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7/30/2019 Competency Assessment for Upstream Oil and Gas Pipeline Installation Inspectors[1]
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GUIDE
Competency Assessment for
Upstream Oil and Gas PipelineInstallation Inspectors
September 2009
2009-0005
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2100, 350 7Avenue S.W.Calgary, AlbertaCanada T2P 3N9Tel (403) 267-1100Fax (403) 261-4622
403, 235 Water StreetSt. Johns, Newfoundland and LabradorCanada A1C 1B6Tel (709) 724-4200Fax (709) 724-4225
www.capp.ca [email protected]
The Canadian Association of Petroleum Producers (CAPP) representscompanies, large and small, that explore for, develop and produce natural gasand crude oil throughout Canada. CAPPs member companies produce about 90per cent of Canadas natural gas and crude oil. CAPP's associate membersprovide a wide range of services that support the upstream crude oil and natural
gas industry. Together CAPP's members and associate members are animportant part of a $110-billion-a-year national industry that provides essentialenergy products. CAPPs mission is to enhance the economic sustainability ofthe Canadian upstream petroleum industry in a safe and environmentally andsocially responsible manner, through constructive engagement andcommunication with governments, the public and stakeholders in thecommunities in which we operate.
Disclaimer
This publication was prepared for the Canadian Association of PetroleumProducers (CAPP). While it is believed that the information contained herein isreliable under the conditions and subject to the limitations set out, CAPP doesnot guarantee its accuracy. The use of this report or any information containedwill be at the users sole risk, regardless of any fault or negligence of CAPP orits co-funders.
Review by April 2014
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Contents
1 Project Scope................................................................................................................2
1.1 Definitions........................................................................................................2
2 Pipeline Installation Inspector Roles and Responsibilities........................................3
3 Qualification .................................................................................................................4
4 Areas of Knowledge, Skill and Competency .............................................................4
4.1 General Pipeline Construction Overview.......................................................44.2 Quality Concepts for Pipeline Construction ..................................................54.3 Overview of Relationships Between Codes and Jurisdictional
Requirements ...................................................................................................64.4 CSA Z662.........................................................................................................8
4.5 Owner Specifications, Drawing Interpretation & Management of Change(MOC) ..............................................................................................................9
4.6 Pipeline Safety ...............................................................................................104.7 Welding/Joining and Non-Destructive Testing (NDT)...............................114.8 Materials: CSA Z245, API, ANSI ................................................................114.9 Environmental Considerations and Regulations..........................................124.10 Surface Rights and Reclamation...................................................................134.11 Crossings: Road, Highway, Railway, Water, Pipeline, Foreign Line,
Heavy Equipment ..........................................................................................144.12 Accountability and Liability .........................................................................154.13 Soft Skills .......................................................................................................16
4.14 CSA B51 (ASME B31.3)..............................................................................184.15 Facilities Additional Requirements ..............................................................19
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1 Project Scope
This Guide to Competency Assessment for Upstream Oil and Gas PipelineInstallation Inspectors (Guide) is intended as a management tool for owners andconstructors of pipelines, to ensure installation inspectors employed have the
technical knowledge and competence to ensure new installations fully satisfy theirrequirements and expectations.
This document provides guidance for the assessment and verification of pipelineinstallation inspectors knowledge and competence within the scope ofapplication of the CSA Z662 Code for Oil and Gas Pipeline Systems. (CSA Z662)
The focus of this document is pipeline installations in upstream, and midstreamoil and gas production 12 diameter. Future revisions may include pipelines>12 diameter, offshore pipelines, oilfield steam distribution pipelines and gasdistribution pipelines, however they are not at included in the scope of this Guide.
Installation of pipeline surface facilities has been included to ensure the inspectoris generally aware of the differences in requirements. This will allow the inspectorto decide whether additional inspection resources are required to ensurecompliance in these associated facilities. Please refer to CSA Z662 for furtherinformation.
