing pump station (if Schedule tie-ins during low flow periods and outside LOW
required). cyclone periods
A10 Commissioning Delays – Poor role Responsibility for commissioning unclear or UNLIKELY MINOR LOW
definition / understanding not defined. Demarcation or shared RARE MINOR
responsibility with region/contractor/
commissioning staff not articulated Roles defined in Commissioning Plan and agreed with LOW
constructor and communicated to all stakeholders.
A11 Interruption to operation of scheme Change control procedures are not followed POSSIBLE MINOR MODERATE Ensure that tie-ins are arranged with District well ahead of
and customers are without water for Poor or inaccurate communication of time (involve in site meetings during commissioning tie-in UNLIKELY MINOR
extended periods progress with District (i.e. contractual period). Ensure bypass-pumping is available during
communication rather than factual commissioning / tie-ins
communication) Schedule tie-ins during low flow periods and outside LOW
cyclone periods

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 19 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

12 Schedule ! Milestones:
The key milestones to be achieved in commissioning the new Asset to be delivered by Project
CW01564 are outlined in the table below: Additional detail is presented in task commissioning
schedule

# Milestone Major events Start Finish Deliverables

Plan commissioning events. Jan 15 Feb 15 Signed Commissioning Plan

Commissioning Determine resources required. Draft Commissioning Activity
1
Plan Tracking Spread sheet (CAMEL)
prepared based on detail design
Agree Agreed preliminary procedures and criteria Feb 15 April 15 Preliminary documents for each
preliminary for: of the identified commissioning
commissioning activities.
procedures, pump All ITP’s & ITR’s; Identification of responsible
station, process Controls FAT; resources.
2 plant unit Pipeline pressure testing; Agreed Pump Station, Filtration
operations, System control cut-over & testing & Plant and Irrigation system
filtration & SAT; control set points and alarms &
irrigation system Pump tests and water hammer tests; simple risk assessment of these
set-points & performed
alarms, etc
Supply Inspection of: Sept 2016 Mar 2017 All ITR’s completed as outlined
Electrical switchboards and transformers in the Commissioning Master
Integrated FAT of local control system Tracker (CAMEL) including all
(PLC/RTU & HMI) and SCADA manufacturer MDR’s and FAT.
FAT of Control system Equipment identified as not meet
3 Supply
Valves and Valve actuators the required specifications
Verifications
Pipe specials brought to the attention of the
Instrumentation supplier and defects rectified
prior to installation.
Packaged plant (ie chlorination, UV
Prerequisite for Construction
filters, compressors, surge vessels, etc)
Verification.
Construction/Installation Inspection of: Dec 2016 Aug 2017 ITR’s completed as outlined in
Valves and fittings & Actuators the Commissioning Master
All Electrical equipment Tracker (CAMEL).
All mechanical equipment (ie Pumps, All defects identified and brought
surge vessels packaged plant, etc) to the attention of the project and
Instrumentation commissioning manager.
Construction Earthing Prerequisite for Pre-
4
Verification Pipelines (welding, coatings, spark tests, Commissioning Tests.
etc).
Civil & Structural works (compaction,
concrete, buildings, etc)

Test all major equipment in a standalone Aug 2017 Sept 2017 Completed pre-commissioning
energised environment ITR as outlined in the
Energise electrical systems & earthing; Commissioning Activities and
Set-up electrical equipment settings (CB Master Equipment List.
5 Equipment Pre- Defects noted and reported.
protection settings, level cells etc)
Commissioning
Commence integrated SAT of local
control systems and SCADA (including
all communications)
Load all agreed programs & settings;
Water Corporation Infrastructure Asset Handover Process 14/01/2014
Uncontrolled if printed Commissioning Plan Page 20 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

# Milestone Major events Start Finish Deliverables

Energise hydraulic components;

