Best Practice Guide to

Commissioning a Piped
Irrigation System

BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM | i

 Contents
Introduction 1
Date of Issue: TBC
Revision: TBC 2016 Commissioning purpose 1

Address for comments: Structure of this manual 3

'Best Practice Guide to Acknowledgements 3
Commissioning a Piped
Irrigation System'
Irrigation New Zealand 1. Commissioning process 4
PO Box 69119
Lincoln 1.1 Commissioning plan 6
Christchurch
www.irrigationnz.co.nz 2. Commissioning documents 11
ISBN Numbers:
Printed: TBC 3. Training 14
PDF: TBC

© Irrigation New Zealand 2013 4. Flushing 14

Appendices 15
Appendix 1: Commissioning process 15
Supported by Sustainable Farming Fund
Appendix 2: Pump station commissioning checklist 19
Appendix 3: Example as-built plans 20
Introduction
Rapid irrigation development has taken place in New Zealand, particularly in the last two
decades, with increasing levels of investment in irrigation systems and irrigation research.
In general, irrigation has been highly successful and has driven agricultural intensification
in the drier areas, improving and sustaining the general well-being of rural communities.
However, some irrigation systems have under-performed in economic terms, and
independent irrigation audits have highlighted shortcomings in irrigation system design
and management. Reasons for this include:
• Poor understanding of client priorities and needs
• Unrealistic expectations by the owners at the system proposal stage
• Capital cost over-runs due to poor contract control
• Substandard design and installation
• Poor system start up and commissioning procedures prior to handover to owners
and operators
• Poor irrigation system management and service provisions.
It is important that all systems regardless of complexity and size are commissioned.
In addition, water regulators (regional councils), government agencies, the agricultural
community and the general public have lifted their expectations for better responses
by irrigators to potential adverse effects of irrigation on water quantity and quality.
Increasing pressure is being placed on irrigation system owners to lift the level of
environmental performance whilst still maintaining economic and affordable productivity.
Irrigation New Zealand, in consultation with its Technical and Trade stakeholders as part
of its mission to promote excellence in irrigation, has initiated the development and
review of this irrigation Commissioning and As-Built Manual.

Commissioning purpose
Commissioning is a process by which agreement is reached that the installed system
meets the design performance specifications. It verifies that the system is complete to
the required workmanship standards, is safe to operate and is ready to perform as per
the designer’s and operator’s system performance expectations. The base line as-built
Key Performance Indicators (KPIs) are determined and can subsequently be used as a
reference point for future condition and performance assessment of the irrigation system.
Commissioning occurs at the substantial completion of the installation contract and as
the first transition into the operational period. The contract should be clear on when the
ownership and responsibility changes from the installer to the owner and whether any
defect periods comes into force that requires the installer or designer to maintain control
obligations. In most cases the commissioning is the point in time when responsibility for
the system is handed over from the designer and installer to the owner/operator and may
have implications for insurances, maintenance programmes and consent compliance.
This Commissioning and As-Built Manual provides a consistent practice guide for
designers, installers and operators of piped agricultural irrigation systems in New Zealand.
It includes a general commissioning plan and as-built drawing approach with specific
items that must be considered when planning, designing, and implementing a new
irrigation development.

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INTRODUCTION

This manual provides guidelines to undertake the commissioning of simple to complex

on-farm piped irrigation projects. It ensures that all of the main testing, start-up,
commissioning and handover aspects of the irrigation development have been considered.
It includes the following components:
• electricity/diesel power supply and associated control equipment
• motor and pump
• headworks
• monitoring, data logging and telemetry equipment
• distribution network
• water application equipment.
It is expected that designers, installers and operators will follow the general processes
outlined in this manual, but many will have their own specific procedures and interpret
it according to the requirements of individual properties and system types. All decisions
made must comply with statutes, regulations, and other legal requirements and
industry standards.
In the context of this document it is assumed any reference to the operator means
the owner, their operational staff or the owner’s agreed representative for completion
acceptance within the INZ Standard contract agreement.
The manual is part of a suite of Irrigation New Zealand documents to be used in
conjunction with one another. The other documents include:
• The New Zealand Piped Irrigation Systems Design Code of Practice (INZ, 2013)
• The New Zealand Piped Irrigation Systems Design Standards (INZ, 2013)
• The New Zealand Piped Irrigation Systems Installation Code of Practice (INZ, 2012)
• The Standard Irrigation Contract (INZ, 2013)
• The New Zealand Piped Irrigation Systems Performance Assessment Code of Practice
(INZ, 2014)
• Irrigation development checklist (INZ, 2013)
The Commissioning and As-Built Manual applies only to piped irrigation systems.
It does not cover:
• Surface water irrigation methods
• Surface water structures (e.g. races or ponds)
• Irrigation equipment manufacturing or quality standards
• Installation of irrigation systems
• Performance assessment of irrigation systems.
Those activities should be guided by the relevant existing codes of practice.
This Commissioning and As-Built Manual does not amend or replace other industry,
performance indicators, guidelines, codes of practice and standards; or provide sufficient
information for designers, installers or owners intending to work outside of their current
area of expertise.

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 INTRODUCTION

Structure of this manual

This manual is provided to show the designer how a commissioning plan document
should be prepared for the installer and what information should be included to satisfy
the operator.
This manual contains key sections:
• Commissioning process
• Commissioning Plan
• Commissioning documents.

Acknowledgements
Organisations, individuals and stakeholders contributing to the preparation of this
Commissioning and As-Built Manual include:
• Irrigation New Zealand
• Opus International Consultants Ltd
• INZ Technical and Trade stakeholders review process at industry meetings, who
willingly provided advice.
Financial support for preparation of the Code of Practice has been provided by:
• Ministry of Primary Industries (Irrigation Acceleration Fund)
• Irrigation New Zealand.

BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM | 3

 1. Commissioning process
The following sequence of steps is suggested:
• Set up commissioning expectations in contract
• Put together a suitably qualified and experienced commissioning team.
• Draw up commissioning plan
• Collect pre commissioning documentation
• Undertake pre commissioning checks
• Undertake commissioning – appendix 1
• Sign off.
The critical starting information needed includes:
A. System Constraints (what will be tested)
—— system description (including operational and control philosophy descriptions);
—— flow, pressure and other KPIs according to the agreed performance criteria set out
in the contract
—— limits for high, low and normal operation;
—— limits for failed operation and emergency response;
—— safety provisions;
—— Monitoring and telemetry
—— environmental protection.
B. Contractual information needed to manage the commissioning exercises
includes, with reference to the contract provisions:
—— Budget (if additional to the Installer’s price);
—— timetable, including milestones and hold points if necessary for large systems
being commissioned in sub-sections;
—— roles for each party;
—— quality control to ensure outputs and reports are valid and acceptable to the
parties;
—— documentation and reporting procedures, including as built plans required.
C. A communications plan that identifies key participants and responsibilities.

Once this information is assembled, a start-up and commissioning plan can be written
that identifies timetables, procedures, measurable performance requirements and
acceptance criteria as well as process or method.
The commissioning exercise involves a start-up (of components, sub-systems and
systems) that is well planned and executed, followed by the commissioning of the
overall systems that secures appropriate confidence in the system performance to
meet overall expectations.

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 1. COMMISSIONING PROCESS

The following table outlines the components and phases within the commissioning process.
Table 1. Commissioning components and phases

Phase 1 Phase 2 Phase 3

a. Equipment Commissioning, Monitoring /
Sub systems testing b. Sub sytems start up whole system run up optimisation
water
source
Intake n/a check functional verify functional establish
maintenance cycle

Pumps check all electrical dead head test verify flow/head/ establish maintenance
check rotation cut outs and alarms power across whole cycle regular test
“bump test” VSD and SS setup process range to check drop off
including extremes in function

Filter check all check functions verify functional establish

electrical check flush discharge maintenance cycle
set up controller

Automation electrical test set up verify settings refine settings

initial programme check emergency
stop/start

Backflow check install check functional verify functional establish

maintenance cycle
whole irrigation system

Headworks check install set up valves control refine valve settings refine valve settings
pressure /
Flow control produce headworks
as-built drawings

Distribution pipe pressure test, produce overall leak and joint establish
network leak and joint systems as-built inspections maintenance cycle
inspections drawings

Field valving check install test control signals check and refine settings
set up pilots balance settings

Emitters check install equipment specific full field evaluation establish maintenance
checks, set up use CoP Evaluation cycle, full field
pivots, guns etc to check against the evaluation using
contractual KPIs CoP Evaluation

Monitoring check install set up monitoring verify functional establish maintenance

and instrumentation cycle, establish
compliance reporting

Flushing/cleaning clear pipelines check auto verify functional establish maintenance

discharge flushing systems cycle

output is test report

output is output is
and certificates of
commissioning maintenance and
compliance as-built
report compliance report
drawings

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1. COMMISSIONING PROCESS

1.1 Commissioning plan

GOALS
The goal of the commissioning plan for the project includes:
• Completion of a well-documented operational system
• Undertaking a well-planned and complete commissioning service that examines full
operating ranges of the system to ensure compliant functioning of all systems and
sub-systems
• Minimising start-up failures and replacements
• Clarifying hand over from installer to operator.

CONSTRAINTS
Constraints to meeting these objectives include:
• Time and scheduling
• Budget and contingencies
• Pre-test and pre-run competency prior to commissioning work
• Weather
• Cooperation and availability of participants and technical support
• Completeness of commissioning plan and pre-preparation of test program
• Safety
• Existing operation (maintenance of).

OUTLINE
A commissioning plan should include the following
• Scope
• Who is involved
• Responsibilities
• Timelines
• Quality control
• Sub-systems
• Budget
• Communications plan
• Administrative needs
• Outputs.

1. SCOPE
The scope of the commissioning plan should be a statement of the overall expectations
of the plan together with a description of the disciplines to be included in the
commissioning work. The work should be broken down into the key components and the
interfaces of the components should be identified. Reference documents such as flow
diagrams, parts lists, construction drawings, etc. should be identified. The commissioning
instructions should include step by step procedures for checks before the first start,
checks after starting and operational tests.

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 1. COMMISSIONING PROCESS

The purpose for the irrigation system and background should be described to allow the
commissioning report to be read as a standalone document in the future by operators and
their maintenance technicians.

2. WHO IS INVOLVED
The expectations of three primary groups that either “advise”, “produce” or “take
ownership” for the systems being commissioned will have differing expectations on why
commissioning is needed, what it is and how it should be done. A simplistic comparison
of expectations that are typical for designers, installers and operators is given in the
following Table 2.
Table 2. Commissioning expectations

Designer Installer Operator

• That the systems should be • That the installation was done • Knows where the responsibility for each stage of
installed in accordance with in accordance with the letter of development rests and when the transfer point is.
the intent of the drawing the drawings and specifications as
• That the systems are installed in accordance
and specification. interpreted by the installer.
with the needs of the operator as proposed by
• That the final drawings and • That if the systems do not the designer.
specifications convey the function to meet the expectation
• That once the system is accepted, the controller
needs of the operators. of others, that the design is at
may be reconfigured by Operators to suit their
fault and changes will require
• That parts, sub-systems own needs.
scope increase.
components, etc. have
• That, under warranty terms set out in the contract,
been run-in by the installer • That the start-up and
if a component or system fails, the installer is
to confirm operational commissioning will not exceed an
responsible and the problem will be fixed.
suitability prior to start-up unrealistic time scheduled by the
and commissioning so that installer. • Where an independent verifier has been
no delays will occur. nominated in the contract, that this person will
• That the operator should
ensure contractual requirements are met.
• That all checks and tags accept parts or subsystems
(locked valves or electrical unconditionally once a start-up • That start-up and commissioning will follow a
isolators) are verified has been achieved if specifically detailed plan and all systems will be checked and
safe prior to start-up allowed for in the terms of guaranteed operational in accordance with the
and commissioning. the contract. operators’ expectations.

