Commissioning Execution Plan (CEP)

Project Title: Commissioning Execution Plan for Produced Water Treatment

and Injection Plant
Facility Location: Onshore Oil & Gas Processing Facility (Firm Land Terrain)
Prepared For: [Asset Owner]
Prepared By: [EPIC Contractor Name]
Date: [Insert Date]

1. Introduction
This Commissioning Execution Plan (CEP) defines the strategy,
responsibilities, procedures, and schedule for the commissioning and startup
(CSU) of the Produced Water Treatment and Injection Plant (PWTIP)
integrated within an existing onshore oil & gas processing facility. The CEP
covers all systems and subsystems, including special package equipment,
electric motor-driven rotating machinery, and auxiliary support systems.

2. Objective
The primary objective of this Commissioning Execution Plan is to: - Ensure
systematic and safe commissioning of all plant components and systems -
Confirm functionality and performance as per design and technical
specifications - Provide seamless integration into the existing facility - Ensure
regulatory and HSE compliance

3. Project Overview
The PWTIP includes the following major components: - Desanding
Hydrocyclone Package - Nutshell Filters Package - Oil Skimmer
Vessel - Produced Water and Oil Holding Tanks - Reciprocating
Produced Water Injection Pump - Centrifugal Transfer Pumps -
Electric Motors for All Equipment - Two Gas-Driven Generators
(Prime Power) - One Black Start Generator - Fire and Gas (F&G)
System - PLC-based Control System

4. Commissioning Scope
Commissioning will be carried out in the following phases: - Pre-
Commissioning (by EPIC Contractor) - Commissioning (Jointly by EPIC,
Asset Owner, and Vendors) - Startup (Led by Asset Owner) - Performance
Testing and Handover

5. Roles and Responsibilities

 Asset Owner: Oversight, operational interface, final approval
 EPIC Contractor: Planning, execution, documentation, coordination
  Vendor Representatives: Package-specific inspection, testing,
startup support
6. System Boundaries and Tagging
All systems will be broken down into Commissioning Units (CUs) and Sub-
Systems (SSs) based on process and utility streams. Tags will follow ISO
14224 / project-specific tagging standards.

7. Execution Strategy
The commissioning approach will adopt a system-based and progressive
commissioning methodology. This includes: - Function testing from field to
control room - Motor solo runs and functional interlock testing - Vendor-
assisted mechanical runs for rotating equipment - Wet commissioning with
treated produced water

8. Power and Control System Considerations

 Primary Power: 2 Gas-driven Generators
 Backup Power: Black Start Generator
 Load testing, synchronization, and blackout recovery tests shall be part
of commissioning
 Control System: Integrated PLC system with HMI interface, interlock
logic validation, and F&G interface testing
9. Health, Safety, and Environment (HSE)
All commissioning activities shall comply with: - Site HSE Plan - Permit-to-
Work (PTW) procedures - LOTO (Lock-Out Tag-Out) protocols - Emergency
Response Plan

10. Commissioning Procedures

Each equipment/system will have specific commissioning checklists and
procedures, such as: - Electrical Continuity and IR Testing - Mechanical
Alignment and Coupling Checks - Leak Testing (Hydrotest / Pneumatic as
applicable) - Instrument Loop Checks - Control Narrative Validation

11. Documentation and Deliverables

Deliverables include: - Commissioning Dossiers for each subsystem - Punch
List A/B/C tracking - Vendor Startup Reports - Signed System Handover
Certificates (SHC)

12. Schedule and Milestones

Commissioning shall align with the overall project schedule. Major milestones
include: - Mechanical Completion Certificates (MCC) - Energization Approval -
Cold Commissioning Completion - Wet Commissioning & Functional Testing -
Final Handover

13. Risk Management

A Commissioning Risk Register will be maintained and updated throughout
the process. Key risks include: - Electrical faults and power system instability
- Misalignment or malfunction of rotating equipment - Control system
configuration errors

14. Training and Readiness

 On-the-job training sessions for Asset Owner’s Operations Team
 Vendor-led sessions for special equipment packages
15. Handover Strategy
System Handover shall follow a progressive path: - Pre-commissioning
Acceptance (by QA/QC) - Commissioning Acceptance (by CSU team) -
Operations Readiness and Final Acceptance