1.1 Definitions
Competence
The ability to do something well, measured against a standard, relative to a
specific job using his/her skills, knowledge, abilities, and qualifications.
Competent
A person who has the skills, knowledge, and training to consistently performspecific work activities according to predefined standards; the ability to applyskills, knowledge, and training in a specific working environment.
Examination
Quality control functions performed by the manufacturer, fabricator, or installer.As referenced in this document examiner is the person(s) who performs qualitycontrol examinations.
Owner
Owner includes a lessee, a person in charge, person who has care and control anda person who holds out that the person has the powers and authority of ownershipor who for the time being exercises the powers and authority of ownership.(Alberta Safety Codes Act)
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Pipeline (see CSA Z662)
Those items through which oil or gas industry fluids are conveyed, including pipecomponents, and any appurtenances attached thereto, up to and including theisolating valves used at stations and other facilities.
Upstream Pipeline Installation Inspector
Inspector is the person(s) who oversees all aspects of pipeline construction andpipeline facilities construction on behalf of the owner. The inspector should betrained and competent in the acts, codes, regulations, specifications and standardsapplicable to the engineered design.
2 Pipeline Installation Inspector Roles and Responsibilities
The primary role of the pipeline installation inspector is to act within theirassigned scope, as the owners representative to verify or ensure that the
requirements as specified in the engineering design have been fully satisfied.
Their responsibilities include:
i) Ensure that engineering and design is complete and available for reviewprior to construction.
ii) Ensure safe work practices are followed as outlined by OccupationalHealth and Safety.
iii) Create or verify documentation adequate for compliance with regulatoryand engineering design requirements.
iv) Ensure corporate cost control measures are adhered to.v) Adhere to ground disturbance requirements.
vi) Ensure Corporate Material Receiving, identification, traceability andstorage practices are adhered to.
vii) Inspect field fabrication to ensure compliance to design specifications,codes and standards (e.g. B31.3, CSA Z662).
viii) Liaise between design engineer and project engineer to ensure inspectionwork is completed as planned.
ix) Ensure that individuals involved with special processes such as welding,heat treatment and non-destructive testing (NDT) are qualified andcertified in accordance with the requirements.
x) Document certification and qualifications of personnel to verifydemonstrated competency for all critical work.
xi) Review and evaluate contractors quality program to ensure compliancewith owner requirements.
xii) Generate or ensure generation of nonconformance reports and assist indevelopment of action plans to resolve.
xiii) Monitor general awareness and compliance to Section 217.1 of theCriminal Code (Bill C-45).
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3 Qualification
The owner should be able to demonstrate the qualification and competence ofpipeline installation inspectors has been adequately verified and documented.
There is currently no requirement for certification of pipeline installationinspectors.
The onus is on the owner to evaluate and ensure the inspector is competent andhas the knowledge to ensure all regulatory and integrity requirements have beensatisfied.
Pipeline installation inspectors may not require competence in all areas ofpipeline installation. Inspectors may choose to specialize in one area of pipelineinstallation. Documentation should be maintained by the owner demonstratingverification of competency of the inspector for all areas where the inspector isemployed.
4 Areas of Knowledge, Skill and Competency
4.1 General Pipeline Construction Overview
The pipeline installation inspector should have skills and knowledge in all aspectsof pipeline construction and regulations utilized in pipeline and pipeline facilitiesconstruction. This should include:
Licensing and notifications
Ground Work: Ground Disturbance, Environmental Impacts,Timber Salvage, Grading, Topsoil Stripping, Ditching, RockTrenching
Pipe handling and Stringing, Pipe Bending, Pipe Coating, PipeLaying
Back Filling, Rock Shielding, Ditch Padding
Pipe Supports/Anchors
Crossings, Pipe Weight Installation, Horizontal Directional
Drilling (HDD) requirements
Tie-ins, Hot Taps and Cold Taps
Block Valve Installation
Pressure Testing and Test Mitigation Plan
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Joining/Welding, Welding Repairs Composite materials
Management of Change (MOC) Orders, Quality Control/QualityControl Records, Non-Destructive Testing (NDT) Interpretation
De-watering, Pigging
Commissioning, turn over documentation, cleanup and fencerepairs, erosion control, Cathodic Protection, pipeline markers,
reclamation
Drawing interpretation
General content and scope of the Z-662 Code
General understanding of jurisdictional and regulatory involvement
Materials and basic design requirements and materials selection
Materials identification
Fabrication, Assembly and Installation
4.2 Quality Concepts for Pipeline Construction
The pipeline installation inspector should understand, in general, the concepts ofQuality Control and Quality Assurance (QA/QC). Outlined below are the basicelements of QA/QC:
Definition ofQuality: How to meet project requirements relating to federal,provincial and owner codes standards and specifications.
