Commissioning Book

Controls Check Out Book
Project: MJB
Rev
0
By
MJB
Description
Initial Revision for CUI 2001
This book, once assembled from the attached documents and other sources, forms the complete
documentation necessary to undertake a Controls Check Out project. The contents are:
Tab
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Document
Titlepage
Contents
Location Drawings
Loop Drawings
SAMA Drawings
Motor Schematics
PLC Logic Drawings
DCS Logic Slot Drawings
Check Out Procedures
Check Out Activity Definitions
Check Out Introduction
Client Safety Information
Attached
Yes
Yes
Yes
Yes
Yes
Source
This doc.
This doc.
Separate
Separate
Separate
Separate
Separate
Separate
This doc.
This doc.
This doc.
Separate
Check Out Procedures

The following procedure details the general check-out activities only, and does not discuss documentation
or safety issues which also have to be handled by the check out teams.
Not all activities apply in all circumstances
Check Out Procedures 600VAC Starter

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Construction Complete Starter

Construction Complete Field
Check Ready Tag, Motor Tag, and Overload Tag on DCS
Verify PLC Logic against Logic Drawing
Verify Starter wiring against Motor Schematic
Close Disconnect
Check Ready Indication in PLC
Check Ready Indication in DCS
Disable Output in PLC
Test Local Stop and Start
Test Local Emergency Stations
Test DCS Stop and Start
Simulate Overload
Clear overload from Field
Simulate Overload
Clear overload from DCS
Enable Output in PLC
Bypass interlocks
Start and stop motor from field
Start and stop motor from DCS
Check Motor run indication in PLC and on DCS
Verify proper rotation
Open Disconnect
Remove all bypasses
Check Out Procedures 600VAC Starter w/ Cheater Cord

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Check Ready Tag, Motor Tag, and Overload Tag on DCS
Open disconnect
Remove 120VAC control transformer fuse
Install cheater cord
Simulate Overload
Simulate Overload
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Bypass interlocks
Remove cheater cord
Reinstall 120VAC control transformer fuse
Remove all bypasses
Check Out Procedure 2300VAC Starter

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Check Ready Tag, Motor Tag, and Fault Tag on DCS
Verify Disconnect Open
Install Cheater Cord
Test Starter Stop and Start
Simulate Fault
Clear overload from Starter
Simulate Fault
Simulate Fault
Bypass interlocks
Remove Cheater Cord
Close Disconnect
Verify proper rotation
Open Disconnect
Remove all bypasses.
Check Out Procedure DCS Transmitter

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Construction Complete at Transmitter

Verify installation against Loop Drawing
Activate DCS Point and check for signal
Lift transmitter wire and check for loss of signal in DCS
Compare transmitter displayed value against DCS
Compare transmitter calibration against DCS
Compare transmitter calibration against Loop
Simulate transmitter range and check in DCS
9. Verify alarming enabled and operates if appropriate

10. Verify transmitter valved in and connected to process
Check Out Procedure PLC Switch

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Construction Complete at switch

Verify logic against PLC Logic Drawing
Activate DCS Point and compare de-energized states to Loop and Field
Install fuse
Compare current state to PLC and DCS
Simulate process or signal change
Compare changed state to PLC and DCS
Compare switch calibration against Loop
Verify alarming enabled and operates if appropriate
Verify switch is functional and in proper state
Verify switch valved in and connected to process
Check Out Procedure Modulating Valve or Actuator

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Construction Complete at device

Verify air supply valved in and at correct pressure
Activate DCS Point at safe level and check for signal
Lift device wire and check for loss of signal in DCS
Compare device state against DCS state
Compare device calibration against DCS
Compare device calibration against Loop
Stoke device in 25% increments up and down range
Leave device in safe / rest / fail position
Check Out Procedure On/Off Valve or Actuator

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Construction Complete at device

Verify air supply valved in and at correct pressure
Verify PLC logic against Logic Drawing
Disable and force output off in PLC
Verify proper state against PLC
Verify proper state against Loop Drawing
Install fuses
Enable output in PLC
Bypass interlocks
Force valve open and closed from PLC
Test DCS control and indication of valve
Remove all bypasses
Software Check Out