Pressure test mechanical equipment and
pipe work;
Point to point test of instrumentation;
Conduct M&E testing of equipment;
Record system pipe work pressures after
pump shutoff.
Equipment Commence operation of equipment: Aug 2017 Sept 2017 Equipment and control systems
Commissioning Complete local control system and confirmed to operate as designed.
SCADA SAT during equipment Any deviation from the specified
bumping / running / operation including operation noted.
remote operation from OC.
6 Initial operating set points, loop tuning
parameters, and equipment settings
Controls and equipment tested under
each identified mode of operation (as far
as possible).
Test operation of interlocks.
Process & Operation monitoring with the upgraded or Sept 2017 Oct 2017 Confirmation of unit operations
Integration new system: and system interactions
Commissioning Confirm operation of equipment online
tests (Reg Valve, Remote operated butterfly
7 valves)
System flow rate operational tests prior
to system wide integration tests
Water Hammer Tests (if required)
Arrange for completion of any
outstanding project requirements
Proving Period Reliability Testing – Project dependent. Nov 2017 Jan 2018 Confirm continued integrated
8 operation and performance of the
upgraded elements of the system.
Input to O&M Add as-commissioned data to ROM, Oct 2017 May 2018 Accurate O&M's, As-
Manuals & LOM and ORM’ as applicable. Commissioned Drawings.
Training Assist with compilation of all vendor Trained Staff
9 manuals
Ensure drawings are redlined and
submitted for as-builds.
Co-ordinate or assist with training
Project closure Project close out May 2018 Jun 2018 Commissioning Report
Summarises Commissioning Activities
10 in commissioning report. Update project
requirements register
Assist project manager with updates to
Asset Handover checklist.

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 21 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

13 Communications
The Contractor will be required to review the commissioning plan and provide feedback following
commencement of the project. Any comments or updates should be provided to the Principal’s
Commissioning Manager for inclusion in the plan for final sign-off.
During the construction phase of the project, commissioning progress against the Plan, schedule
and CAMEL will be discussed and minuted at the Project progress meeting chaired by the
Superintendent’s Representative (Typically on a fortnightly basis)
Verification records required to support each stage of commissioning as identified in this plan are
to be completed and forwarded to the commissioning manager.
Electronic Commissioning records will be maintained under the specific Aqua project file in the
Commissioning Folder. The folder has been placed under PMBs aqua file structure. A hard copy
file has been created for paper records.
Title Aqua Folder Hard File
Commissioning 8586938 JT1 2013 04347 V01
Quality 8586934 JT1 2013 02233 V01
Project 8586938 JT1 2013 00495 V01
All verification and certificate records will be lodged electronically and reference linked from the
CAMEL.
Once construction is nearing completion (when pre-commissioning is commencing) separate
Commissioning and Handover progress meetings will be held on a fortnightly basis, these will be
chaired and minuted by the Commissioning Manager. They will be attended by the Inspectors, the
Asset Delivery Representative, the Contractor’s Commissioning Manager, and others as required.
Once active on-site commissioning is underway (i.e. preparing to energise the site), daily site
meetings will be held covering commissioning to keep all participant’s informed of progress.
Notices of energisation are to be used to label items of equipment as they are energised and all
personnel on site are to be made aware of energisation plans and energised equipment through site
meetings and signage. The standard Water Corporation isolation and tagging process is to be
followed. Site meetings will be documented for distribution to agreed stakeholders by the
Commissioning Manager.
A Commissioning Report and Commissioning Validation Report will be completed by the
Commissioning Manager at the end of the project and made available to all Water Corporation
project stakeholders.

