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Testing and Commissioning Plan Template

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PROJECT NAME & LOGOS

COMMISSIONING MANAGEMENT
PLAN

Document No: 00001


PROJECT NAME & LOGOS

REVISION DRAFT 01 02 03 04
DATE
PREPARED
BY:
CHECKED
BY:
APPROVE
D BY:

Summary of Revisions/ Changes:

Revision 01:
Commissioning Management Plan

TABLE OF CONTENTS

1.0 INTRODUCTION 4
1.1 PURPOSE 4
1.2 REFERENCES, DEFINITIONS & ABBREVIATIONS 4

2.0 SCOPE & LIST OF SYSTEMS COVERED IN THIS DOCUMENT 8


2.1 GENERAL 8
2.2 MECHANICAL SYSTEMS 8
2.3 ELECTRICAL SYSTEMS 8
2.4 EXTRA LOW VOLTAGE SYSTEMS 9
2.5 MISCELLANEOUS SYSTEMS/TEST 9

3.0 COMMISSIONING RESPONSIBILITIES & OBLIGATIONS 10


3.1 COMMISSIONING TEAM 10
3.2 RESPONSIBILITIES 11

4.0 PROGRAMME & PROGRESS REPORTING 14


4.1 COMMISSIONING PROGRAMME 14
4.2 PROGRESS REPORTING 15

5.0 OVERVIEW OF COMMISSIONING STRATEGY 16


5.1 TESTING STRATEGY 16
5.2 STAGES OF THE PROJECT 16

6.0 SYSTEM DESCRIPTIONS, TESTING & COMMISSIONING PROCEDURES /


STRATEGY / INTERFACES 27
6.1 MECHANICAL SYSTEM 27
6.2 ELECTRICAL SYSTEMS 42
6.3 EXTRA LOW VOLTAGE SYSTEMS 51
6.4 MISCELLANEOUS SYSTEMS 55

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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Commissioning Management Plan

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 REFERENCES, DEFINITIONS & ABBREVIATIONS

1.2.1 REFERENCES
The following other Contract Documents may contain requirements that relate
to this section of contract document submittals:

 Section for Data Requirements for Data & Document Submittals


 Section for General Submittal Requirements
 Section for Quality Requirements
 Section for System Start-Up & Testing
 Section for Record Documents (As Built)
 Section for General Operation and Maintenance Data
 Section for Demonstrations & Training
 Section for Start Up Procedures
 Section for Testing, Adjusting & Balancing
 Material & Equipment Specifications – Divisions
 Manufacturers Data
 Conditions of Contract
 Installation Specifications and Method Statements
 Relevant Codes
 Contract Drawings
 Tender Addendums
 Post Tender Clarifications

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1.2.2 DEFINITIONS

(a) Manufacturing Phase: the period during which the manufacture,


fabrication and assembly of the system, or a distinct element of the
system, is carried out off-Site;

(b) Factory Acceptance Test (FAT): the factory acceptance test(s)


required for materials / system components.

(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.

(d) Commissioning Phase: The process of advancing systems, beyond


the individual system start-ups, to a state of fully integrated,
demonstrated, and documented operational order, according to design
documents, during which the Employer’s operating personnel is
instructed in correct integrated systems operations. Commissioning
includes performance testing to demonstrate that the integrated
equipment and systems meet Contract performance requirements. This
is achieved by beginning in the design phase and documenting design
intent and continuing through construction, acceptance and the warranty
period with actual verification of performance.

The commissioning process shall encompass and coordinate system


documentation, equipment start-up, control system calibration, testing
and balancing, performance testing and training.

Commissioning during the construction phase is intended to achieve


the following specific objectives according to the Contract Documents:

 Verify that applicable equipment and systems are installed


according to the manufacturer’s recommendations and to industry
accepted standards.
 Verify and document proper performance of equipment and
systems;
 Verify that the delivered O&M documentation is thorough and
complete;
 Verify that the Employer’s operating personnel are adequately
trained.
 Identification of deficiency or areas needing remedial actions and
required timing for completion, such as, immediate need to
complete test before further work or future testing, or before
system handover.

(e) Commissioning Plan: an overall plan, developed du ring the


construction Phase t hat provides the structure, schedule and

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coordination planning for the entire testing and commissioning


process.

(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.