Appendices: - A. System Commissioning Matrix - B. List of Commissioning

Procedures - C. Vendor Support Plan - D. HSE Risk Register - E. SHC Template

Confidence Level: High. This plan is based on established industry practice

for commissioning of onshore produced water treatment facilities (IPLOCA,
2023; API RP 1FSC, 2018).
References: - American Petroleum Institute (2018). Recommended Practice
for Facility Systems Commissioning, API RP 1FSC. Washington, DC: API. -
International Pipeline and Offshore Contractors Association (IPLOCA) (2023).
Commissioning Guidelines for Onshore Facilities. Available at:
https://www.iploca.com - NORSOK Standard Z-007 (2020). Completion,
Commissioning and Start-up. Oslo: Standards Norway.
URL: https://www.api.org/products-and-services/standards |
https://www.iploca.com
Co Pilot Response is below:

Below is a draft Commissioning Execution Plan (CEP) for the Produced Water Treatment and
Injection Plant. This plan outlines the approach, phases, roles, and detailed procedures required
to commission the plant safely and effectively within the existing Oil & Gas Processing Facility.

1. Introduction
1.1 Purpose
The purpose of this document is to provide a comprehensive plan for commissioning the
Produced Water Treatment and Injection Plant. It defines the scope, roles, schedules, test
procedures, and safety protocols for successfully integrating the new production systems with
the existing facility infrastructure. All equipment—driven by electric motors powered by two
gas-driven power generators and a black start generator—will be commissioned according to
rigorous quality and safety requirements.
1.2 Scope
This CEP covers:
 Equipment Systems: Desanding hydrocyclone, nutshell filters, oil skimmer vessel, oil
holding tank, produced water storage tanks, a reciprocating produced water injection
pump, and various centrifugal pumps.
 Power Supply: Integration with two gas-driven generators and a dedicated black start
generator ensuring continuous power supply.
 Site Condition: The facility, situated on firm land, with foundations and equipment
installations validated for site-specific conditions.
 Stakeholders: Involvement of the Asset Owner, the EPIC contractor, and vendor
representatives for specialized equipment packages.
1.3 Background
This plant is part of an existing Oil & Gas Processing Facility. The integration of new produced
water treatment and injection systems represents a critical upgrade that requires seamless
coordination between owner, contractor, and vendors to meet both production and
environmental objectives.

2. Commissioning Organization and Roles

2.1 Project Organization
  Asset Owner: Responsible for final approval and overall project oversight.
 EPIC Contractor: Leads the installation, pre-commissioning, and overall commissioning
activities.
 Vendor Representatives: Provide technical support and validation for special equipment
packages.
2.2 Key Roles and Responsibilities

S/ Role Action Responsibility

N Party

1 Project Manager PPL

2 Commissioning FOSL Overall coordination of commissioning activities;

Lead schedule management; reporting progress.

3 Electrical & PPL & Verifies electrical systems, control panels, and
Instrumentation FOSL integration with gas-driven & black start generators.
Lead

4 Mechanical PPL Supervises mechanical tests and functional checks

Systems Engineer across treatment and injection equipment.

5 Safety and QA/QC PPL Oversees all safety protocols, quality assurance, and
Specialist environmental compliance during commissioning.

6 Vendor Technical FOSL Validate installation, perform specialized testing on

Leads equipment (e.g., desanding hydrocyclone, nutshell
filters).

3. Pre-Commissioning Activities
3.1 Documentation and Design Review
 Review of design specifications, vendor manuals, and installation checklists.
 Verification of as-built drawings versus design documentation.
3.2 Installation and Inspection
 Equipment: Confirm proper installation of the desanding hydrocyclone, nutshell filters,
oil skimmer vessel, oil holding tank, produced water storage tanks, reciprocating and
centrifugal pumps.
 Power Systems: Validate installation and wiring of electric motors, gas-driven
generators, and the black start generator.
 Site Conditions: Verify foundation stability and integrity on the firm land terrain.
3.3 Safety and Environmental Checks
 Completion of hazard and operability (HAZOP) studies for commissioning activities.
 Implementation of lockout-tagout (LOTO) protocols and PPE requirements as per site
standards.