i) Elements of Quality including but not limited to:
Quality system (Quality Plan and Program)
Contract Review
Design Change Control
Document and Data Control
Purchasing
Item Identification and Traceability
Process Control (Welding, Coating)
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Inspection and Testing
Inspection, Measuring and Test Equipment(IM & TE)
Control of Nonconforming Product
Corrective and Preventive Action
Handling, Storage and Preservation of Material and Equipment
ii) Responsibilities for monitoring and verification Quality Records
iii) Review of Contractor Quality Program
4.3 Overview of Relationships Between Codes and JurisdictionalRequirements
The inspector should be familiar with the regulatory and jurisdictionalrequirements utilized in pipeline and pipeline facilities systems construction. Thiswill require an understanding of various regulatory instruments issued by theapplicable regulatory authority such as: legislation, regulations, guidelines, Codesof Practice, Instructions, Information Letters, Information Bulletins, andDirectives.
Understanding the regulatory requirements is essential as they may supersede orsupplement the applicable industry code of construction requirements (e.g. CSAZ662). The inspector should be competent and have knowledge to fulfill the
following responsibilities:
Determine the applicable regulatory authority
Identify pertinent regulatory documents applicable to their scope ofresponsibility
Identify and ensure pertinent regulatory approvals are in place
Understand notification or hold point requirements
Understand documentation, record keeping, reporting and retentionrequirements
Determine documentation required to be submitted for regulatoryauthorization/approval
Identify where regulatory requirements may supersede orsupplement industry code of construction requirements
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Understand incident and failure reporting requirements
Understand any local/municipal requirements
The inspector should be familiar with regulatory requirements based on the
location of the pipeline being installed. This may include:
Canada and Offshore: National Energy Board (NEB)
Alberta: Energy Resources Conservation Board (ERCB)
British Columbia: Oil and Gas Commission (BC OGC)
Saskatchewan: Minister of Energy and Resources (MER)
Ontario: Technical Standards and Safety Authority (TSSA)
Local Municipal Bylaws
The types of activities that may trigger regulatory requirements that the pipelineinstallation inspector should be aware of includes:
Permits to construct, license to operate
Landowner notification and access, survey requirements
Call before dig/line location training, certification, notification,
procedures
Water and road crossing restrictions
Environmental restrictions and approvals
Requirements for pressure testing (approvals, acceptable testfluids, disposal of test fluids, test pressures, records, charts,
documentation)
Non-destructive testing (NDT) additional requirements for visual
examinations, test methods, test frequencies, acceptancerequirements
In-line inspection (ILI) tools notification, approvals
Crossing of other pipelines, utilities (3rd party crossings) notification, inspection, documentation
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Depth of cover requirements
Pipeline marking and signage requirements
4.4 CSA Z662
The inspector should have a general understanding of the entire CSA Z662standard and the ability to navigate and locate any and all required informationencompassed within the standard.