(g) Functional Performance Test: test of the dynamic function and


operation of equipment and systems using manual (direct observation)
or monitoring methods; includes Static and Start-up (Energising) tests.
Functional testing is the dynamic testing of systems (rather than just
components) under full operation (e.g., the Chiller pump is tested
interactively with the Chiller functions to see if the pump ramps up
and down to maintain the differential pressure set-point). Systems are
tested under various modes, such as during low cooling or heating
loads, high loads, component failures, unoccupied premises, varying
outside air temperatures, fire alarm, power failure, etc. The systems
are run through all the control system’s sequences of operation and
components are verified to be responding as the sequences state.
Contractor shall develop the functional test procedures in a sequential
written form, coordinates, oversees and documents the actual testing,
which is usually performed by the installing contractor or vendor. FT’s
are performed after pre-functional checklists and start-ups are
complete.

(h) Individual Component Tests: tests on a specific component or piece


of equipment. Examples are miscellaneous factory tests, Emergency
Generators, etc.

(i) Integrated Systems Tests: integrate various “stand-alone” systems


into a coordinated set of integrated systems functioning together.
Examples include Fire Alarm System/Smoke Evacuation
System/Elevator & Escalator Controls all functioning in unison.

(j) Manual Tests: using hand-held instruments, immediate control


system readouts or direct observation to verify performance
(contrasted to analysing monitored data taken over time to make the
“observation”).

(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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(l) System Tests: involves testing a complete “stand-alone” system and


all of its components. Examples would be the electrical power
distribution system, water supply system, etc.

(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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2.0 SCOPE & LIST OF SYSTEMS COVERED IN THIS DOCUMENT


2.1 GENERAL
This document relates to the requirements under the contract regarding
Inspection, Testing, Commissioning and Acceptance of the Mechanical,
Electrical, ELV & works as per the Contract Documents referenced and listed in
the reference section of this document.

The systems covered by this document are defined under the following general
scope headings:

 Mechanical Systems (Section 2.2)


 Electrical Systems (Section 2.3)
 Extra Low Voltage (ELV) Systems (Section 2.4)
 Medical Equipment and systems (Section 2.5)
 Miscellaneous systems (section 2.5a)

2.2 MECHANICAL SYSTEMS

 Hydraulic Testing of Pipe Work


 Chilled Water Pumps
 Flushing & Chemical Cleaning of Chilled Water Pipe Work
 Chilled Water Pressurisation Units
 Chilled Water Dosing System
 Duct Work Leakage
 Fire Damper Drop Tests
 Centrifugal Fans & Axial Fans
 Refrigerant Piping
 Split System Air Conditioning Units
 Fan Coil Units
 Computer Room Air Conditioning
 Air Terminals
 Testing & Balancing of VAC Systems
 Water Storage Tanks
 Potable Water Transfer & Booster Pumps
 Chlorination of Potable Water System
 Sewage & Sump Pumps
 Above Ground Drainage
 Below Ground Drainage
 Fire Fighting - Pumps
 Fire Fighting - Fire Suppression Piping System
 Fire Fighting - Clean Agent Extinguishing System (FM200)
 Fire Fighting - Hydrant System

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2.3 ELECTRICAL SYSTEMS

 HV Power Supply Distribution Network


 Transformers
 Power Feeder Cables
 LV Boards (Main Distribution Boards, MCC’s & SMDB’s)
 Capacitor Banks
 Variable Frequency Drives
 Bus Bar
 LV Distribution & Final Circuits
 Emergency Generator Sets
 Auto Transfer Switches
 Earthing
 Lightning Protection
 UPS / Battery System

2.4 EXTRA LOW VOLTAGE SYSTEMS

 Fire Alarm System (FAS)


 Building Management System (BMS)
 Security & Access Control System (SACS)
 Close Circuit Television (CCTV)
 Master Antenna Television System (MATV)
 Master Clock System (MCS)
 Emergency Lighting (EL)
 Central Battery System (CBS)
 Nurse Call System (NCS)
 Audio Visual (AV)
 Public Address System (PAS)
 Audio Visual Intercom and Induction Loop System (AVI, ILS)
 Access Control System (ACS)
 Structured Cabling Network (SCN)
 Lighting Control System (LCS)

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2.5 Equipment and Systems

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3.0 COMMISSIONING RESPONSIBILITIES & OBLIGATIONS


3.1 COMMISSIONING TEAM
The Commissioning Team consists of Specialist commissioning contractors,
????, and those other personnel dedicated (i.e. t he Consultant Engineers),
the contractors and his subcontractors/Vendors, & occasionally members from
other construction packages.

