Testing and Commissioning Plan Template
Testing and Commissioning Plan Template
Testing and Commissioning Plan Template
COMMISSIONING MANAGEMENT
PLAN
REVISION DRAFT 01 02 03 04
DATE
PREPARED
BY:
CHECKED
BY:
APPROVE
D BY:
Revision 01:
Commissioning Management Plan
TABLE OF CONTENTS
1.0 INTRODUCTION 4
1.1 PURPOSE 4
1.2 REFERENCES, DEFINITIONS & ABBREVIATIONS 4
7.0 APPENDICES 60
7.1 METHOD STATEMENT TEMPLATE 60
7.2 OPERATION & MAINTENANCE MANUAL TEMPLATE 60
7.3 COMMISSIONING ACTIVITY SCHEDULES (Sample) 60
7.4 COMMISSIONING TEAM ORGANISATION CHART (Sample) 60
7.5 COMMISSIONING TEAM CV’s (Not Included) 60
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1.0 INTRODUCTION
1.1 PURPOSE
This document defines the methodology for the inspection, testing and
commissioning of the Mechanical, Electrical, Extra Low Voltage Systems (ELV)
and medical equipment for the project from testing & commissioning, client
training to acceptance/handover phase for the Works. This procedure reflects
the requirements of the Contract Documents and the obligations of ??????
project team and client, the consultants & the commissioning authority and the
relevant contractors, subcontractors and equipment suppliers as well as a
streamlined approach to allow for complete testing of the systems while
maintaining the necessary requirements associated with the works.
1.2.1 REFERENCES
The following other Contract Documents may contain requirements that relate
to this section of contract document submittals:
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1.2.2 DEFINITIONS
(c) Construction Phase: the period during which the fabrication, assembly
and installation of the system, or a distinct element of the system, is
carried out on-Site.
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(f) Final Acceptance Phase (FAP): the period when the system
functional and performance tests are carried out in the presence of the
Employer to demonstrate the system as a whole complies with the
operational requirements of the Contract.
(k) Static Tests: I nitially, equipment and systems are visually inspected
to verify that all components have in fact been installed and that
installation is in accordance with contractual and technical
requirements. Physical testing of the electrical and mechanical
systems is then performed, with none of the equipment or systems
energized or operating. Test includes verification of circuits,
terminations, power circuits and pipe work pressure tests.
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(m) Device Testing & Inspections: shall be performed on all devices that
have stand alone soft test features. All visual status indication lights
shall be checked for proper operation and inspections shall include all
external visual inspections to ensure that the device has the same
features, colours, dimensions as per the material submittal.
1.2.3 ABBREVIATIONS
CLIENT Client
PM Project Managers
S&L Design Managers
Mcon MEP Consultant
MC Main Contractor
SC Subcontractor
CC Conditions of Contract
ITP Inspection and Test Plan
FcAT Factory Acceptance Test
FAP Final Acceptance Phase
ICD Interface Control Document
CD Civil Defence
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The systems covered by this document are defined under the following general
scope headings:
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3.2 RESPONSIBILITIES
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Stage 1
Utilising information from the Main Contractor Programme & the Clients
Representative (Design Information) ??? shall produce a Draft Skeleton
Commissioning Programme.
The Commissioning Programme will highlight all significant dates, which will
include, but not be limited to, the following information:
- Earthing
- Lightning protection
Water supply available dates
Gas supply available dates
Foul and surface water system available dates
Wild air dates
Commissioning dates for all the mechanical, public health, electrical, fire
alarm, security, BMS and lifts, etc. engineering systems as defined in
related specifications.
Dates for completion of the engineering services provided
Dates and dependencies for systems in beneficial use
Dates and durations for demonstrations of the engineering systems to
the statutory bodies.
Clients representative staff training dates
Client demonstrations
Stage 2
Stage 3
Stage 4
Stage 5
(See Appendix 7.4 for a copy of the latest Commissioning activity sheet
and 2 week look ahead sample document.)