Following are sections of direct importance to upstream oil and gas:
A general understanding of:
1. Reference Publications (Clause 2)
2. Gas Distribution Systems (Clause 12)
3. Aluminum Piping (Clause 15)
A detailed understanding of:
1. Design (Clause 4)
2. Materials (Clause 5)
3. Corrosion Control (Clause 9)
4. Operating, Maintenance and Upgrading (Clause 10)
5. Applicable sections of Annexes
A comprehensive understanding of:
1. Scope (Clause 1)
2. Definitions (Clause 3)
3. Installation (Clause 6)
4. Joining (Clause 7)
5. Pressure Testing (Clause 8)
6. Plastic Pipelines (Clause 13)
7. Oilfield Steam Distribution Lines (Clause 14)
*IMPORTANT: The above categorizations are not for the full scopeof industries covered by the CSA Z-662 specification, but are forupstream oil & gas only. For applications outside of the upstreamindustry the categories may be very different.
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4.5 Owner Specifications, Drawing Interpretation & Management ofChange (MOC)
Inspectors should understand the application of owner specifications, including:
Purpose and need for owner specifications How to access specifications for project or work
Specification revisions and updates
Relationship between specifications, codes and jurisdictionalauthority
Interpret and locate specifications on drawings, e.g.: vendordrawings, plot plans, tie-in and line lists, piping plans, flow
diagrams
Relationship between specifications, standards and best practices
Specifications, management of change, change orders, revisioncontrol
1) Inspector should have a working knowledge of pipeline and pipeline facilitiesconstruction drawings. This will include the following drawing types:
1. Topographical
2. Facility plot plan and elevation drawings3. Typical excavation detail drawings including basic pipeline anchor and
support details, various creek and road crossing details and cathodic
protection
4. Civil engineering drawings
5. Pipeline construction alignment drawings (construction plan/survey
drawing)
6. Legal land site descriptions
7. Piping isometric and orthographic
8. Pipeline system maps
9. Process flow and Process & Instrumentation Diagrams (P & ID)
10. Detail construction and welded steel construction.
11. Welding and NDT symbols
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12. Basic electrical and instrumentation drawings
The inspector should also have a general understanding of related activities suchas surveying and line location.
4.6 Pipeline Safety
The inspector should have a thorough knowledge of appropriate safety practices
and requirements applicable to the construction of pipelines, including:
Work preparation
Personal Protective Equipment (PPE)
Workplace Hazardous Material Information System (WHMIS)
Hazard recognition and control
Front end operational hazards and controls
Rigging and hoisting hazards and controls
Pipe hazards and controls
Pipe assembly and coating hazards and controls
Specialized work hazards and controls
Environmental hazards and controls
Back end operational hazards and controls
Vehicle operation
Equipment operation and inspections
Emergency response
Medical service requirements
Hazards related to Cathodic Protection
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4.7 Welding/Joining and Non-Destructive Testing (NDT)
The pipeline installation inspector should understand, in general, the variouswelding processes utilized in pipeline and facilities construction. The pipelineinstallation inspector should understand the various factors that affect weld
quality and the inspection and test methods used to ensure and verify acceptableweld quality. In general this will include:
Detailed knowledge of CSA Z662 Joining Clause (Clause 7)
Overview of welding processes (including special processes used inpipeline construction.
Basic welding metallurgy (new material/in-service materials/tie-points.
Welding consumables including filler metals, fluxes, shielding gases
Welding procedure specifications and qualification testing
Closure weld procedures
Welder Qualification Testing
Practical considerations for welding in the field
Weld faults and acceptance criteria
Repair welding
In-service maintenance welding, repair and Hot Taps
Joining non-metals (mechanical/bonding)
Basic NDT for welds - Visual Test (VT) , Radiographic Test (RT) ,Ultrasonic Test (UT), Magnetic Particle Test (MT)
4.8 Materials: CSA Z245, API, ANSI
The pipeline installation inspector should understand, in general, the variouscodes and standards utilized in material selection for pipeline and facilitiesconstruction.