Where commissioning, including communication, plans are developed, the components,

sub-systems and systems are more likely to be ready for start-up and commissioning at
the scheduled dates.
Attendance of operating personnel, suppliers/manufacturers’ representatives, Installer
personnel and project design engineers needs to be properly determined and scheduled.
The timetable will meet the intended start-up and commissioning exercises where good
project management and cooperation is obtained from all participants and where clarity
of what is expected is obtained from the outset. Think of the focus of the participants
as identified in Table 2 to ensure the overall commissioning expectations are clearly
understood and quantified.
A commissioning plan is needed to meet warranty requirements as well as conformance
with KPI requirements. It will rarely meet all the expectations of participants if the
potential conflicts are not explained and accepted at the outset.

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1. COMMISSIONING PROCESS

3. RESPONSIBILITIES
Responsibilities of all participants should be clearly identified including designer, installer
and operator. Key words/activities that apply to responsibilities are identified in Table 3.
The responsibilities should be checked and agreed.
Table 3. Commissioning responsibilities

Responsible individual(s)
Item Designer Installer Operator

Timetable

Budget control

Scope revision –

Start-up testing – –

Commissioning – –

Repairs/troubleshooting – –

Re-testing – –

Measurement – –

Documentation –

Acceptance/approvals –

Transfer of control –

A responsibility matrix should be used to identify the key activities and responsible
personnel. This may be included in part in a contract specification. Add or delete items
and names to the list as needed for the project.
If the system is large and complex enough to warrant a commissioning manager, they
should be named and their role in the process defined. They will plan all matters of
time­tabling and communications as necessary supported by the designer, installer and
operator as required. They may be an independent appointment or a role agreed within
the contract from either the designer or the installer organisation.
It may be necessary to have additional suitably qualified electrical and pump engineers
in attendance if these roles are not provided directly from the installation organisation.
Electrical certification may be required to meet statuary requirements over and above
the commissioning of the overall irrigation system. For warranty compliance where very
large pumps are to be started up and commissioned specialist engineers from the pump
supplier may need to be in attendance often when associated with diesel power plants.

4. TIMELINES
Where multiple contractors are involved for subsystems (or associated works)
coordination, planning and sequence of events that could be dependent on each other
needs consideration. Sequence and order of subsystem commissioning also needs to be
outlined. An expected time schedule is needed

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 1. COMMISSIONING PROCESS

The following steps need to be initiated at least one month prior to commissioning start:
1. Prepare a commissioning manual binder, suitably tabbed to contain the
administration material and records for the project.
2. Meet with Operator to confirm scope, measurements and actions to be tested,
schedule and budget.
3. Confirm the Installer’s and subsystem contractor’s completion of start-up and
commissioning timetable with contingency plans.
4. Confirm availability of personnel
5. If using an independent verifier under the contract terms then meet with Operator
and Installer to review responsibilities and obtain confirmation.

5. QUALITY CONTROL
Quality control (QC) includes planning, determining a means of assurance and measuring
expected results. The QC planning should identify responsibility, results and standards
from within the contract and an agreed means of measurement and definitions.
The process provides the work results including means of inspection, testing results
checklists etc.
A QC plan should be provided in a section of the commissioning binder for the project.

6. SPECIFIC IRRIGATION SUB-SYSTEM COMMISSIONING

Where available, the Control System philosophy (how the designer intended the system
to be run) and any systems description write-ups and construction drawings need to be
available to the commissioning manager. These should be used to identify and isolate any
special sub systems or components and their function, control ranges and test parameters.
This could include systems as set out below.
For complex pump stations Pumping and Instrumentation Diagrams (P&ID’s) should be
available from the mechanical or electrical sub-installers or designers. These are needed
where complex control systems or motor control panels are installed. P&ID’s are to be
used to identify all control equipment and valves and are to be identified clearly with
tags. Operating sequences are to be checked within the equipment control ranges as
identified in the Control System philosophy and construction Drawings.
For the following equipment manufacturer’s recommendations should be adopted as the
minimum standard for commissioning. Their information and checklist processes should
be appended to this manual and the generic checklists provided herein for later reference.
• Hydraulic protection valves
• Infield valves
• Irrigation controller
• Disc filters
• Back flush solenoids
• Hydraulic protection valves
• Quick acting pressure relief valve
• Pressure reducing
• Water meter
• Data logging and telemetry capability
• Air valves
• Chemical injection
• Backflow protection devices
• Driplines, pivots, gun or drag-line irrigators (otherwise known as emitters).

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1. COMMISSIONING PROCESS

7. BUDGET
Transparency around the cost of the commissioning process and the provision for it in the
quote needs to be outlined and understood. Budgets are normally provided separately
from the plan. This will be prepared by and agreed by all parties. This should be used to
administer and control project scope and budget.

8. COMMUNICATIONS PLAN
A champion must be identified as the commissioning authority. The commissioning
authority must lead and manage the full commissioning process.
All of the participants should agree on the communications plan reporting structure
and should be clearly identified in the commissioning plan. Key contacts, names and
availability should be provided in a list for all participants.