Tag Checkout Digital Composites
1.
Tag exists
Verify the tag exists on the system
2. Tag location correct
Verify the tag location (UCN and Node) matches correct HPM
3. Descriptions and label
Verify description and label against function on logic drawing
4. Number of states, descriptions, engineering units, and colors
Verify number of states and their descriptions from logic drawing
Verify the engineering units and colors from inference
5. Inputs
Verify inputs against logic drawing and PLC ladder logic
6. Input Logic
Verify inputs logic against logic drawing and forcing or activating PLC ladder logic
7. Alarm modes and priorities
Verify alarm mode and priorities against source document
8. Graphics and Change-zones
Verify proper appearance and functionality on graphics including description, labels, colors, and
change-zones. Simulation of inputs and outputs may be required.
9. Outputs
Verify outputs against logic drawing
10. Output Logic and momentary states
Verify outputs and momentary states against logic drawing and PLC ladder logic by commanding
states
11. Narrative matches functionality
Verify tag accomplishes narrative functionality requirements
Tag Checkout Logic Slots

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Tag exists
Tag location correct
Verify the tag location (UCN and Node) matches correct HPM and tag numbering system
Inputs
Verify inputs against DCS Logic Slot drawing
Logic
Verify logic against DCS Logic Slot drawing including blocks, negations, and output control flags
Outputs
Verify outputs against DCS Logic Slot drawing
Narrative matches functionality
Tag Checkout Digital Outputs

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Tag exists
Descriptions and label
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Verify description and label against function on logic drawing

Verify the tag location (UCN, Node, module, and slot) matches loop drawing
Inputs
Verify driven inputs against loop drawing and DCS Logic Slot drawing.
Logic
Verify output is not inverted
Tag Checkout Analog Inputs

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Tag exists
Verify description and label against loop drawing
Input
Verify input against loop drawing and other tags.
Range and Engineering units
Verify calibrated range and engineering units against loop drawing
Graphics and Change-zones
Verify proper appearance and functionality on graphics including description, labels, colors, percentage
or engineering units, bar graphs, and change-zones. Simulation of inputs and outputs may be required.
Alarm modes and priorities
Outputs
Verify output connections against loop drawing
Tag Checkout Analog Outputs

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Tag exists
Inputs
Verify driven inputs against loop drawing and other tags.
Outputs
Verify outputs loop drawing
Output Logic
Verify outputs characterization and forward or reverse acting state against loop drawing
Tag Checkout Analog Control
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Tag exists
2. Tag location correct
Verify the tag location (UCN, Node) matches loop drawing
3. Descriptions and label
4. Inputs
Verify inputs against loop drawing and other tags.
5. Range and Engineering units
Verify calibrated range and engineering units against loop drawing
6. Graphics and Change-zones
Verify proper appearance and functionality on graphics including description, labels, colors, percentage
or engineering units, bar graphs, and change-zones. Simulation of inputs and outputs may be required.
7. Alarm modes and priorities
8. Control strategy
Verify the control strategy matches the SAMA and narrative, including overrides and interlocks or
manual control
9. Outputs
Verify outputs loop drawing
10. Output Logic
Verify outputs characterization and forward or reverse acting state against loop drawing
11. Narrative matches functionality
Check Out Activity Definitions