4. Commissioning Phases and Procedures

The commissioning will occur in clearly defined phases:
4.1 Dry Commissioning
 Electrical Systems:
o Verify cable integrity, grounding, control panel operation, and interlock systems.
o Test control signals and communication between the plant and the SCADA
system.
 Mechanical Systems:
o Validate mechanical alignment and integrity of all rotating equipment.
o Confirm that all valves and actuators are operational without process fluid.
4.2 Wet Commissioning
 System Cleaning and Flushing:
o Execute cleaning protocols and flush lines to remove debris from installation.
 Individual Equipment Testing:
o Desanding Hydrocyclone and Nutshell Filters: Run initial process water to assess
performance and particle removal efficiency.
o Oil Skimmer Vessel and Oil Holding Tank: Monitor oil separation performance
and verify correct level control operation.
 o Produced Water Storage Tanks: Validate filling procedures and sensor accuracy.
o Reciprocating Injection Pump & Centrifugal Pumps: Conduct flow, pressure, and
performance tests with actual produced water conditions.
 Power Integration:
o Execute startup tests for the two gas-driven generators and the black start
generator.
o Validate backup power transitions and synchronization procedures.
4.3 Integrated System Commissioning
 Full-System Trials:
o Operate the entire plant under simulated load conditions to verify control loops
and process interactions.
o Coordinate load sharing between power generators and evaluate the impact on
critical systems.
 Emergency and Safety Tests:
o Conduct emergency shutdowns, alarm tests, and review of the safety interlock
functionality.
o Ensure all stakeholders are engaged during simulated emergency scenarios for
clarity of roles.

5. Commissioning Schedule
A detailed project schedule will be developed in collaboration with all stakeholders. A sample
timeline is provided below:

Start Date
Activity Duration Responsible Party
(Tentative)

Documentation and Design Review Week 1 1 week All stakeholders

Equipment Installation & Inspection Week 2 – Week 4 3 weeks EPIC Contractor & Vendors

Dry Commissioning Activities Week 5 1 week Commissioning Team

Wet Commissioning (Individual Week 6 – Week 7 2 weeks Mechanical & Electrical

 Start Date
Activity Duration Responsible Party
(Tentative)

Equipment) Leads

Integrated Testing and Full-System

Week 8 1 week All stakeholders
Trials

Final Reporting & Handover Week 9 1 week Commissioning Manager

Note: This schedule is tentative and subject to adjustments based on site conditions and test
outcomes.

6. Testing and Verification Procedures

6.1 Test Procedure Documentation
For each equipment or system, detailed checklists and acceptance criteria will be prepared.
Typical test documentation will include:
 Pre-test checklists
 Test protocols (both for dry and wet commissioning)
 Data collection forms and performance logs
 Deficiency reports and corrective action records
6.2 Electrical and Control Systems
 Validate control panel logic and SCADA integration.
 Run continuity and insulation tests on wiring, ensuring synchronization between
generators and equipment controllers.
6.3 Mechanical and Process Systems
 Measure pump flow rates, pressures, and vibration levels.
 Perform calibration of sensors (e.g., level, pressure, flow) and ensure proper operation
during simulated process conditions.
6.4 Integrated System Testing
 Validate overall process performance including the transition between treatment stages
(desanding, filtration, separation) and the injection process.
  Confirm that emergency shutdown and safety interlock systems operate as designed.

7. Safety, Health, and Environmental Protocols

 Safety Procedures:
o Mandatory adherence to site-specific HSE guidelines.
o Pre-commissioning safety briefings and training, including LOTO procedures and
emergency response.
 Environmental Monitoring:
o Monitoring of produced water quality during testing.
o Assessing any emissions or spills, with mitigation measures in place.
 Emergency Preparedness:
o Clear documentation of emergency shutdown procedures.
o Regular coordination with local emergency teams and on-site response drills.

8. Documentation and Reporting

 Test Reports and Records:
o All testing results, deviations, and corrective actions will be documented in
formal test reports.
o Compilation of QA/QC documentation for each equipment package.
 Handover Documentation:
o Commissioning certificates, operational manuals, and “as-built” drawings will be
compiled into a final handover package.
 Lessons Learned:
o A post-commissioning review session will be scheduled to capture lessons
learned for future projects.

9. Roles and Responsibilities Recap

Re-emphasize collaboration:
 Asset Owner: Final validation and acceptance.
  EPIC Contractor: Oversee day-to-day commissioning operations, address installation
deviations, and document testing procedures.
 Vendor Representatives: Provide expert insight into the operation and troubleshooting
of specialized equipment systems.
Regular coordination meetings will be scheduled, ensuring transparency and timely resolution
of any challenges.

10. Risk Management and Contingency Planning

10.1 Risk Identification
 Potential equipment malfunctions or communication failures during integrated system
trials.
 Power interruptions during testing phases despite available generators.
10.2 Mitigation Strategies
 Maintain backup systems (including black start generator) and ensure readiness of spare
parts.
 Develop contingency procedures to delay or re-sequence commissioning tests if critical
issues are identified.
10.3 Documentation and Reporting
 All risks, incidents, and corrective measures will be recorded and reviewed as part of the
final commissioning report.