9. ADMINISTRATIVE NEEDS AND AUTHORITIES TO ACT

The administrative needs and authorities to act on behalf of the installer and owner
during commissioning need to be defined and agreed so that the commissioning
manager has the ability to make urgent decisions regarding stopping and starting the
system and emergency responses that may be needed to protect staff and equipment.
These may need to be specified in the contract specifications. A commissioning binder
is to be prepared for each project and is to contain suitable sections for guidelines and
project records.
A copy of the commissioning binder is to be filed and provided to the owner /operator
at the conclusion of the project and used to record any abnormal events that required
authority to be exercised.

10.OUTPUTS
The minimum requirements of commissioning documents are:
1. A list of measured KPI’s and actions as achieved during the commissioning
2. A summary document of all the relevant operating KPI’s and any specific
commissioning actions as determined by the designer as identified in the contract
3. Any as-built drawings and information identifying departure from construction
drawings or specifications as approved (or not) during the installation process.
4. Manufacturers’ Operations manuals for all items of equipment
5. Maintenance schedule for all items of equipment
6. A final summary O&M plan combining all specific equipment as configured for this
particular project.

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2. Commissioning documents
1. COMMISSIONING KPI’S AND ACTIONS
As part of the contractual arrangements and commissioning plan a list of KPI’s to measure
and actions to complete are agreed. To commission a system a series of steps need to be
followed. Recording and reporting the actions taken and values measured will form the
basis of the commissioning documents.
In general terms the steps will be similar to what is outlined in Appendix 1. Each individual
system will have its own unique requirements which will mean either:
• the steps outlined need to be more detailed
• the order of the steps are changed
• the content of the steps are changed
• steps are added or not carried out.

2. SUMMARY DOCUMENT
Aimed at the owner/operator the summary should contain only the relevant operating
performance measurements and as-built information for the O&M manual. It should be
the key document that contains the baseline information that is pertinent to the day to
day operation of the system.

3. COMPLIANCE REPORT OF WATER METER VERIFICATION

The report will have two components
A. Detailing the correct installation and verification of the water meter
B. A check of the data logger and /or telemetry system confirming the outputs read
the same as the input data from the water meter

4. AS-BUILT DRAWINGS
Hard copies of As-Built drawings with detailed indexes and referencing must be provided.
Electronic copies of drawings can be AutoCAD or IrriCAD if this is available. In the absence
of accurate electronic drawings, well executed hand drawings showing the same level of
detail and accuracy could be provided, however the preference is for electronic drawings.
All drawings developed during the detailed design should be provided as part of the
commissioning documents and include:
• Index sheet with locality plan, project title and list of drawings;
• Overall site plan;
• Detailed site plans with set out data and pipelines
• Piping and Instrumentation Diagrams
• Detailed civil and structural drawings also including pipe long sections;
• Single line diagrams should be produced for all electrical equipment.
• Outline drawings showing equipment arrangement, overall dimensions, weights
and foundation arrangements. Schedule of components included in the equipment
together with the name of the manufacturer and the component type reference.
• Internal layouts of individual electrical panels are required identifying each
component. For multiple items such as motor starters, generic drawings are
acceptable for each type of starter.
• Comprehensive drawings to aid maintenance (as distinct from construction) should
be supplied. These drawings should be supplemented to include instrumentation
and mechanical information as appropriate to allow ease of maintenance.
• Final easement drawings

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2. COMMISSIONING DOCUMENTS

5. OPERATIONS MANUAL
An Operation Manual should be provided for each piece of equipment. The manual
should include but not be limited to:
A. General description, including:
—— A full description of the equipment with a tabulation of dimensions and
performance ratings
—— Alignment tolerances and check requirements should be stated
—— Location
—— Principles of operation – basic working description, ranges, including novel
features and any automatic control
—— Performance criteria
—— Design criteria
—— Overview of how to monitor the equipment using the control system.
B. Safety management
C. Environmental management
D. Detailed operation for each item including a step-by-step procedure:
—— Description
—— How to operate each of the control system functions (Start-up, Shutdown,
Manual and Auto Control)
—— How to monitor the equipment using the control system in all of its operating
modes
—— Troubleshooting
—— Stopping
—— Emergency stopping
—— Abnormal operation, as applicable.
E. Software Documentation – this should fully describe the operation of any control
software installed and should include the following:
—— Systems overview – an overview of all user software modules including detailed
written descriptions, system flow diagrams and logic diagrams.
—— Module descriptions – a complete description of each user software module
(program, routine and subroutine) including commented source code listings, flow
diagrams, operator interface and resource requirements.
—— Operating instructions – a complete set of user operating procedures including
system generation, loading, configuration, start-up, on-line modification, shut-
down and general troubleshooting.
F. Record keeping requirements
G. Duty statements for operators
H. Emergency response
I. Cross references to the maintenance schedules.

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 2. COMMISSIONING DOCUMENTS

6. MAINTENANCE SCHEDULE
The Maintenance Schedule should be prepared for all mechanical and electrical
equipment including control and instrumentation systems. A basic schedule of tasks
against time forms the basis of the schedule.
The Maintenance Schedule should include but not be limited to:
• Key contacts
• Routine maintenance – step by step procedure for preventive maintenance work
carried out at intervals of two weeks or less.
• Periodic maintenance – step by step procedure for fault correction and preventive
maintenance carried out at intervals in excess of two weeks, involving replacement
of consumables only. A list of any necessary special tools should be included.
• Test data and troubleshooting – instructions to qualified tradesmen for assessing
the operational performance of the equipment.
• Schedule of tasks against time
• System user and supplier responsibilities
• Spare parts list – illustrations and schedules for identification and specifications of
all items in the equipment. The recommended spare parts stock must be indicated.
—— As an appendix if needed – Repair, overhauling and dismantling – step by step
procedures to extract, fully dismantle, re‑assemble and re-install the equipment.