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Introduction (Scope/objective)
Prerequisites to Procedure
Design Parameters
Reference Documents/Drawings
Pre Start Checks/Pre-commissioning
Logic Diagram
Commissioning/Test Procedures
Interfaces
Documentation
Demonstration Procedures
Instrumentation
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Staffing
Safety Aspects & Permit to Work Requirements
Attachments (ITP/Risk Assessments/Test Sheets)
The FcAT shall be defined into one of six (6) categories for each product as
follows:
Commercial (off the shelf) Equipment
Project Specific Equipment
Basic Functional Test (one unit per batch)
Detailed Functional Tests (one unit per batch)
Typical Unit Demonstration
Factory Inspection Only
Each test shall be recorded, witnessed and certified in accordance with both the
manufacturers’ standard quality inspection process and with the project specific
requirements (if any).
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All records and witnessing of test, provision of certificates and the like shall be
in accordance with project requirements.
Equipment/Item Description
Order number and original manufacturer’s name
Date of Test
Component/Item Identification Number
Component/Item Serial Number
Type of Test conducted
Result of Test and Comments thereon
FAT shall be carried out either on each product type/item of equipment, giving a
typical test result and certificate, guaranteeing that other items within the
product type/range of equipment will conform to these results, and/or on each
individual product type/item of equipment whereby each item shall have
individual test results and certifications.
The above details a mechanical system; the electrical systems will follow a
similar format. As part of the commissioning process and for the O&M’s
commissioning test sheets need to be accurately indexed, filed as part of the
Contractor Quality Plan.
As part of the pre-installation activities the indexing and filing system for all test
sheets will be agreed and implemented.
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???? will record and minute all commissioning meetings and circulate these to
all relevant parties.
5.2.3.1 GENERAL
Commissioning includes setting to work, testing & balancing and performance
testing to demonstrate adequacy of the system, and complete verification of the
performance of all the systems and services.
overall system. This provides information on each segment of the system and
provides for easier identification of any faults and/or failures which can then be
rectified without having to investigate the whole system to find any such fault
and/or failure.
In each of the above instances testing activities will include (but may not be
limited to) the following:
(b) Documentation
???? will review all final test documentation, procedural sheets and test sheets
then issue to the relevant parties and arrange for witness for all tests and
commissioning.
Above tests are in addition to those detailed in the standard commissioning test
packs i.e. Fan test sheets, air distribution, pumps etc, where sample test will be
carried out on an area by area basis.
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???? will conduct regular inspections and hold regular meetings with the
Commissioning Team to produce reports & milestone filtered programmes,
detailing all key dates for third party and authority witnessing / verification &
approval.
???? will ensure all test documentation is in place prior to final acceptance &
that all relevant parties have witnessed & signed all documentation.
???? will:
Create a site specific training manual template and issue it to all
contractors, sub contractors & specialist / suppliers.
Liaise with all contractors, sub contractors & specialist / suppliers and
obtain their detailed proposals & requirements for training.
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???? will ensure that all test and commissioning results, comments and
tabulations are signed and approved prior to incorporation.
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6.1.1.5 INTERFACES/REQUIREMENTS
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NOTE: The pump final commissioning will form part of the VAC Testing &
Balancing section.
6.1.2.5 INTERFACES/REQUIREMENTS
Water Supply (Permanent/Temporary/Tanker)
Drainage (Permanent/Temporary/Tanker)
Power (Permanent/Temporary)
BMS
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The flushing will not commence until the pipe work pressure tests, as described
in Section 6.1.1, and the pump commissioning, as described in Section 6.1.2,
are signed off. The flushing & chemical treatment of chilled water pipe work will
be contained within method statement.
6.1.3.5 INTERFACES/REQUIREMENTS
Water Supply (Permanent/Temporary/Tanker)
Drainage (Permanent/Temporary/Tanker)
Power (Permanent/Temporary)
Chemicals
NOTE: The pressurisation final settings will be dictated by the system design.