Actuate switch The switch is actuated as close to the process or device as possible. The possible tests, in
decreasing order of accuracy is with a process change, a process simulator, manually activating the switch,
and finally jumpering or removing a wire on the switch.
Actuate valve / actuator Actuate the valve / actuator to ensure proper direction of travel and smooth
operation across complete range in both directions without stiction or hysteresis.
Check Advanced Controls This is a generic activity to indicate to the commissioning teams that there is
additional, non-typical control associated with an item.
Check air supply Verify air supply to the positioner/valve is charged and at the correct operating
pressure.
Check alarm indication and priority Verify alarm, if configured, responded to a change in the field
state.
Check all spares marked and taped back Verify all spare conductors are marked with the cable number
and spare and neatly secured out of the way.
Check bonding Verify the bonding of the panel to the upstream power source by the use of the bonding
conductor in the cabling. Where multiple power sources exist, the panel must be bonded to each.
Check communication Verify the control systems equipment in the cabinet is communicating to the
other elements of the control system.
Check communications cables in place and secure Verify communications cabling is complete,
properly terminated, mechanically secure, and protected from strain or damage.
Check configuration Verify that the configuration of the control system matches that of the design.
Check controller point functionality Verify the regulatory control point on the loop associated with an
output for proper inputs, operation, alarming, and outputs.
Check DCS alarm horn Verify the DCS alarm horn sounds, with the correct tone, for each priority of
alarm.
Check DCS Graphic Verify DCS Graphic, if present, responded to a change in the field state
Check DCS Point Verify DCS Point, if present, responded to a change in the field state and that the
description, range or states, and engineering units are correct.
Check DCS Point when device disconnected Verify DCS Point displays an error when the field device
is disconnected to prove the continuity of the loop.
Check field calibration against control system Verify the state the instrument or device is reporting or
is in matches the state indicated or used in the control system. On existing or calibrated-verified analog
instruments, use a two-point check. On new, unverified, analog instruments use a five-point check. For
inputs, the test signal should be inserted as close to the process as possible, with a 4-20ma simulator being
the least-desirable check. For outputs, the test signal should come from the control system.
Check field calibration against loop Verify the state the instrument or device is reporting matches the
state indicated on the loop drawing.
Check field station With the motor run output forced off, check the stop and start buttons for proper
operation, including PLC I/O if wired.
Check fuses in place and properly sized Fuses are to be checked for appropriate size against the
construction documentation. Where large numbers of fuses exist, a random sampling of the fuses is
sufficient. Do not change fuse sizes in existing starters if they do not match. Mark up on motor schematic.
Check integrity of cabinet / JB Verify the control panel is securely mounted, without unsealed
penetrations except for conduit and wiring duct, and not located or damaged in a way that would
compromise the interior.
Check interlock functionality If the DCS input is used for interlocking, verify the interlock operates
correctly
Check light on local panel Verify the panel-mounted light responds to the control system.
Check Logic Slot functionality Verify the logic in a DCS Logic Slot associated with a device.
Check motor rotation with operations With an operations or mechanical representative bump test the
motor to ensure rotation is correct.
Check orderly layout and ventilation Verify the JB or cabinet is arranged in a clean and professional
fashion, and that any heat-producing items are able to radiate and have a clean convention-flow.
Check PLC I/O Verify PLC I/O responded to a change in the field state
Check PLC logic functionality Verify that the plc logic matches the design, and operates correctly.
Check process / device connection Verify that the instrument or device is correctly connected to the
process in a secure, reliable fashion, and any process lines are installed in accordance with good practices,
filled if required, and valved in.
Check / simulate starter overload Simulate overload in starter and verify starter would de-energize, and
DCS alarms, if configured.
Check starter power Once the MCC or cheater power is applied, verify the control circuit is energized.
If the starter is wired to the PLC, verify PLC input for starter power.
Force output and check input Force a change of state in the PLC and ensure the DCS input follows the
PLC.
Simulate full signal range Using a process simulator or 4-20ma generator, ramp the device through the
full signal range.
Test run / stop from DCS Verify DCS can stop and start the motor, if configured.
Test run / stop from field - With the output enabled, test start and stop the starter from the field. Verify
run indication from starter in PLC, if wired.
Verify current state The current state of the instrument or device is compared to the current state of the
process or equipment for agreement.
Check Out Information

