Commissioning Safety

Commissioning is the process of bringing installed systems to operational status for the first time.
It involves energising electrical systems, pressurising pipes, starting motors, and introducing process fluids.
First-time operation reveals latent defects including loose connections, leaks, and wiring errors.
Multiple hazardous energy sources become active simultaneously during commissioning activities.
A commissioning plan must define the sequence, responsibilities, and safety controls for each system.
Lockout isolation points must be established before energisation for emergency shutdown capability.
Workers not involved in commissioning must be excluded from the area during live testing.
Pre-commissioning checks including continuity, insulation resistance, and alignment must be completed first.
Communication between the commissioning engineer, operators, and safety team must be continuous.
Commissioning often takes place while other construction activities continue nearby on the same site.

First energisation	Systems operating for the first time are most likely to fail — defects reveal themselves under live conditions.
Multiple energy sources	Electrical, mechanical, chemical, and pressure energy sources all become active during commissioning.
Interface risk	Commissioning areas adjacent to ongoing construction require strict demarcation to protect non-involved workers.

Do

Don't

Prepare a commissioning plan defining the sequence, controls, and responsibilities
Complete all pre-commissioning checks before energising or pressurising any system
Establish exclusion zones around systems being commissioned for the first time
Verify emergency shutdown systems are operational before starting live testing
Brief the commissioning team on the specific hazards and emergency procedures
Maintain continuous communication between all commissioning team members
Energise systems in a controlled sequence — not all at once
Monitor for leaks, unusual noise, vibration, and overheating during first operation
Record all commissioning data including test results, defects, and corrective actions
Coordinate with the construction team to demarcate commissioning areas clearly

DON'T energise systems without completing all pre-commissioning checks first
DON'T allow non-commissioning workers inside the exclusion zone during live testing
DON'T start multiple systems simultaneously — commission them in controlled sequence
DON'T bypass safety interlocks or protection devices during the commissioning process
DON'T ignore minor leaks or faults — de-energise, repair, and retest before continuing
DON'T commission without confirming emergency shutdown systems are operational
DON'T rush commissioning to meet handover deadlines — defects under pressure cause incidents
DON'T assume the installation is correct — commissioning exists to verify it
DON'T leave systems energised unattended during the initial commissioning period
DON'T skip the commissioning plan — ad hoc testing misses critical safety steps

See also: MEICA Safety Awareness | Pre-Commissioning Checks

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