6.1.4.5 INTERFACES/REQUIREMENTS
The chilled water system
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Power (Permanent/Temporary)
BMS
6.1.5.5 INTERFACES/REQUIREMENTS
Power (Permanent/Temporary)
BMS
Chemicals
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6.1.6.5 INTERFACES/REQUIREMENTS
A duct work leakage test kit.
6.1.7.5 INTERFACES/REQUIREMENTS
Duct work complete
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NOTE: The fan final commissioning will form part of the VAC Testing &
Balancing section.
6.1.8.5 INTERFACES/REQUIREMENTS
Duct work complete
Power (Permanent/Temporary)
BMS
6.1.9.5 I NTERFACES/REQUIREMENTS
Split AC
NOTE: The fan final commissioning will form part of the VAC Testing &
Balancing section.
6.1.10.5 INTERFACES/REQUIREMENTS
Ductwork
Power (Permanent/Temporary)
6.1.11.5 INTERFACES/REQUIREMENTS
Power (Permanent/Temporary)
Chilled Water
BMS
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NOTE: The fan final commissioning will form part of the VAC Testing &
Balancing section.
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Fan tests
Duct traverses
Terminal balance
Fan static profiles
Fan & coil performance tests
Staircase pressurisation tests
Pump tests
Chilled water balancing
Full load temperature/performance checks
The testing & balancing of the VAC system will be contained within method
statement.
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6.1.14.3 INTERFACES/REQUIREMENTS
Power (Permanent/Temporary)
AHU’s
Ductwork
BMS
6.1.15.5 INTERFACES/REQUIREMENTS
Water Supply (Permanent/Temporary/Tanker)
Drainage (Permanent/Temporary/Tanker)
BMS
6.1.16.5 INTERFACES/REQUIREMENTS
Water Supply (Permanent/Temporary/Tanker)
Drainage (Permanent/Temporary/Tanker)
Power (Permanent/Temporary)
BMS
The flushing will not commence until the pipe work pressure tests, as described
in Section 6.1.1, and the potable water pump commissioning, as described in
Section 6.1.2, are signed off. The chlorination of potable water pipe system will
be contained within method statement reference **.
6.1.17.5 INTERFACES/REQUIREMENTS
Water Supply (Permanent/Temporary/Tanker)
Drainage (Permanent/Temporary/Tanker)
Power (Permanent/Temporary)
Sanitary ware
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6.1.18.5 INTERFACES/REQUIREMENTS
Water Supply (Permanent/Temporary/Tanker)
Drainage (Permanent/Temporary/Tanker)
Power (Permanent/Temporary)
BMS
6.1.19.5 INTERFACES/REQUIREMENTS
A Pneumatic pressure test kit
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The pump commissioning will not commence until the installation mechanical &
electrical checklists are signed off. The fire pump commissioning will be
contained within the method statement.
6.1.20.5 INTERFACES/REQUIREMENTS
Water Supply (Permanent/Temporary/Tanker)
Drainage (Permanent/Temporary/Tanker)
Power (Permanent/Temporary)
The fire suppression system commissioning will be contained within the method
statement.
6.1.21.5 INTERFACES/REQUIREMENTS
Water Supply (Permanent/Temporary/Tanker)
Drainage (Permanent/Temporary/Tanker)
Fire Pumps
Power (Permanent/Temporary)
Fire Alarm System
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6.1.22.5 INTERFACES/REQUIREMENTS
Power (Permanent/Temporary)
Fire Alarm System
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6.2.1.5 INTERFACES/REQUIREMENTS
Test Instrumentation
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6.2.2.5 INTERFACES/REQUIREMENTS
Test Instrumentation
Panels that have been factory tested and that do not require to be dismantled,
only require insulation tests. The LV Panel Testing will be contained within the
method statement.
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The following parameters are used for acceptance: the LV Panel results are in
accordance with limits set out in BS 5486, 6231 & 7430. The testing will be
offered for witness by the Resident Engineer throughout all stages with at least
24 hours notice prior to inspection.