3.1.1 MEMBERS APPOINTED BY CLIENT

Client’s Staff: individuals each having authority to act on behalf of and


represent the Consulting organisations and to execute the authorities so
vested in them as per the terms of the Contract.
Employer’s Project Staff: staffs that by definition have responsibilities in
regard to the testing and commissioning procedures and those who have the
authority to sign off and accept the tested and commissioned Works.

Employer’s Operations and Maintenance Staff: personnel (or those


entities that perform O&M / FM Services on behalf of the Employer), who
will participate in Testing and Commissioning activities, including training.

3.1.1 MEMBERS APPOINTED BY CONTRACTOR

???? have been appointed by MC to as their 3rd party commissioning specialists


to manage all the commissioning & O&M documentation processes as dictated
in this document. ??? have authority to act on behalf of MC to implement the
testing and commissioning process through coordinated actions.

???? commissioning team consist of a ???? (Project Manager), ???


(Senior Electrical Engineer), ???? (Senior Mechanical Engineer) and ???
(Senior ELV Engineer). As commissioning data is collated and more tests
throughout the project are booked to be witnessed by ???, it may be
necessary to call on extra witnessing agents to assist with the documentation
and test verification process.

??? documentation team consists of a Document Manager, ???? , Technical


Authors, lead by ??? in the UK, A Document Assistant, ??? and Integration
Specialists

3.1.3 MEMBERS APPOINTED BY THE SUBCONTRACTOR / TRADE


CONTRACTORS & VENDORS

All Contractors/Subcontractors/Vendors will appoint a Commissioning


Manager/ Specialist to become their single point of contact having authority to
act on behalf of the entity he or she represents. The team will consist of, but
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may not be limited to, representatives of the Trade Subcontractor,


Material/Equipment Vendor, installation subcontractors, other suppliers, and
other specialists as deemed appropriate.

3.1.3 MEMBERS REQUIRED FOR STATUTORY INSPECTIONS

Governmental Agency Staff: Representatives of the various Governmental


Agencies who are required by regulations or contracts to attend such
inspections, such as ???

3.2 RESPONSIBILITIES

3.2.1 EMPLOYER’S RESPONSIBILITIES


 Assign operation and maintenance personnel and schedule them to
participate in the testing and commissioning team activities including, but
not limited to, the following:
 Coordination and Planning meetings.
 Training in operation and maintenance of systems, subsystems, and
equipment.
 Attending Testing and test meetings.
 Demonstration of operation of systems, subsystems, and equipment.

3.2.2 CONSULTANT’S RESPONSIBILITIES


 Review and comment on submittals from Contractor for compliance with
the Contract Documents, and the testing and commissioning plan.
Review and comment on performance expectations of systems,
equipment, interfaces between systems.
 Observe and inspect construction and report progress and deficiencies.
In addition to compliance with the Contract Documents, inspect systems
and equipment installation for adequate accessibility for maintenance
and component replacement or repair.
 Attend all Testing and Commissioning coordination, planning and
progress meetings.
 Participate in selected commissioning activities as required.
 Sign off on all Testing and Commissioning activities as and when required
by its defined responsibilities under the Contract. Each system will have a
front cover sheet and will be signed off by date and whether in attendance
or not.

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3.2.3 PROJECT MANAGERS RESPONSIBILITIES

 Provide utility service connections required for the testing and


commissioning process, including the provision if necessary of temporary
services.
3.2.4 ????? RESPONSIBILITIES

 To confirm testing and commissioning procedures, oversee and document


performance tests, facilitate the testing and commissioning process,
initially review and approve Contractor, Subcontractor and Trade
Contractor/vendors testing and commissioning plans and sign-off on the
performance testing.

