Commissioning Checklists

Validate performance and reduce risk of unplanned downtime, and conduct efficient installation, functional, and operational checks with a mobile app

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Published December 10th, 2020

What is Commissioning?

Commissioning is a systematic process of verifying the performance of facilities, systems, and assemblies to ensure trouble-free outcomes and mitigate the risk of unplanned outages or downtime. Project managers, contractors, and construction engineers also perform pre-commissioning to confirm that equipment installation and function follows client specifications.

What is a Commissioning Checklist?

A commissioning checklist is used to easily perform comprehensive installation, functional, and operational inspections, resolve any detected failures and prevent costly project delays.

This article features:

1) how to determine pre-commissioning and commissioning activities;
2) mobile inspection app to instantly assign corrective actions for failed items; and
3) free commissioning checklists you can download, customize, and use.

At What Point Does Pre-commissioning End and Commissioning Begin?

There are regional differences when it comes to common parlance in pre-commissioning and commissioning. Pre-commissioning is sometimes referred to as Cold Commissioning, Static Commissioning, or Mechanical Completion; on the other hand, commissioning is sometimes referred to as Hot Commissioning, Live/Dynamic Commissioning, or Start-up. Therefore, commissioning teams experience difficulty in determining the proper procedure. Here is a run-down of what needs to be done during pre-commissioning and commissioning, respectively:

Pre-commissioning Procedure

  1. Piping and Instrumentation Diagram (P&ID) Check, also known as System Check or Walkdown, should be performed by the commissioning team to identify engineering and construction errors. Create a P&ID Punch List and address identified issues before pre-commissioning.
  2. Pre-commissioning activities start from mechanical completion, where running-in of equipment such as control system sequence tests (Dry Commissioning), water or solvent introduction to closed-loop pumps (Wet Commissioning), and other operating scenarios where process fluids are NOT YET used.

The Defining Point: Pre-Startup Safety Review (PSSR)

PSSR is a thorough safety inspection of a new or modified facility to be conducted before commissioning. This is the point where pre-commissioning ends and commissioning begins. Correct any system failure, resolve all safety risks, and re-take the PSSR to comply with health and safety regulations prior to commissioning.

Commissioning Procedure

  1. Commissioning is the overall performance testing of the facility and its systems such as HVAC, pumps, piping, and lighting. Outstanding punch points should be resolved before routine operation. During a manufacturing plant commissioning, process conditions are established and process fluids (the actual raw materials to be used for routine production) are introduced into the system.
  2. Initial Operation, or the first production run, aims to determine if the production process manufactures output that meets design requirements. Easily identify non-conformance and adjust the system or optimize the process by performing a first article inspection prior to routine production.

Commissioning Checklist App

Adhering to pre-commissioning and commissioning procedures can be challenging and drafting the commissioning report can be time-consuming. iAuditor, the world’s most powerful inspection software, can enable project managers, contractors, and construction engineers to perform trouble-free pre-commissioning and commissioning activities.

  • Capture photo evidence of detected failures and assign corrective actions
  • Easily create and use checklists anytime, anywhere, and on any mobile device
  • Send/receive notifications for scheduled installation, functional, and operational checks
  • Automatically generate and share commissioning reports before leaving the facility. Preview sample report.
  • Use for free with small teams. Unlimited reports and storage, integrations, and real-time analytics for premium accounts.


Shine Colcol

SafetyCulture Staff Writer

Shine has been professionally writing about virtually anything since her internship for a digital publisher of niche blogazines. She is passionate about building a culture of continuous improvement in the environmental, health, safety, and quality space through well-researched, engaging, and impactful content.