14 Training
Formal training will be supplied to operational staff on the operation of the new assets and control
systems. Training will be provided by the Contractor and MESB commissioning specialists.
The operations and maintenance training will be based on the Operations & Maintenance manuals,
which will need to be delivered at least 2 weeks in advance of the scheduled training dates. The
Operations & Maintenance manuals are to be developed by Water Corporation’s Maintenance
Planning section, with input from electrical/mechanical subcontractors, the Commissioning
Manager and other Water Corporation personnel.
Training dates will be aligned to the commissioning activities and will need to be included in
project schedules.
Training dates and training format is to be discussed and agreed with the region. Training sessions
will include an awareness and familiarization session covering all new equipment that is installed
as part of this project, including the communications system and SCADA.
The training plan for this project will be based on the Water Corporation’s Training Guidelines.
Water Corporation Infrastructure Asset Handover Process 14/01/2014
Uncontrolled if printed Commissioning Plan Page 22 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

15 Appendices " Additional Documentation

1. CAMEL TBA

2. PM-#367317-Disinfection of Water Mains.

3. PM-#365544-Working on Storages and Bringing New Storages On-Line.

4. PM-#3069762-C-CONCRETE TANK-PC-R.

5. PPM-#12647540-Cunderdin 75ML Storage Tanks and Pipeline test water disposal plan
SIGNED)

6. Schedule

7. Pressure Test Certificate

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 23 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

APPENDIX 6

COMMISSIONING SCHEDULE - OUTLINE

Tie in new inlet outlet and bypass valve in off peak period (Winter) – schedule as early as
design and project approval will allow. Mainline outage required.

Fill and Test Inlet and outlet lines, allow 5 days

Factory Acceptance Test, 1 or 2 days at earliest convenience probably during main

construction period.

Supply Verifications of equipment at contractor’s premises prior to despatch to site

Occasional visits during procurement period.

Cleaning and Leak testing of tank roof, allow 1 week

Fill tank with initial 0.15m load – 1 day

BTEX and TPH testing 5 to 10 days

Fill each tank 7 to 10 days

Each tank Stabilisation period 7 days

Each Tank Leak Test 7 days

First tank complete earliest 21 days or latest 24 days, second tank start fill when first tank
starts stabilisation period. Both tanks complete earliest 28 but more likely 34 days.

SAT and Instrumentation set to work 2 to 3 days in parallel with tank fill

Set to work and reg valve testing, 3 days (Tue to Thursday)

See also Commissioning Logic PM-#12307845-Cunderdin Tank Commissioning Logic

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 24 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 Asset Commissioning Plan
CW01564 Cunderdin 75 ML Storage Tank Facility

APPENDIX 7
Water Distribution Main Pressure Test Record Sheet
Subdivision/Distribution Main Name:
Suburb: __________________________________________
Main Extension File No.: ____________________WAPC:
_________________________________
WCFB: ____________Sheet No.: ___________________WC Plan No.: _______________
Consulting Engineer:___________________________________________
Contractor: ___________________________________________________________

1. Mains Tested in accordance with Water Supply Distribution Standard

Main Type Length Test Remarks

Diameter m Pressure
DN kPa

Note: There is no allowable leakage rate for any type of pipe. Cement mortar lined pipes shall be
filled 48 hours before testing to allow for take up.

2. Date Tested: ___________________________ PASSED FAILED

3. Duration of Test: _______________________ MINUTES

4. Signed By: Date: ___/___/___

Contractors’ Representative:_____________________________________________

Name of Contractor’s Representative:______________________________________

Witnessed by Water Corporation’s Inspector:________________________________

Water Corporation Infrastructure Asset Handover Process 14/01/2014

Uncontrolled if printed Commissioning Plan Page 1 of 25
AQUA document number 12032778; AQUA file number JT1 2013 04347 V01
 COMMISSIONING PROCEDURE M-REGV-EC.V0.0

Regulating Valve – Cunderdin New Storage

COMMISSIONING SESSION
SYSTEM CONFIGURATION TO PERMIT FLOW RATE OF TBAML/DAY:
DRAFT PROCEDURE BASED ON CW01413 SIMILAR PROCEDURE – SOME REFERENCES
REMAIN AS A GUIDE AND WILL BE UPDATED IN DUE COURSE
1. EQUIPMENT TESTED

REGULATING VALVE xxxREGVxxxx VALVE Kv VERSUS % OPEN CHARACTERISTIC

0
2. OBJECTIVE

The objectives of this activity are to:

1. Test the installed Kv versus % open characteristic of Valve xxxREGVxxxx between valve positions % to 100% open.
2. Assess Valve Kv accuracy, stability and repeatability
3. Develop a curve for valve position vs differential pressure = Flow.
4. Verify factory Kv Curve
Note. The commissioning activity is not limited simply to the exercise of testing equipment and data collection. The activity
includes a post test debrief followed by an expected 1-2 weeks of review of the commissioning outcomes. This review will
require some resources from the Project, MESB, OAM, IPB and potentially the Designer / IDB.