 ????’s activities include, but not limited to, the following:


 Organize and lead the testing and commissioning teams.
 Coordinate and update the phased testing and commissioning plan.
 Convene team meetings/workshops for the purpose of coordination,
communication and conflict resolution, discuss and report progress of
the test and commissioning processes. Responsibilities include
arranging for facilities, preparing agenda and attendance lists, and
notifying participants. Preparation and distribution of minutes to team
members and attendees within a time frame agreed at the outset of the
testing and commissioning.
 During the construction phase, conduct an initial coordination meeting
for the purpose of reviewing the test and commissioning activities and
establishing tentative schedules for operation and maintenance
submittals, operation and maintenance training sessions, Test and
Balancing works and Project completion.
 Prepare Project-specific test and inspection checklists for the use
during the t e s t i n g a n d commissioning process.
 Liaise with and supervise Subcontractors/Trade Contractors and
equipment Vendors under the Contractor’s direction to monitor and
update (where necessary) the testing and commissioning procedures.
Include design changes and scheduled test and commissioning
activities coordinated with overall Project planning.
 Identify testing and commissioning team member responsibilities, by
name, firm, and trade specialty, for performance of each testing and
commissioning task.
 Prepare a system by system commissionability appraisal, agree actions
required from the appraisal and follow through to implementation on site.
 Schedule, direct, coordinate, witness, and document testing,
commissioning, inspections, and other related activities.
 Compile test and commissioning data, inspection reports, and
certificates and include them in the systems manual, commissioning
report and the O&M Manuals.
 Certify date of test acceptance and commissioning for each item of
equipment for start of warranty periods.
 Review Project Record Documents for accuracy. Project Record
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Documents requirements are specified in the Contract Documents


 Prepare operation and maintenance template.
 Review operation and maintenance manuals.
 Prepare and conduct operation and maintenance training, including
the formulation of a training programme, all in accordance with the
Contract requirements.
 Prepare regular testing and commissioning reports, for each phase
and segment/sectional activities.
 Assemble the final test and commissioning documentation, including
the test and commissioning report to be included in the final handover
documents.
 Certify that testing and commissioning work is complete and
systems are tested, commissioned and operational in accordance
with the Contract Documents, including calibration of instrumentation
and controls.
 Evaluate performance deficiencies ( i f a n y ) identified in test and
commissioning reports and, in collaboration with the entity
responsible for system and/or equipment supply and/or installation,
recommend and ensure performance of corrective action.
 Participate in final review at acceptance meeting and review and
approve final test and commissioning documentation.

3.2.4 MAIN CONTRACTOR / SUBCONTRACTORS / TRADE


CONTRACTORS & VENDORS RESPONSIBILITIES
(Under the supervision and direction of the Project Managers):

 As directed by the ??? , assign representatives with expertise and authority


to act on behalf of subcontractors and schedule them to participate in and
perform testing and commissioning team activities including, but not limited
to, the following:

 Participate in maintenance orientation and inspections


 Participate in procedures meetings for testing and commissioning.
 Conduct test and commissioning activities for all systems, equipment
as directed by SPM and in accordance with both the subcontractor’s
and the Main Contractor’s test and commissioning procedures and
programme.
 Participate in final review and acceptance meetings.
 Give input to planning for operation and maintenance data submittals,
equipment start-up, and testing to Contractor for incorporation into the
O&M plan and documentation.
 Participate in training sessions for Developer's operation and
maintenance personnel.
 Provide updated Project Record Documents to the Main Contractor.
 Submit operation and maintenance manuals for all systems,
subsystems, and equipment to Main Contractor, as specified in the
Contract Documents

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 Provide technicians who are familiar with the construction and


operation of installed systems. Develop specific test procedures and
participate in testing of installed systems, subsystems, and
equipment.

4.0 PROGRAMME & PROGRESS REPORTING


4.1 COMMISSIONING PROGRAMME
An overall Commissioning Programme will be produced, monitored and
updated by ??? . Incorporating comments and advice from SPM, the
Consultant, the Main Contractor and the Sub Contractor.