7. ELECTRICAL COMPONENTRY COMMISSIONING, MAINTENANCE

AND DOCUMENTATION
Details of the mains switchboard, control panels, and distribution boards. Information to
be presented on the drawings include, but are not limited to the following:
• Construction details
• Dimensions, overall and of individual sections
• Component details including layout, component reference, make and
catalogue number
• Wiring diagrams
• Drawings showing details of the boards, location of earths, meters, mains
entry points
• Test certification.
The maintenance manual should provide a full description of the electrical systems that
have been provided as part of the contract.

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 3. Training
As part of the commissioning and handover process appropriate training should be
provided to ensure the owner and staff are adequately trained in the operation and
maintenance of the system. Training should be completed before contractual completion
with the intention that it is completed during the final commissioning tests.
Both the installer and designer should coordinate to deliver training for the owner.
Depending on the complexity of the system the following steps may need to
be undertaken:
• Outline a training methodology.
• Develop a practical training programme aimed at preparing staff for the
management, operation and maintenance of the irrigation scheme.
• Detail documentation and training manuals to be provided.
• Detail any vendor documentation and training manuals to be provided.
As part of the training the Installer should arrange for the vendors of equipment included
in the works to provide training to meet the specific operations and maintenance
requirements of their equipment.

4. Flushing
Flushing of the system is required prior to commissioning. Successful flushing
typically requires:
1. Key elements to remain disconnected until flushing has been completed. This
includes sprinklers and lateral lines
2. Defining flushing velocity: Sufficient velocity to ensure material in pipe is
mobilised. This may be limited by the capacity of the pump.
3. Defining flushing time: Sufficient time to ensure material is transported through
the system. A theoretical transport time can be calculated but it is sensible to
allow for material to move more slowly than the water so a conservative time is
advised (6 x fluid transport time is not overly conservative).
4. Defining flushing points; typically:
—— end of the line
—— off the bottom of pipes
—— ideally a sluice valve.

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Appendices
Appendix 1: Commissioning process Remember that safety is a key
component in all activities.
1. COMPLETE COMMISSIONING PLAN Ensure the personal protection for
Commissioning plan checklist all participants.
The following section provides a checklist to complete to have a comprehensive
commissioning plan prior to the commissioning exercise to ensure it goes smoothly.

Activity Checked
Identify commissioning manager and primary contact personnel. Unless someone more appropriate is
available or appointed, the Designer should be prepared to take control.
Prepare a binder to contain the commissioning program and records.
This may need suitable tabs for large complex systems. The binder can form the start of the O&M manuals.
Confirm what components are to be tested.
1. Power supply – safety, compliance, failsafe
2. Intake performance – CoP & std compliance, structural integrity
3. Motor performance – CoP & std compliance, KPI
4. Pumps performance – CoP & std compliance, KPI
5. Mainline and distribution network – CoP & std compliance, leaks
6. Valves – CoP & std compliance, operational ability
7. Filters – CoP & std compliance, operational ability
8. Control systems – operability
9. Water meters – CoP & std compliance, verification
10. Telemetry – accuracy, operability,
Assemble commissioning team – Identify who will be responsible for each commissioning component
Identify, define and list sequence of tasks and subtasks to ensure completion
Identify and list specific tasks each team member is responsible for and which, manufacturer’s or
sub Installers representatives should be advised to attend the commissioning event.
Identify and arrange a suitable commissioning date(s) when the commissioning process is scheduled to
commence and finish – with both the Installer and Operator and ensure each is advised of what assistance
they should provide. The Designer may also need to be in attendance for complex systems.
Identify any contractors outside of managers direct jurisdiction and coordinate to enable
commissioning completion
Obtain pre-commissioning documents
1. Consents
2. Design drawings and details
3. KPI’s – Understand what information and how to gather and measure it.
4. Variances
As built drawings and plans – construction, P & ID’s
Identify any possible impact on overall property operations

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APPENDICES

2. OBTAIN PRE-COMMISSIONING DOCUMENTATION Pre-commissioning and high level checks include:

Pre commissioning documentation • Reviewing both safety issues and the basic
commissioning plan with all present.
1. Consents and conditions
• Ensuring that water supply is available for pump testing
2. System concept design drawings and details and any necessary consents are in place to allow
3. Design KPI’s of system extraction and discharge of test volumes.
i. Required Service Period. • Ensuring the Power Supply is available. (Power is assumed
ii. System down Time. to be electricity if power is diesel then a different set of
procedures are required).
iii. Maximum Daily Application.
• Ensure that any required safety equipment will be
iv. Maximum Return Period.
available and its use and hazards are understood by
v. Maximum System Required Flowrate. all those associated with the commissioning process.
vi. Maximum Water Abstraction rate. This might include sound ear muffs, hard hats, confined
vii. Minimum Application Uniformity (e.g. DUlq). space (open trenches for pipe joint inspections) entry
apparatus, open water egress provisions, etc.
viii.Maximum Soil Application Intensity.
• Ensure that any required PLC programming and
ix. Energy Input in KW or whatever is appropriate
commissioning instrumentation will be available. This
(e.g. Amps and Voltage or Diesel consumption
might include clamp on flow meters, pressure gauges, etc
per hour).
where installed instruments need to be verified.
x. Pressure and Flow Values at critical points for
• Confirm the situation of line valving and the end-of-line
all required duties.
consequences.
—— US of pump
Pre-plan the commissioning event as much as practical;
—— DS of pump
particularly be ready to assign appropriate tasks to
—— DS of Headworks manufacturer’s representatives in attendance.
—— Critical Points in Mainline
—— US of irrigator/Zone valves 4. UNDERTAKE COMMISSIONING
—— DS irrigator/Zone Valves Stage 1 tasks
—— Critical points within irrigator/Zones Stage 1 is effectively ensuring that all of the system
(pressure only). components are in place and operating, specific KPI
measurement and stress testing is not carried out.
4. As-built variances to design and agreement
documentation Prepare system for Testing and Operation
5. As-built drawings and plans a. Fill main pipe system with water. As Built
i. Construction Drawings. Documentation should detail specific procedures.
In general the following will need to be followed:
—— Overall Layout showing underground pipes, cables
ecetera. i. A method for getting water into the pipe is required.
It may be that the pump will need to be running
—— Zone Layouts and Valves.
although not fully commissioned to achieve this.
—— Pump Station and Headworks.
ii. The system needs to be in as open mode as possible
ii. Hydraulic Model, P and ID and Flow Schematics. to allow air to escape. Normally air relief valves will
be installed to achieve this.
3. UNDERTAKE A HIGH LEVEL INSPECTION AND iii. The filling velocity needs to be as low as possible.
COMPLETE PRE-COMMISSIONING CHECKS About 0.15 to 0.3m/s. This will minimise the risk
of water hammer damage during filling. Patience is
A site inspection and checks is undertaken to: required.
• Determine if commissioning can proceed iv. On-going monitoring of the process is required to
• Gain familiarity ensure that issues are identified and solved before
• Identify problems to be immediately addressed. adverse consequences are.
• Identify anomalies and potential hurdles b. Switch power on by qualified electrician.
• Undertake Health and Safety Audit.