3. REFERENCES / SUPPORTING DOCUMENTS

Site Configuration Validation Tables and Flow Paths (AquaDOC )
DWG Sets:
- Site Configuration Drawings JB79 xxx, System Characteristic document Aqua Doc JB79 xxx
- P&ID’s , JB79 xxx
- Layout, JB79 xxx ,
- Regulating Valve – System Curve, Aquadoc tba
- Valve Mechanical Summary Drawing, Aquadoc tba

4. SAFETY
Ensure WC JSA / JHA blank forms and WC Tags are available and crew are familiar with them. Any
4.1
isolations are to follow WC Isolation and Tagging Procedures.
Ensure that JSAs are complete for set-up of instruments and data logging equipment and completion of
4.2
testing.
JSA / JHA - Prior to the Commissioning Session hold a pre-start meeting toolbox meeting to discuss
4.3 activities, agree responsibilities then perform a step by step JSA / JHA. This is to be recorded on the
WC JSA and supplied to each site / work crew prior to commencing work.

5. EQUIPMENT
Upstream Dataloggers to be placed in xxxx locations along the DNxxx main see drawing xxxx

6. SYSTEM SETUP / PRE-REQUISITES

6.1 Confirm with OC or Region that the scheme or plant is ready before test
Confirm all relevant instrumentation listed below is functioning.
Set up instantaneous data recording on MicroSCADA, local OIP / HMI (NMT site) for the duration of the
tests for the following:
- Inlet Flow rate from MFE3819
6.2 - Reg Valve position
- Reg Valve upstream pressure data logger ( at air valve closest to RV)
- Reg Valve downstream pressure ( at air valve closest to RV)
- Pressure Data Loggers installed in at least x locations along conduit
- Record each data logger ID for each location. Record polling frequency and start time.
6.3 Confirm mobile phone & land-line contact arrangements with OC / Region .
 COMMISSIONING PROCEDURE M-REGV-EC.V0.0

Regulating Valve – Cunderdin New Storage

COMMISSIONING SESSION
SYSTEM CONFIGURATION TO PERMIT FLOW RATE OF TBAML/DAY:
DRAFT PROCEDURE BASED ON CW01413 SIMILAR PROCEDURE – SOME REFERENCES
REMAIN AS A GUIDE AND WILL BE UPDATED IN DUE COURSE
6. SYSTEM SETUP / PRE-REQUISITES
Confirm that a Contingency plan is in place in case of problems during testing (surge, mechanical
6.4
noise, safety)