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:

 Design/production information release dates and approval for all the


mechanical, public health, electrical, fire alarm, security, BMS and lifts,
etc. engineering systems as defined in related specifications.
 Submission and approval of the detailed project specific commissioning
procedures and method statements and ‘data packs’ for all the
mechanical, public health, electrical, fire alarm, security, BMS and lifts,
etc. engineering systems as defined in related specifications.
 Factory Acceptance (FAP) testing dates
 Building fabric completion dates that are critical for the commencement
of the pre-commissioning and commissioning.
 Dates for inspection of the completed installation of all the mechanical,
public health, electrical, fire alarm, security, BMS and lifts, etc.
engineering systems as defined in related specifications.
 Pre-commissioning dates for all the mechanical, public health, electrical,
fire alarm, security, BMS and lifts, etc. engineering systems as defined in
related specifications.
 Electrical power on dates to include:
- Primary HV Substation
- HV Ring Mains distribution
- Main LV switch rooms and distribution
- Motor Control Centres (MCC’s) to mechanical plant
- Individual plant items
- Planned temporary power supply requirements
- Lifts
- Power supplies to Fire Alarm equipment
- Power supplies to BMS equipment
- Power supplies to security equipment
- Lighting and Lighting control systems
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Commissioning Management Plan

- 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

The Consultant shall formally approve the Draft Skeleton Commissioning


Programme for content and logic.

Stage 3

Utilising the approved Skeleton Commissioning Programme ???? will then


produce a complete Commissioning Programme. In conjunction with the
Contractor, Sub Contractors, Trade Contractors, Vendors and the Clients
Representative ???? will assign a duration and manpower to each task
therefore creating a workable programme. The programme at this stage will
have filters added so specific sub sections/services can be drawn out to enable
the Contractor, Sub Contractors, Trade Contractors and Vendors to assign the
manpower required for a specific task or service.

Stage 4

The Consultant shall formally approve the Commissioning Programme.

Stage 5

Owing to the late appointment of ???? as the commissioning authority and a


lack of existing commissioning programs.. It has been decided to use ????’s
commissioning activity Sheet (CAS Sheet) in Conjunction with a 2 week look
ahead plan to book in contractors as a fail safe way of achieving dates.

(See Appendix 7.4 for a copy of the latest Commissioning activity sheet
and 2 week look ahead sample document.)

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4.2 PROGRESS REPORTING


???? will report to the project team the accurate status of progress of all works
on the Commissioning Programme. By routinely updating the actual progress
against the baseline dates and reviewing variances ???? will report to the
Commissioning Team on any points of concern or delays and if possible
suggest acceleration solutions.

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5.0 OVERVIEW OF COMMISSIONING STRATEGY


5.1 TESTING STRATEGY
The fundamental testing strategy is that during the manufacturing, construction
and commissioning phases of the works, system requirements as detailed in
the technical specifications are verified by inspection, test(s) or submission(s)
which provide test analysis or product data to prove that a specification
requirement(s) have been met. During the acceptance phase of the works a
subset of this testing is again repeated in the presence of the Employer during
the Final Acceptance Tests prior to the taking over of the works.

5.2 STAGES OF THE PROJECT

5.2.1 DESIGN/PLANNING PHASE

5.2.1.1 COMMISSIONABILITY STUDY


To enable a degree of services familiarisation ???? will carry out a review of all
contract documentation such as drawings, specifications, design information,
specialist suppliers/manufacturers design & shop drawings to ensure all
standards are adhered too and that all commissioning requirements are
incorporated.

5.2.1.2 PRODUCTION OF COMMISSIONING PROGRAMME


???? will produce an integrated Commissioning Programme incorporating all
services, project sectors, segments and zone requirements, including device
and sub-system tests. The Programme will be compiled within the constraints of
the published contract & construction programmes. The Programme will show
all key milestones together with all inter relationships and all interface between
systems and external services.

5.2.1.3 PRODUCTION OF METHOD STATEMENT TEMPLATE


???? will produce a method statement template that fully complies with the
project specification & client requirements this will include but not be limited to:

 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)

(See Appendix 7.1 for a copy of the template)

5.2.1.4 PRODUCTION OF O&M TEMPLATE


???? will produce a Operation & Maintenance Manual template that fully
complies with the project specification & client requirements this is to include,
but not be limited to the following:

 Introduction/Health & Safety


 Description of Installation
 Plant & Equipment Schedules
 Operating Procedures
 Planned Maintenance
 Emergency & Fault Finding Procedures
 Safety Procedures
 Manufacturers’ Literature
 Testing & Commissioning Data
 Record Drawings

(See Appendix 7.2 for a copy of the template)

5.2.1.5 MANUFACTURING & PRE-CONSTRUCTION


The pre construction phase includes manufacturing of equipment and/or
material; this shall include submission in respect of material acceptance and
detailed factory test procedures.