16 | BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM

 APPENDICES

Testing of Individual Elements for connectivity, safety Stage 2 tasks

and operability Stage 2 tasks require measurement and testing different
a. Mains Power Supply by Qualified Electrician: elements with pressure and across the operating range.
i. Mains to transformer Inclusive. Pumps – Electrical
ii. Transformer to Switch Board. This will require both mechanical and electrical input
(See schedule 2 for specific pump station checklist).
iii. Switchboard
1. Provide the means of allowing pump to be operated
iv. Other Elements I.e. pump motors.
through its range without risking the main pipe
v. Check switches work. or pump.
b. Main Pipes: This may require isolating from the main line and
i. Check air relief valves all operating. providing an alternative sink.
ii. Check all air obvious air has been expelled. Air relief 2. Provide a suitable method to measure flow and
valves should no longer be venting or sucking air. pressure. This is likely to be equipment already
installed.
iii. Check for obvious leaks.
3. Check Pump Operation.
iv. Check manual valves work.
a. Stop/Start.
v. Check all pressure gauges and transducers are reading
appropriate static head. b. Confirm pump is spinning in the correct direction.
c. Pumps, Headworks (Filters, valves and above ground i. Speed ramping if available.
pipe and ancillaries): ii. Safety switch operations.
i. Complete pump station checklist detailed in iii. Verify and record pump duty characteristics across
Appendix 2 a range of flows.
ii. Check for obvious leaks. Headworks
iii. Check for loose bolts, fittings etc. 1. Manual Valves. Check they seal properly.
iv. Check manual valves work. 2. Check Valves. Check they seal properly.
d. Irrigation Zones: 3. Automatic Valves.
i. Check for leaks. a. Confirm purpose.
ii. Check manual valves working. b. Check pilot plumbing.
iii. Check Pressure gauges reading appropriate c. Check manual override on/off function.
pressure reading.
d. Check electronic remote on/off and
control functions.
e. Check hydraulic pilot control functions,
e.g. Sustaining, reducing etc.
Filters
1. Check head loss at design flow.
2. Check automatic cleaning operations.
a. Start stop settings
b. Overall operation
Pressure Gauges
1. Check gauge reads correctly against master gauge.
Flow meters
1. Verify accuracy according to current regulations.
2. Verify accuracy of logged data and telemetry outputs
(if installed) against meter displays

BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM | 17

APPENDICES

Distribution network Final commissioning

Operate at pressures to test pipe system.
1. Test each zone individually and calculate KPI’s.
1. Pressure test as per specifications against PN rating.
a. Energy Input.
2. Check for obvious leaks.
b. Flow rate.
Zones and irrigators c. Pump inlet Pressure.
1. Application equipment d. Pump Outlet Pressure/Filter Inlet Pressure.
a. Complete manufacturers commissioning e. Headworks/Filter Outlet Pressure.
recommendations and process
f. Key mainline pressures (low and high points).
b. Ensure control panel functional and accurate
g. US Zone Valve pressures.
c. Ensure travelling irrigators can complete their full
h. DS Zone Valve pressures.
length and range of travel successfully
i. Individual Emitter flows and pressures.
d. Sprinklers positioned correctly and free from
obstruction j. Nearest Sprinkler/emitter.
e. Check structural integrity, loose bolts, fittings etc i. Farthest Sprinkler emitter
f. Check for leaks ii. Highest Sprinkler emitter
g. Check manual valves working. iii. Lowest Sprinkler emitter.
2. Emitters – sprinklers, drippers, micro sprinklers iv. Random selection of in between emitter/
sprinklers.
a. Check all individual emitters spray pattern is correct
k. Minimum Application Uniformity (e.g. DUlq).
b. Check sprinkler package correctly fitted on Pivot
l. Maximum Soil Application Intensity.
c. Check emitters free of obstructions
2. At lowest envisaged duty.
d. Check all connections
3. At highest duty.
3. Manual Valves. Check they seal properly.
4. Mock emergency scenarios: Check to see how
a. Check Valves. Check they seal properly.
system responds.
b. Automatic Valves.
a. Pipe break.
c. Confirm purpose.
b. Pump/Power failure.
d. Check pilot plumbing.
e. Check manual override on/off function. 5. DOCUMENTATION
f. Check electronic remote on/off and control 1. Record information appropriately
functions. 2. Complete compliance reports
g. Check hydraulic pilot control functions, 3. Store and collate information to complete
e.g. sustaining, reducing, etc. As Built Information
Control system 4. Provide final documentation to owner.
1. Check operability
2. Check individual operation of valves/pumps.
3. Check accuracy of output information.