6.2.3.5 INTERFACES/REQUIREMENTS
Test Instrumentation
Power (Permanent)
Calibration of meters
Load Test
Proving of Harmonic Filtering
6.2.4.5 INTERFACES/REQUIREMENTS
Power (Permanent)
MDB’s
Site Load
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6.2.5.5 INTERFACES/REQUIREMENTS
Power (Permanent/Temporary)
Associated Units
BMS
The Bus Bar system commissioning will be contained within the method
statement.
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6.2.6.5 INTERFACES/REQUIREMENTS
Test Instrumentation
6.2.7.5 INTERFACES/REQUIREMENTS
Test Instrumentation
Power (Permanent)
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6.2.8.5 INTERFACES/REQUIREMENTS
Test Instrumentation
Load Banks
Power (Temporary/Permanent)
Final Site Loads
BMS
FAS
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contract specification. The testing will be offered for witness by the Resident
Engineer through out all stages with at least 24 hours notice prior to inspection.
6.2.9.5 INTERFACES/REQUIREMENTS
Power (Permanent/Temporary)
Generators
Fire Pump
6.2.10.5 INTERFACES/REQUIREMENTS
Test Instrumentation
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6.2.11.5 INTERFACES/REQUIREMENTS
Test Instrumentation
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The fire suppression system commissioning will be contained within the method
statement.
6.2.12.5 INTERFACES/REQUIREMENTS
Test Instrumentation
Site Load/Load bank
Power (Permanent/Temporary)
BMS
The fire alarm commissioning will be contained within the method statement.
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6.3.1.5 INTERFACES/REQUIREMENTS
Power (Permanent)
As per Cause & Effect Matrix & site specification
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6.3.2.5 INTERFACES/REQUIREMENTS
Power (Permanent)
As per I/O Schedule & site specification
6.3.3.5 INTERFACES/REQUIREMENTS
Power (Permanent)
As per I/O Schedule and site specification
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6.3.4.5 INTERFACES/REQUIREMENTS
Power (Permanent)
Cameras
SACS
The CO2 Monitoring & Car Park Ventilation Control system commissioning will
be contained within the method statement..
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6.3.5.5 INTERFACES/REQUIREMENTS
Power (Permanent/Temporary)
Fans
BMS
FAS
6.4.1 LIFTS.
6.4.1.1 SYSTEM DESCRIPTION
Ten lifts in number serving area’s throughout the project provided, installed and
commissioned by Kone Lifts.
The fire suppression system commissioning will be contained within the method
statement.
6.4.1.5 INTERFACES/REQUIREMENTS
As per site specification schedule.
Fire alarm
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Load shedding.
6.4.3.5 INTERFACES/REQUIREMENTS
Power (Permanent/Temporary)
Water
Fire Fighting
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6.4.4.5 INTERFACES/REQUIREMENTS
All mechanical and electrical systems related to the equipment requiring
the permit.
6.4.5.5 INTERFACES/REQUIREMENTS
Power (Permanent)
Water
FAS
Fire Fighting System
BMS
SACS
All relevant other Plant
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6.4.6.5 INTERFACES/REQUIREMENTS
Power
Lighting
All Plant
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7.0 APPENDICES
7.1 METHOD STATEMENT TEMPLATE
7.2 OPERATION & MAINTENANCE MANUAL TEMPLATE
7.3 TRAINING MANUAL TEMPLATE
7.4 COMMISSIONING PROGRAMME (Sample)
7.5 COMMISSIONING ACTIVITY SCHEDULES (Sample)
7.6 COMMISSIONING TEAM ORGANISATION CHART
7.7 COMMISSIONING TEAM CV’s
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Appendix 7.1
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Appendix 7.2
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Appendix 7.3
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Appendix 7.4
Commissioning Programme
(Sample)
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Appendix 7.5
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Appendix 7.6
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Appendix 7.7
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