These off-site Factory Acceptance Tests (FAT) shall be dictated by the


manufacturer’s standard QA/QC procedures and as defined in their approved
quality manual. Any additional and/or alternative testing as required by the
project specifications shall also be included.

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.

QA certificates from all manufacturers/suppliers shall be provided not only for


the item of equipment/material tested, but also where available, for all individual
components of the equipment.

Any sub-manufacturers/sub-suppliers who have carried out individual


component tests shall also submit test certificates and test records as and
where available.

All test records and/or certificates for all components or items of


equipment/material shall contain the following information:

 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.

During any system installation as a pre-commissioning requirement, individual


device tests shall be performed.

5.2.2 CONSTRUCTION PHASE


During this phase of the Works, installation of the services will be monitored
and reported on by ???? with a particular regard to the commencement of the
testing and commissioning. The monitoring will pay particular attention to the
status of any installation, when individual device tests can commence, and the
conformity of the installation to the specification with regard to ensuring such
installation is completed to ensure testing and commissioning can be carried
out with the least possible problems. (i.e. ease of access to equipment, lines
and levels of conduit, pipe or other linear installations, connectivity to power and
water etc.). This will be implemented through a number of processes these are

5.2.2.1 SERVICES INSTALLATION MONITORING


???? will carry out site inspections to assess installation progress across all
systems and disciplines. Confer with contract Package Managers & Specialist
suppliers at regular intervals to ensure installation conformity to specifications
with regard to commissioning media.
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5.2.2.2 INSTALLATION REPORTING


???? will produce a data base Asset Register document which relates to
installation of the systems with a particular reference to construction /
commissioning programmes and schedules.
These documents will be referred to as Commissioning Activity Schedules
(CAS sheets) and will monitor the installation, pre-commissioning,
commissioning progress and handover of each piece of plant/equipment. ????
will put in place a formal handover document from the installation team to the
commissioning team prior to any pre-commissioning and commissioning
commencing.
CAS sheets will form the basis for monitoring all commissioning works and
contain the exact status of each system. Part of their function is to detail
systems which do not meet the specification requirements and the remedial
actions required to finalise those systems.

5.2.2.3 MONITOR IMPLEMENTATION OF COMMISSIONING


REVIEW (COMMISSIONABILITY STUDY)
???? will follow up on their Commissionability study as described in section
5.2.1.1 to ensure all agreed comments/additional devices etc as requested are
implemented initially onto construction drawings and subsequently installed on
site.

5.2.2.4 SPECIALIST COMMISSIONING METHOD STATEMENT


REVIEW
???? will obtain from the subcontractors, trade contractors and vendors their
dedicated commissioning method statements, as per the template in Appendix
7.1, risk assessments & individual service Inspection Test Plans. ???? will then
carry out the following:

 Review and comment on the documents and assist where necessary in


bringing documents up to the required project standard and to ensure
conformity to contract documents.
 Produce a comprehensive commissioning documentation structure so
that all system records can be easily filed retrieved and re-produced.

5.2.2.5 PRODUCTION OF DEDICATED TEST PACKS


The Subcontractors, Trade Contractors & Vendors shall produce for each
individual system a test sheet pack consisting of the following:

 Front Sheet – detailing system location, system identity code, reference


documents used, status of document
 Pre-commissioning Sheet(s) - detailing all pre-start inspections and
checks
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 Pump/Fan/Motor Sheets – detailing all design & measured test data


 Air/Water Distribution Sheets – detailing all design & measured data
together with relevant valve/damper balanced & locked positions.
 Pressure Profile Sheets – detailing pressure losses/drops across major
components i.e. pumps, coils, fans, filters etc.
 Schematic – single line diagram detailing extent of system, component
parts, test positions, VCD positions, valve positions etc.
 Commissioning Report – brief description of system, methodology used
& any anomalies discovered when commissioning.
 Test Instrument List – detailing instrument type, manufacturer, model,
serial No., range, & calibration date. Note: All actual calibration
certificates to be kept on site in dedicated binder(s) as part of the
commissioning documentation suite together with an up to date log of
actual calibration dates & required calibration dates.
 Review specialist manufacturers test documentation & incorporate into
overall commissioning documentation.

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.