18 | BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM

 APPENDICES

Appendix 2: Pump station commissioning checklist

Activity Checked
Do not take safety risks, regardless of the pressure or voltages. Ensure that one person is always standing by
especially when access is by ladder.
Generally mechanical/electrical commissioning procedures should be undertaken in parallel with automation
commissioning procedures so that there is a minimal loss of time.
Calibrate instrumentation as required.
Program any VSD (Variable Speed Drive) or SS (Soft Starter) units involved.
Confirm the setting of safety devices, such as overload sensors and relays, timers.
Check pump motor rotation:
Note that the correct direction of rotation for any centrifugal pump with a volute casing will be the same as
the discharge tangent points. A centrifugal pump will always move liquid out the discharge, regardless of motor
rotation, so detecting flow is not a guarantee of correct rotation. Proper phasing must be confirmed.
Stand away from the motor while someone “bumps” it then, just before the motor coasts to a stop, carefully
observe the direction of rotation of the impeller shaft at the fan cooling end where visible. If necessary
disconnect the pump and observe the rotation of the impeller. NEVER insert anything including fingers into a
pump to check rotation.
If not practical, the pump can be operated in both directions and the correct direction of rotation will be that
which produces the best performance and least pump noise.
The rotation of a submersible well pump can only be determined by operating in both directions, and the
correct direction of rotation will be that which produces the best pump performance. Note that reverse
rotation will not harm the pump or motor.
Ensure that any pump inlet valves are full open (gate valve handwheels should be turned until they stop, then
backed out ½ turn).
Pump discharge valves should normally be full open. They may be partially throttled if the line is not filled. (Line
filling procedures should be approached with considerable caution and filling rates determined by the Designer
according to air relief rate allowances.)
Butterfly valves can be closed by an uneven (turbulent) flow pattern. Confirm butterfly valves vanes are
properly oriented relative to flow patterns especially where adjacent to elbows. Ensure the handles are securely
latched in place.
Ensure that pump casings are properly vented using air bleed points if necessary.
Ensure all thrust anchors, tie back bolts and safety components are secure.
Start pumps using a manual control switch. If the pump is either extremely noisy (blocked inlet) or extremely
quiet (airlocked) immediately stop the pump. Beware of vertical turbine pumps that are extremely quiet
(airlocked) as their water lubricated bearings can fail in a matter of seconds!
With the pump running, check operating amperage, which should be reasonably close to nameplate. Immediate
concern is warranted only if in excess of motor service factor amperage.
With the pump running, check operating voltage on all leads.
Briefly check the pump discharge pressure at shutoff head. This is an excellent indication of pump performance
and if this agrees with the published pump curve, chances are high the pump is performing correctly.
With the pump control switch in AUTO, simulate operating levels and/or pressures to confirm proper operation
of the control system. Finally, observe actual system operation for as long as practical.
The ramp-up and ramp-down time settings of VSD and SS units, or the opening and closing time settings of
pump control valves should generally be a 1:2 ratio. In other words, ramp-down or closing should be double
ramp-up or opening. As a starting point, ramp-down/closing times should be about 10s for pumps up to 10kW,
about 20s for pumps up to 25kw, about 30s for pumps up to 40kW, about 45s for pumps up to 150kW.
When commissioning automatic valves, first ensure all cocks are open, then vent the cover. Confirm that the
valve is properly flow direction oriented. Do not tamper with factory pre-adjusted pilot settings.

BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM | 19

20
|
APPENDICES

PE
80
63
OD
PN
9

PE
80

300 mm
1
60
O
D

e.

3N
bl nd
PN
9

o.
Ca 9 a
m N

PE
8
4m D P

06
re O

3
Co 90
PE
-
2 80

OD
PE8

PN
9
0 63
OD
PN9

200
2-
80
C
7
PE ore 4

BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM

m
DP
5 O m Ca
b
and
N9 le.
Appendix 3: Example as-built plans

PE80 75 OD PN
9 and
2-Core 4mm Ca
ble.

100
a
9
PN nd
OD
50 PN9
0
80
8
PE 75 OD
PE

50
Pipe Key
PE80 160-OD PN9
PE80 90-OD PN9
PN9
50 OD
PE80 75-OD PN9

10 mm
P E80

0
PE80 63-OD PN9
PE80 50-OD PN9
PE80 40-OD PN9
Dripline 16mmOD
Emmitter:1.1LPH@0.4m PC

Revision Amendment Approved Revision Date Project

IRRIGATION NEW ZEALAND

IRRIGATION SYSTEM COMMISSIONING ASBUILTS
PO Box 12-003, Thorndon
STANDARD DRAWINGS
Wellington Office Sheet
+64 4 471 7000 Wellington 6144
New Zealand
Drawn Designed Approved Revision Date TYPICAL MOCK FARM
Ken Mercer Nick Adams August 2014 LAYOUT DETAILS
Project No. Scale Drawing No. Sheet. No. Revision
1:1250 @ A1
1:2500 @ A3 0 20 40 60 80 100 120 m
353129.00 1:1250(A1), 1:2500(A3) INZ/COMMISSING/ASBUILTS 01
Original Sheet Size A1 [841x594] Plot Date 19 Aug 2014 @ 4:38 p.m. Path O:\env\agriculture&food\irrigation_new_zealand\proj\3-53129.00 irrigation system commissioning as built standards\Drawings\Final drawings\final drawing.dwg Layout Plan
 Air Relief Valve: Combination:
25mm: Amiad
Air Relief Valve: Combination:
Control Valve: Solenoid: AC: 25mm: Amiad
Pressure Reducing: 40mm: Dorot
Control Valve: Solenoid: AC:
Isolation Valve: Flanged Butterfly: Pressure Reducing: 40mm: Dorot