7. DESCRIPTION

Estimated total time the assets / system will be required for Commissioning Activity: 2-3 Hrs (excluding preparation
activities & system start / stop) SEE NOTES RELATING TO TANK AVAILABLE VOLUME
Make contact with Ops Centre to inform them that site preparations are about to start.
Place commissioning tags on equipment.
Configure the site so that flow tests can be performed (note that no valve changes are required. Control mode and data
acquisition issues only).
Tank water level to be reduced to approximately half level, a level of -7m from TWL Note that low level alarm will occur at
-2.9m and low low alarm will also be triggered. BWL for this tank is -4m. All alarm levels are to be recorded during the test/
The test will also make an assessment of the system curve for the DN1400 supply main at the tested supply rate. System
configuration 7 (identified in PM 690365) or closest possible system state is requested for this test.
Record current set point from OIP and then reset to 100%. (may need to be done after switch to LOCAL). Request Local
from OIP
At IWSS Zone 13, site 1321 Take the valve into remote manual mode and drive valve to 0%. On request from
Commissioning Manager on site, put regulating valve to LOCAL control mode. Note: Low flow alarm will be triggered.
Reset high flow alarm set point to 126ML/d.
Accept control of assets from Operations Centre.
Open Regulating valve at specified position increments and time intervals:
o From 0% to 100% open in twelve 5% or 10% increments. Notify Ops Centre at each step change. Record parameters
as required. 13 steps from 0 to 100 5, 10, 15, 20, 25, 30, 40, 50, 60, 70, 80, 90, 100
o A record of progress made versus storage volume used will be maintained to ensure that the test will not overrun on
water capacity.
For each valve position log the specified data after a nominal 5 minute period (ie until flow / pressure is stable): Refer to
section 7.2 and 7.3 for details of the data to be recorded, logged &/or downloaded from corporate systems.
Estimated time required for the above activity is 2 continuous hrs. Plotting data download and vetting would take a
further 2 hrs. Review would follow this (1 day)
Close Regulating valve slowly:
o From 100% to 0% in reverse of opening sequence, 13 steps
Repeat recording of system data for each valve position over a nominal 5 minute period (ie until flow / pressure is stable).
Return control of Assets to the Operations Centre for return to normal operations, reapply flow set points amended in set up
for this test.

8 POST TEST ACTIVITIES

Mark-up / update system operating envelop DWG(s). Notes to include flow path tested and
8.1
hydraulic conditions tested..
Use field test data to establish safe valve operating speeds and control PID settings for
further automated testing as required
8.2 Annotate Drawings with agreed constraints, guidance notes and preferred operating ranges
Ensure data is compared to factory / contract curves on M-REGV-Kv Curve Modelling
8.3
Spreadsheet-EC-ITR – AquaDOC # 7413417

9. PERSONNEL REQUIRED
Commissioning Manager Tim Cross
System Operations Coordinator (OC)
Data Loggers
 COMMISSIONING PROCEDURE M-REGV-EC.V0.0

Regulating Valve – Cunderdin New Storage

COMMISSIONING SESSION
SYSTEM CONFIGURATION TO PERMIT FLOW RATE OF TBAML/DAY:
DRAFT PROCEDURE BASED ON CW01413 SIMILAR PROCEDURE – SOME REFERENCES
REMAIN AS A GUIDE AND WILL BE UPDATED IN DUE COURSE
9. PERSONNEL REQUIRED
Chlorination Module Observation
Operations Coordinator
10. NOTES / COMMENTS
Envisage 1 day to set up data loggers and 1 day to complete testing.