5.2.2.6 OPERATING & MAINTENANCE MANUAL PREPARATION &


REVIEW
During the installation works, the production of the Operating & Maintenance
manuals should commence. Each subcontractor, supplier, specialist
manufacturer etc.., shall produce a complete O&M document utilising the
template in Appendix 7.2 for each of the manuals as noted within Section 1.1
of the template.
???? will review all manuals prior to 1st draft submission in order to get
documents up to the required project standard.
NOTE: MANUALS MUST BE REVIEWED AND SUBMITTED IN DRAFT
FORMAT PRIOR TO ENERGISATION OF A SYSTEM / SERVICE.

5.2.2.7 FACTORY ACCEPTANCE TESTS (FAT)


Factory acceptance tests will be carried out as per the specification
requirements and as per Section 5.2.1.5 with no deviation. ???? will attend
those FAT as required by SPM and report on the following:
 Review specialist suppliers/manufacturers test results carried out during
the FAT to ensure compliance to the specification.

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 Advise of any failures in equipment tested and on the rectification


measures taken to ensure successful FAT.
 Collate all test results & reports into final documentation submissions &
Operating & Maintenance Manuals.

5.2.2.8 COMMISSIONING MEETINGS


???? will arrange and administer meetings to agree and submit all relevant
documentation for testing and commissioning and ensure that each meeting
agenda covers all relevant topics such as:
 Health & Safety
 Documentation Progress - Method Statements, Test Sheet Package
Production, Operating & Maintenance Manuals Production.
 Installation Progress affecting Commissioning.
 Wild Air & other milestones progress.
 Individual services testing and commissioning reports.
 Testing and Commissioning Progress (after commencement).
 Coordination and interface (internal & external) reports.
 Interface from Construction to Commissioning

???? will record and minute all commissioning meetings and circulate these to
all relevant parties.

5.2.3 COMMISSIONING & HANDOVER

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.

The process shall encompass all system documentation, start-up and


continuous (time period) testing, calibrations, testing & balancing, training and
after all results are accepted, inclusion into the final Operation and Maintenance
Manuals.

It is intended that the commissioning process achieves the following:

 Verification that equipment and systems are installed correctly in


accordance with the contract documents, the manufacturers’
recommendations and good industry practice.
 Verification of correct performance of all equipment and systems
 Verify that the Operational & Maintenance documentation is complete,
adequate, and understandable and has been produced and delivered in
accordance with the contract.
 Identification of any faults / failures and the requirement of remedial
actions as to whether these are to be carried out prior, during or after the
Final Acceptance Tests.
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Upon complete installation of any individual equipment component or complete


system a series of precedent actions need to be undertaken before actual
system commissioning takes place. These are generally divided into the
following categories:

 Equipment & System Inspections


 Individual component/equipment tests
 Sub-System Functional Tests
 Segmental System tests
 Laboratory Tests
 Zone Testing
 Individual Integration/Interface tests
 Full system commissioning
 Final Acceptance Tests

5.2.3.2 INSPECTION, TESTING & COMMISSIONING

(a) Equipment & System Inspections


Prior to any equipment being put into operation the factory authorised service
representative shall carry out a field service report and this will be issued to the
Engineer for witnessing and approval.

These pre-commissioning inspections verify the type of equipment/system


installed the conformity to the contract specifications and the correctness of any
installation.

Generally visual, but with a “working” test to confirm power/service connections


are approved and ready for system/equipment service.

(b) Individual Component / Equipment Tests


Tests on specific components or items of equipment within a system should
verify that these items and/or components meet the specification requirements,
are fit for their intended purpose and operate in a manner as required by the
system design.

Test on power and service connections, reliability of components, operating


levels, (both at static and peak operational levels), integration and interface
connection confirmations and readout/report system confirmation are required
under this section.

(c) Sub-System Functional Tests


Each sub-system shall be tested as a “stand alone” system, verifying that the
sub-system is operational in its own right.

(d) Segmental System Tests


Many systems are subdivided into segmental systems and each segment
should be tested as if it were both a “Stand-alone” system and as part of the
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Commissioning Management Plan

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.

(e) Zone Testing


The project is divided into specific construction zones. This may require part
systems located within these zones to be tested separately so as to clearly
identify if any fault and/or failure is evident within any particular zone. As with
segmental tests this provides for easier identification of any such fault and/or
failure within a system or sub-system.