300 mm
Lever Action: 50mm
Isolation Valve: Flanged Butterfly:
Connector: PE 63OD to GP 50ID Lever Action: 65mm

Connector: PE 75OD to GP 65ID

D1-3 VALVE NEST
FS3b-6 VALVE NEST

Air Relief Valve: Combination:

200
25mm: Amiad

Isolation Valve: Flanged Butterfly:

Lever Action: 50mm

Connector: PE 63OD to GP 50ID

Air Relief Valve: Combination: Travelling Irrigator Moveable

25mm: Amiad Sprinkler Connections
Control Valve: Solenoid: AC:
Pressure Reducing: 40mm: Dorot
Isolation Valve: Flanged Butterfly:
Lever Action: 65mm

Connector: PE 75OD to GP 65ID

100
FS1-3a VALVE NEST
5x 10 x
Pipe dia Pipe dia

50
Dam Suction Pipe (Others)

Concrete Pad

10 mm
Air Relief Valve: Combination: Air Relief Valve: Combination:

0
25mm: Amiad 25mm: Amiad

Isolation Valve: Flanged Butterfly: Isolation Valve: Flanged Butterfly:

Lever Action: 65mm Lever Action: 80mm

Connector: PE 75OD to GP 65ID Connector: PE 90OD to GP 80ID

PIVOT CONNECTION PUMP SHED

Revision Amendment Approved Revision Date Project

IRRIGATION NEW ZEALAND

IRRIGATION SYSTEM COMMISSIONING ASBUILTS
PO Box 12-003, Thorndon
STANDARD DRAWINGS
Wellington Office Sheet
+64 4 471 7000 Wellington 6144
New Zealand
Drawn Designed Approved Revision Date TYPICAL MOCK FARM

BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM

Ken Mercer Nick Adams August 2014 NEST DETAILS
Project No. Scale Drawing No. Sheet. No. Revision

|
353129.00 NTS INZ/COMMISSING/ASBUILTS 02
Original Sheet Size A1 [841x594] Plot Date 19 Aug 2014 @ 4:39 p.m. Path O:\env\agriculture&food\irrigation_new_zealand\proj\3-53129.00 irrigation system commissioning as built standards\Drawings\Final drawings\final drawing.dwg Nest Details

21
APPENDICES
22
|
APPENDICES

300 mm
Selected Returned Returned
Insitu Insitu Insitu

500
500
500
material material material

200
50 Typ.

BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM

Imported Screened and Screened and
compacted selected Insitu selected Insitu
bedding material material

Pipe Pipe
Pipe Pipe Pipe

Pipe Dia. plus 100mm

Pipe Dia. plus 100mm
Pipe Dia. plus 100mm
Bedding sand Bedding sand Bedding sand

50
50
50

100 Typ. Location of 2-core 4mm 100 Typ. 100 Typ. 50 Typ.
control cable where
applicable

100
TYPICAL TRENCH TYPICAL TRENCH TYPICAL TRENCH
DETAIL; MAIN PIPE DETAIL; SUB-MAIN PIPE DETAIL; MULTI PIPE

50
10 mm
0
Revision Amendment Approved Revision Date Project

IRRIGATION NEW ZEALAND

IRRIGATION SYSTEM COMMISSIONING ASBUILTS
PO Box 12-003, Thorndon
STANDARD DRAWINGS
Wellington Office Sheet
+64 4 471 7000 Wellington 6144
New Zealand
Drawn Designed Approved Revision Date TYPICAL MOCK FARM
Ken Mercer Nick Adams August 2014 TRENCH DETAILS
Project No. Scale Drawing No. Sheet. No. Revision

353129.00 NTS INZ/COMMISSING/ASBUILTS 03

Original Sheet Size A1 [841x594] Plot Date 19 Aug 2014 @ 4:35 p.m. Path O:\env\agriculture&food\irrigation_new_zealand\proj\3-53129.00 irrigation system commissioning as built standards\Drawings\Final drawings\final drawing.dwg Trench Details
 300 mm
200
100
NOTE:

ALL UNDERGROUND PIPEWORK TO BE PE 80 PN8 UNLESS OTHERWISE STATED.

# = PIPE ACCESSORY (REFER TO SHEET 603)

# = PIPE SUPPORT TYPE (REFER TO SHEET 604)

50
10 mm
0
Revision Amendment Approved Revision Date Project

IRRIGATION NEW ZEALAND

IRRIGATION SYSTEM COMMISSIONING ASBUILTS
PO Box 12-003, Thorndon
STANDARD DRAWINGS
Wellington Office Sheet
+64 4 471 7000 Wellington 6144
New Zealand
Drawn Designed Approved Revision Date TYPICAL PUMP STATION

BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM

Ken Mercer Nick Adams August 2014 DETAILS
Project No. Scale Drawing No. Sheet. No. Revision

|
353129.00 NTS INZ/COMMISSING/ASBUILTS 04
Original Sheet Size A1 [841x594] Plot Date 21 Aug 2014 @ 8:37 a.m. Path O:\env\agriculture&food\irrigation_new_zealand\proj\3-53129.00 irrigation system commissioning as built standards\Drawings\Final drawings\Mock_Farm\Mock_Farm_AsBuilt.dwg Pump Station

23
APPENDICES
NOTES

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The information provided in this publication is intended as a guide and reference resource only and should not be used, relied upon or treated as a substitute
for specific professional advice. While Irrigation New Zealand Limited (including its officers, employees, contractors and agents) (INZ) has taken all due care in
the preparation of the information in this publication, INZ cannot guarantee that every statement is factually accurate.
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24 | BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM

BEST PRACTICE GUIDE TO COMMISSIONING A PIPED IRRIGATION SYSTEM | 25
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