Purpose
The Controls Check Out activity serves to ensure the following:
The construction of the design has been completed as required construction verification.
The design is complete and correct when applied to the installation, and performs as required
integration testing.
The control system is ready for immediate use by operations for process testing or start-up
operational readiness
Timing
CCO is performed after construction is complete, but prior to a dynamic testing or operations group
receiving control of the process.
Workflow
The workflow for Controls Check Out needs to occur in the following order:
Construction complete and contractor QAd
Contractor turns completed items turned over to CCO group
CCO team assigned to perform predefined checks on items
CCO team tests the device and the software for proper operation
Deficiencies from checks are fed back to originators
Repaired deficiencies are rechecked and fed back until there are no outstanding serious deficiencies or
predefined checks
CCO team turns completed items over to a dynamic testing or operations group.
Activities
Paper management This involves receiving paper from the construction group indicating progress,
producing reports for, and receiving reports from the CCO teams, and producing completion reports for
the dynamic testing or operations group..
CCO System management The CCO database system is a large, complex, distributed database that
must be updated regularly with status information. The system develops reports based on that status
information, which must be generated and distributed to the various interested parties.
CCO Management The CCO Manager works to facilitate the CCO teams activities, including
interfacing to construction, dynamic testing, and operations. The manager is also responsible for
progress reporting to scheduling.
CCO Team leadership The team leader directs the controls check out activity, including controlling
direction and safety aspects for the team. They are responsible for reporting progress, speaking for the
team, interfacing with other groups, and distributing direction to the team.
PLC and DCS operation The control system (PLC and DCS) operators direct the field CCO teams in
meeting the check-out objectives. They also manage most of the teams paperwork.
Field checks and repairs The field crews work with the control system end-devices and the PLC and
DCS operators to verify the field device works as required by the controls design. They are also
responsible for any small construction fixes in the course of getting the field devices working.
Roles
DCS
The DCS operator is responsible for checking tags and graphics, verifying DCS based control strategies
and interlocks, actuating field devices from the DCS, tracking progress and writing up deficiency
information.
When the team is checking out analog-only devices, the DCS operator runs the commissioning crew.
PLC
The PLC operator is responsible for verifying logic, interlocks, PLC/DCS communication on the PLC side,
tracking progress and writing up deficiency information.
When the team is checking out digital devices or starters, the PLC operator runs the commissioning crew.
Field Crew Rep

The customers field crew resource is responsible for verifying proper field operation and relaying
deficiencies back to the PLC or DCS operator. They run the field crew. They also handle verifying and
marking the field checkout tags.
Field Tradesman
The field tradesman is responsible for device disassembly, jumpering, cheater-cords, electrical testing, and
in-place repairs.
CCO Administration
The CCO administrators are responsible for maintaining the CCO database and providing work lists to and
receiving work lists from the CCO teams.
They are to assist with paper and information management for the CCO teams when they are not
maintaining the CCO database.
Safety
There are three kinds of safety: Your safety, your co-workers safety, and the physical plants safety.
There are a number of risk factors: Industrial site, construction, electricity, process, mechanical action,
untested systems, unfamiliar area, poor communications.
Think through your actions, and keep others informed of your activities and status.
Assume everything is live
Do not touch any wires before checking them for voltage to ground.
Do not change terminals on energized equipment
Assume all starters are energized at all times.
Do not place any object that is not well insulated (ie: quality multimeter) into the starter cubicle
Do not poke at terminated wires, as they can come off and hurt you
Be careful about fusing. Just because it protects you doesn't mean it will protect the equipment and
vise versa.
If using a meter, ensure it is in the right mode (voltage / current). Consider never putting your meter in
current mode.
Do not do anything that could cause a device to become energized unless you have a lookout
Talk to the rest of the crew. Always tell the other party what you are doing.
Think about what's behind a valve, pump, or actuator. If you don't know, ask.
Be sure you can't be hurt by a test you perform on a device.
Watch out for pinch points and leaning against or placing things on equipment that will move.
The equipment may be old, or brand new and never tested. Be mindful of leaking pipe joints that may
become pressurized, and equipment that might fail.
Check Out System Concepts