11. Post-Commissioning Activities and Handover

 Operational Verification:
o A defined performance monitoring period post-commissioning to validate
ongoing system stability and reliability.
 Training and Handover:
o Comprehensive training sessions for the operations team, covering the nuances
of the water treatment process and emergency protocols.
 Final Handover:
o Submission of the complete commissioning dossier, including test reports,
commissioning certificates, and as-built documentation, to the Asset Owner for
final acceptance.
12. Conclusion
This draft Commissioning Execution Plan sets a robust framework for safely and efficiently
commissioning the Produced Water Treatment and Injection Plant. The plan relies on close
collaboration among the Asset Owner, EPIC Contractor, and Vendor Representatives, ensuring
that every equipment package—from the desanding hydrocyclone to the reciprocating injection
pump—is thoroughly tested and validated. This approach guarantees compliance with safety,
performance, and quality standards while providing the necessary documentation to support
handover and long-term operation.

Additional Considerations:
 In-depth simulation tests and system modeling can be explored to further optimize
commissioning sequences.
 A review session may be scheduled after the pre-commissioning phase to gather field
observations which could improve subsequent commissioning steps.
 Considering emerging digital monitoring tools could further enhance data collection and
real-time system diagnostics during the commissioning process.
This draft is intended to be a baseline that can be customized based on feedback from all
stakeholders and the specific conditions on site. Feel free to ask for more details or suggest
modifications that better align with your project’s unique requirements.
+++++++++++++++++++++++++++++++++++++++++++++++++++++++++++

Great question, Patrick. A robust safety framework is essential for a successful commissioning
campaign—especially in a setting like yours with rotating machinery, high-pressure systems,
electrical installations, and multiple stakeholders involved. Here are key safety protocols that
should be explicitly included in your Commissioning Execution Plan:

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1. Pre-Startup Safety Review (PSSR)**

Before initiating any commissioning activity, conduct a PSSR to ensure all systems meet safety
and operational readiness criteria:
- Equipment installation is complete and as per design.
- Safety systems (alarms, ESD, fire and gas detection) are operational.
- Temporary and permanent access routes are established.

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2. Permit to Work (PTW) System**

Strict enforcement of a PTW system to control high-risk work:
- Electrical isolation permits
- Confined space entry
- Hot work
- Working at heights
- Line break activities

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3. Lockout-Tagout (LOTO) Procedures**

To protect personnel from accidental energization or startup:
- Isolate power (including gas generators and black start systems).
- Tag all equipment under service with clear signage.
- Use group LOTO when multiple teams are involved.

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4. Hazard and Operability Studies (HAZOP) & Job Safety Analysis (JSA)**
- HAZOPs should be completed for all critical systems before commissioning.
- Daily JSAs for every commissioning activity, reviewed during toolbox talks.
---

5. Emergency Response and Evacuation Plan**

- Simulated drills for fire, gas leak, or power loss scenarios.
- Clear communication lines and muster points.
- Emergency shutdown (ESD) testing and functionality checks.

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6. Personal Protective Equipment (PPE) Standards**

Define mandatory PPE based on job roles and areas:
- Flame-resistant coveralls
- Hard hats, safety glasses, gloves
- Hearing protection for compressor/pump areas
- Intrinsically safe communication devices

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7. Commissioning Red Zones and Access Control**

- Demarcate “Live Commissioning” zones.
- Access limited to authorized personnel with sign-in logs.

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8. Environmental Monitoring and Controls**

- Bunding and spill kits around chemical and hydrocarbon tanks.
- Monitoring of produced water discharge quality during testing.
- Noise and emission controls around power generation sets.

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9. Fire and Explosion Risk Mitigation**

- Firewater pumps and extinguishers to be operational.
- Verification of gas detection and suppression systems.
- No ignition sources near volatile process areas.

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10. Safety Audits and Toolbox Meetings**

- Daily toolbox talks tailored to the commissioning activities.
- Regular audits and safety walkthroughs by the HSE team.
- Safety observation programs to encourage reporting of near-misses.

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Want to expand this into a standalone section in your Commissioning Plan—or perhaps a
checklist format your team can use on-site? I’d be happy to draft that up too. Let’s make sure
nothing slips through the cracks.