Definitions of pipe manufacture (e.g. electric and submerged arc welded,seamless)
Definitions of fitting/valve manufacture methods (e.g. forging, casting)
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Definitions of different organizations, including:
i) Canadian Standards Association (CSA)
ii) American Petroleum Institute (API)
iii) ASTM International
iv) American Society of Mechanical Engineers (ASME)
v) Manufacturers Standardization Society (MSS)
vi) American National Standards Institute (ANSI)
Definitions of testing terminology (tensile strength, yield strength -stress/strain, absorbed energy impact test, drop weight tear test
fracture appearance, ductility and hardness)
Definitions of heat treatment (stress relief, annealing, normalizing)
Material and equipment pressure ratings
Material and equipment derating for temperature stress level limitations(for sour service)
Deviations for materials not addressed in Z662 (sufficient technicalinformation and acceptance)
Understanding of required markings
Sour service and NACE MR0175/ISO15156
Material Test 6 Reports (dual certification) CSA/ASME
Requirements for gaskets and bolting (bolt-up procedures)
Fibre-reinforced composite pipe and fittings (manufactured and tested toAPI 15HR)
Effect of alloying agents on manufacture of steel (carbon, manganese,
CE and effect on weldability)
4.9 Environmental Considerations and Regulations
The pipeline installation inspector should, in general, to able to discuss andmanage the various environmental regulations and considerations for pipeline and
facilities construction. In general this will include:
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Spill control/clean up/containment
Waste disposal
Product, chemical and waste storage
Appropriate vegetation management and surface water run-offmanagement
Compliance with atmospheric emissions policy and regulations
Relevant provincial legislation, national and international legislationdealing with the environment
Communication with regulatory agencies and government officials onenvironment issues
Compliance with legislated testing and reporting of environmental issues
Applicable enforcement actions (or applicable regulatory body, e.g.Alberta Environment or ERCB)
Site-specific environmental issues.
Inform residents on environmental issues
Procedures necessary to deal with environmental incidents and the
people that need to be contacted
Approvals and licenses required to operate and the responsibilities thatgo along with the licenses
Communication with the owners environmental group
4.10 Surface Rights and Reclamation
The inspector should have an overall understanding of the land ownership andusage rights of all stakeholders. The inspector should also interface with some orall of the stakeholders and demonstrate due diligence in minimizing adverse
impacts to the landowners and users.
The inspector should be aware of the following:
Land ownership (crown owned, privately owned/leased,aboriginal)
Know the stakeholders
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Land and environment representative(s)
Local and municipal regulations/approvals (development permits,road use, borrow pits, signage, stakeholder approvals)
Required permits/licenses and issue agencies for the related worke.g. permit to construct
Environmental guidelines, procedures and contacts
Public consultation practices
Clearing and timber salvage requirements
Stripping and top soil handling
Right Of Way (ROW) work space and extra work space
Water draw and disposal locations/requirements
4.11 Crossings: Road, Highway, Railway, Water, Pipeline, Foreign Line,Heavy Equipment
The pipeline installation inspector should be knowledgeable and have a thoroughunderstanding of all applicable company specifications and provincial/federalacts, codes, regulations and standards when supervising pipeline installations inthe vicinity of and or underneath roads, highways, railways, and foreignlines/utilities.