Construction Completion Construction is only consider to be complete for an Item when it has been
checked by the construction Q/A crew and been provided to the data entry personnel along with any
drawing markups showing any changes that may have been made during construction. CCO work will only
be made available to the CCO teams once these item lists and markups have been received.
CCO Items - Instruments or Equipment Groups that have been determined to require some sort of Check
Out activity.
Subsystems - Different parts of the process have been broken down into subsystem because they need to
have CCO complete at different times in order to meet the needs of the operations or the GPOP
Commissioning team. All CCO work will be prioritized by these subsystems.
CCO Task These are descriptions of the activities that will be performed as part of CCO on a device.
They are individually tracked for each device, and are marked off as they are completed.
Deficiency A problem that is found while performing CCO on an Item. A detailed description of the
problem needs to be written down so that it can be entered into the database and end up on a work list for
the appropriate repair group. This information will also reappear on the CCO Work list once the deficiency
has been repaired.
Deficiency Type This is used to classify the severity of the deficiency. Must fall into one of the
following 4 categories (later means post shutdown, Wish List means requests that are outside of the
project scope):
Fix Now
Fix Later During Downtime
Fix Later On The Run
Wish List
Deficiency Repair Group These are the various parties who may be responsible for repairing
deficiencies. This includes the contractors, the engineering groups, a different teams from the owner. A
repair group is assigned to each deficiency and is responsible for indicating when that deficiency is
repaired.
CCO Work list - Contains a list of all the Items that have been turned over from construction and have not
been completely checked out already. In most cases it is ordered by priority, then by equipment or
instrument number. The information listed on the CCO Work list consists of:
Project Number
Subsystem Number
Subsystem Description
Subsystem Time Required (when this subsystem is scheduled for turnover to operations or GPOP
commissioning)
Item Tag (Area-Group for Equipment Groups, Area-Type-Group-Suffix for Instruments)
Item Location (includes Elevation, Location and Location Description if they were in AutoIndex)
Item Description
Reference Drawing Number (if it was in AutoIndex)
Device Type (Equipment Group or Instrument)
All CCO tasks required for each item
If deficiencies have previously been found for a given item, all related deficiency information will be
shown also
Deficiency Work list Contains all the information necessary to locate and repair deficiencies found by
the CCO teams, including the following:
Project Number
Subsystem Number
Subsystem Description
Subsystem Time Required (when this subsystem is scheduled for turnover to operations or GPOP
commissioning)
Item Tag (Area-Group for Equipment Groups, Area-Type-Group-Suffix for Instruments)
Item Location (includes Elevation, Location and Location Description if they were in AutoIndex)
Item Description
Reference Drawing Number (if it was in AutoIndex)
Deficiency Description
Deficiency Type
When the deficiency was found
CCO Complete CCO is considered to be complete for an item once all of its CCO tasks have been
completed. Deficiencies can still exist for the item however they cannot be of the Fix Now type.
Safety Documentation
600 VAC Starter CCO Cheater Cord Job Safety Analysis
600 VAC Starter CCO T Leads Removed Job Safety Analysis
600 VAC Starter CCO Full Connection Job Safety Analysis
2300 VAC Starter CCO Cheater Cord Job Safety Analysis
Control Valve CCO Job Safety Analysis
Mechanical Actuation CCO Job Safety Analysis
120VAC Instrument CCO Job Safety Analysis
120VAC Power On Signal Simulation Job Safety Analysis

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Controls Check Out Book

Check Out Procedures

Check Out Procedures 600VAC Starter

Construction Complete Starter

Check Out Procedures 600VAC Starter w/ Cheater Cord

Construction Complete Starter

Enable Output in PLC

Check Out Procedure 2300VAC Starter

Construction Complete Starter

Check Out Procedure DCS Transmitter

Construction Complete at Transmitter

9. Verify alarming enabled and operates if appropriate

Check Out Procedure PLC Switch

Construction Complete at switch

Check Out Procedure Modulating Valve or Actuator

Construction Complete at device

Check Out Procedure On/Off Valve or Actuator

Construction Complete at device

Software Check Out

Tag Checkout Logic Slots

Tag Checkout Digital Outputs

Verify description and label against function on logic drawing

Tag Checkout Analog Inputs

Tag Checkout Analog Outputs

Tag Checkout Analog Control

Check Out Activity Definitions

Check Out Information

Field Crew Rep

Check Out System Concepts

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