Cunderdin Tank Considerations

If we can reduce level to 7m ( BWL is 11m) and take tank level back up to 15m (High, High Level alarm) this would
provide 15,000kL of room. If conducting tests in the morning period then approximately 2000kL may be used by
customers (based on 31 May 12, AM consumption). This would give potentially a net 17,000KL of room in tank for
test flow. Need to monitor outlet flowmeter MFE 3820.
Maximum flow rate is 125ML/day (8532kL/hour) and it would be possible to step up over period of an hour to 100%
(8532kL/hr) and step back in a similar time. Total period 2hours. By plotting progress on the attached chart any risk
of over run of the test can be assessed. Implied in commissioning procedure and outflow rate from the tank to assist in
providing room in the tank. Would suggest consideration be given to pre the test stopping the flow into Dower St and Fremantle
Rd and let them draw water out of the tank during the test. If neither tank is drawing water during the test the outflow from North
Mandurah will be very low at this time of year.
The baseline plan is to use 5 minutes at each step position to allow system to settle and to take readings. This is
viable but may be considered too short. Note also that it will take about 1 minute for the valve to move 10%.
Chlorinator is flow paced and will need to be monitored to ensure that chlorine residual is maintained. Regions DET
to be in attendance. Chlorinator is unlikely to operate well over such a wide range of flow rates - this can be mitigated
somewhat with incoming water Chlorine residual consistently above 0.7mg/L. Higher flow rates over this period may stir up
the tank and cause increased turbity in the supply.
Note that the time for the Reg Valve to move from closed to 100% open is 10 minutes or approximately 1 min for
10% of valve travel.
There is currently no established alternative flow regulation facility should the reg valve develop a fault.
Note that the reg valve bypass valve (potentially an alternative control method) has not been commissioned and is subject to a
design investigation. The operation of this valve at these higher flow rates will result in higher than normal stresses and
turbulence within the DN1400 main and the NMT. There should be some contingency planning to consider potential failures and
required action to deal with them. Contingency will be to inform maintenance authority that test is taking place
Need contingency plan which covers: Possible water discoloration from the DN1400 at the higher flow rates. Although the
pipeline have been on line for over 18 months the high flow rates in summer have been around 45ML/d much less than intended
from this testing. Ops Centre to Liaise
Note Perth Region specifically Mandurah Murray need to be kept advised if testing causes issues for Retic customers on the
outlet of North Mandurah tank due to DN1400 turbidity. Ops Centre to Liaise
Would also suggest the manual valves at the HSTM/Lakes Rd offtake and the manual valves either side of the Reg Valve are
checked and have staff available to operate if this was an issue. DET will be on site with necessary valve key for shutting these
valves if required. DET availability to be confirmed.
The overflow sump at North Mandurah tank is limited although soaks away well but not certain at these high flow rates. There
are design notes relating to the overflow pipework. At the highest flow rate 125ML/day the water level could get very close to the
top of the tank and would immerse some of the roof structure. Overflowing this tank is to avoided during this test sequence.
Providing level of -7m at start point will give enough room to reduce risk of over filling. Levels will be monitored and
testing suspended if TWL being approached too rapidly.

11. SIGNOFFS
NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

 COMMISSIONING PROCEDURE M-REGV-EC.V0.0

Regulating Valve – Cunderdin New Storage

COMMISSIONING SESSION
SYSTEM CONFIGURATION TO PERMIT FLOW RATE OF TBAML/DAY:
DRAFT PROCEDURE BASED ON CW01413 SIMILAR PROCEDURE – SOME REFERENCES
REMAIN AS A GUIDE AND WILL BE UPDATED IN DUE COURSE
NAME (PRINT) COMPANY / ROLE SIGNATURE DATE

       

TIE IN NEW INLET, OUTLET AND

BYPASS VALVE IN OFF PEAK
PERIOD ( WINTER)

LEAK TEST TANK ROOF WASH DOWN AND CLEAN

COMPLETE TANK AND PIPELINE FILL TANKS TO 0.15m
TANK/ROOF INTERNALS
CONSTRUCTION. INSTRUMENTS USING CARTED POTABLE
AND SCADA READY FOR SAT WATER

TAKE SAMPLES FOR BTEX AND FILL, TEST AND DISINFECT INLET RECEIVE BTEX RESULTS AND
TPH ANALYSIS AND OUTLET MAINS COMMENCE TANK 1 FILL

TANK 1 STABILISATION PERIOD.

FILL TANK 1 DISINFECT AND
7 DAYS TANK 1 LEAK TEST
SETTLEMENT PINS
FINAL SETTLEMENT PIN SURVEY 7 DAYS
EST 7 to 10 DAYS
ON COMPLETION

TANK 2 STABILISATION PERIOD.

FILL TANK 2 DISINFECT AND
7 DAYS TANK 2 LEAK TEST
SETTLEMENT PINS
FINAL SETTLEMENT PIN SURVEY 7 DAYS
EST 7 to 10 DAYS
ON COMPLETION

CARRY OUT PERIODIC WATER QUALITY TESTING ( BACTO AND CHLORINE RESIDUALS)

SCADA AND INSTRUMENT SAT SYSTEM SET TO WORK,

ISOLATE OLD ASSETS INTRODUCE NEW AND
CONDUCT REG VALVE TESTS

OPERATIONAL COMMENCEMENT PROVING PERIOD DECOMMISSION RES, REG VVS and SCADA