The pipeline installation inspector should be able to interpret the followingsections of applicable codes and standards:
Public safety
Ground disturbance
Crossing/proximity/tie-in agreement
Emergency shut-down devices
Pipeline identification and marking
Weld procedures
Mandatory non-destructive testing
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Code requirements for record keeping applicable to pipelinesystems
Material test reports
Valve requirements
Valve location and spacing
Erosion control on roadways
Waterway and ditch erosion control
Slope gradients for fine, medium and coarse textured soils
Soil stability and wind erosion
Unstable slopes
Private/Public utility crossing
Bored crossings
Open cut crossings
Crossings of navigable waterways
Arial crossings Cased road and railway crossings
Uncased road and railway crossings
Clean up and restoration
Cathodic protection
4.12 Accountability and Liability
The pipeline installation inspector should have a good understanding of the areasof general accountability and liability as they apply to the inspection of pipelineinstallation. These should include:
Definition of Accountability (see Section 217.1 of the Criminal Code,Bill C-45)
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Understanding elements of negligence:a. Duty
i. Should meet a standard of care (act as a reasonable personwould act or, in the case of expertise, must act as a
reasonable competent person would act)ii. Foreseeable plaintiffs (who there is or who there could be)
iii. Types of duty (voluntary, involuntary imposed by law)
iv. Special duty
b. Breach of Duty
i. Failure to meet the standard of care
ii. Failure to perform or act
c. Cause (direct or indirect)
d. Damages
Avoidance of Personal Liability:
e. Act in the publics best interest
f. Adhere to adopted codes, standards and specifications
g. Act in a non-discriminatory manner
h. Professional and business-like conduct
i. Document
j. Conduct follow-up inspections as required
k. Send decisions to a higher level (deviations from established(design) codes and policies)
4.13 Soft Skills
The pipeline installation inspector be able to demonstrate the soft skills outlined
below:
i) Communications
Effective writing skills
Effective interpersonal communications
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Open and timely communication (who should be told when)
Interpretation of an organizational chart
Identification and communication with all stakeholders (residents
organizations, local media, appointed and elected governmentrepresentatives, others)
Reading skills and comprehension using the English language
Meeting management
Teamwork
Effective interpersonal problem resolution
ii) Computer Skills
Basic computer literacy
Basic word processing skills
Send and receive e-mail
Basic spreadsheet skills
Use of a digital camera
Proficiency with using the internet
iii) Management and Administration
Description and application of risk assessment procedures
Ability to prioritize tasks
Understanding of company structure
Track purchasing activities
Liaise with trucking companies, other plants and operations
Supervision of other employees
Liaise with safety department
Adherence to owners purchasing requirements
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Application of Cost Control measures in the work facility
Personal and work area time management (Planning andScheduling) techniques
Manual and electronic filing
Identify and report all incidents and near misses, hazardidentification
Knowledge of Safe Operating Practices
Recognize and report regulation violation or reportable incident
Read and interpret a Legal Subdivision (LSD) map and a surveymapping system
iv) Community Relations
Effective public community relations
4.14 CSA B51 (ASME B31.3)
The inspector should have a general understanding of the CSA B51 Boiler,Pressure Vessel and Pressure Piping Code and the ASME Code B31.3 for ProcessPiping. Of particular importance is how the inspection and testing requirementsfrom each code are applied to pipelines. The inspector should have generalknowledge of:
CSA Z662 provisions for the application of the B51 and B31.3Codes
General content and scope of the CSA B51 and ASME B31.3Codes
General understanding of typical jurisdictional relationships,involvement with process piping and documentation requirements
Definitions of B31.3 fluid services and how this relates to thematerials and basic design requirements and materials selection
Basic design and materials overview should include overview ofstress tables, requirements for typical materials used
Materials identification
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Detailed understanding of fabrication, assembly and erectionrequirements
Detailed understanding of inspection, examination and testingrequirements
4.15 Facilities Additional Requirements
The pipeline installation inspector should be generally aware of the differentrequirements for pipeline associated surface facilities. This will allow theinspector to determine whether additional inspection resources are required toensure compliance (refer to CSA Z662 Clause 1). The inspector shouldunderstand the types of facilities: well site type facilities compressors stations,dehydration, separator packages, meter skids - and the need to definejurisdictional and code boundaries/specification break.
Knowledge should include:
Pressure Equipment Safety Legislation overview:i. CSA B51
ii. Provincial legislation and regulations for Boilers and PressureVessels
iii. ASME Boiler, Pressure Vessel and Piping Codes
Authorized Inspector (a person appointed by the Provincial Regulator toadminister the provincial legislation and regulations)
Quality Control Program Requirements
Management of Change
Pressure Vessel Installation Inspections
Tank codes and regulations
Pressure Safety Devices
Pre-commissioning and Commissioning
Jurisdictional documentation requirements