(f) Individual Integration & Interface Tests


Full integration and interface testing with all systems, services and linked
components. These tests are to ensure all systems work with and between the
interfaces as described in the specifications.

(g) Full System Commissioning


As each system or service is completed and “linked: by the interface/integration
requirement, full system tests should be carried out. In some instances these
will be conducted in an “operational” simulation and in similar conditions.
However, other “operational” tests will be carried out by the Client during the
Initial Proving Period (IPP) after substantial completion and handing over of the
facility.

(h) Final Acceptance Tests


Bringing commissioned systems to a state of full “dynamic” operation, under
working conditions and in simulated “failure” situations. All modes should be
included, such as seasonal environmental conditions (simulated where
possible), occupied and unoccupied building situations, part and full load
conditions, load shedding conditions both essential and emergency situations.

In each of the above instances testing activities will include (but may not be
limited to) the following:

 Calibration – adjusting instrumentation using known parameters and


specified tolerances.
 Visual Checks – inspections and/or manual adjustments to ensure
correct installation
 Coordination – to ensure all relevant parties are integrated into the
commissioning teams and carry out the functions and approvals
designated to them.
 Demonstrations – to show the adequate and satisfactory operability of
any equipment or system, including showing how instructions and
information within the operation & maintenance manuals are adequate,
precise and clear.
 Technical Assistance – by any specialist engineer or manufacturers
representative to ensure that recommended procedures and technical
instructions are followed.
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 Testing – by the application of voltage, pressures, mechanical or natural


forces, or other input, to establish integrity of the installation and
equipment.
 Logic Proving – to ensure that the logic of any control system conforms
to design schematics and diagrams.
 Verification – to ensure that all equipment and systems conforms to its
intended purpose.

5.2.3.3 PROCEDURAL REQUIREMENTS


These are often repeats or continuation of previous actions or procedures and
include:

(a) Commissioning Progress Monitoring / Reporting.


???? will produce regular reports detailing progress of each type of system,
area served, any delays or potential delays, impact of delays & recovery
measures to be implemented to avoid programme slippage.

(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.

(c) Final Commissioning & Testing of the building services


???? will verify the final testing & commissioning of all services to ensure that
works are being carried out as detailed in the individual service/system method
statements.

(d) Specialist System Interfaces


???? will ensure that all interfaces are in place and commissioned by:
 Liaising with BMS specialist contractor in setting of all final control
parameters.
 Liaising with Fire Alarm Specialist contractor in ensuring cause & effect
operations (Specialist sub contract shall produce a full ‘Cause and Effect
Plan’ for review and submission to the Clients Representative).
 Liaising with all other third parties to ensure continuous service of power
and other utilities for these tests.
 Coordinate all external interfaces with other package contractors and
relevant parties.

(e) Final Plant Component Proving


????, in conjunction with Control System and BMS specialist, will prove all
systems control within their design tolerances. This will be part of the BMS
commissioning witnessing and will be proven during the Sequence of Operation
(SOPs) sign off.

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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(f) Specialist Suppliers / Manufacturers Commissioning


???? will co-ordinate specialist suppliers / manufacturers activities ensuring that
a minimum of disruption occurs to other commissioning works. Witness & verify
operation of all specialist suppliers’ equipment as per their previously approved
commissioning method statements & test documentation. Once all testing
works have been verified, the test results will be submitted to the Clients
Representative with a request for inspection.

5.2.3.4 OPERATING & MAINTENANCE MANUAL FINAL COLLATION


During initial inspections and tests the 1st draft will be enhanced to incorporate
all comments made by the Clients Representative. After final installation plus
testing and commissioning is complete, the as built drawings, testing and
commissioning results and certificates will be incorporated into the O&M
manuals for final submission to the Client.

5.2.3.5 LOCAL AUTHORITY LIAISON


???? will arrange conformity with all contract and statutory requirements so the
Main Contractor can liaise wit
 Civil Defence

???? 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.

5.2.3.6 PRODUCTION OF CLIENT TRAINING SCHEDULE


???? will work with the Main Contactor, Sub Contractors, Trade Contractors &
Vendors to produce Client Training Strategy document encompassing the
following activities:
 Comprehensive programme detailing each type of course, duration,
sequence & relationships with other systems
 Description of each course, scope of work to be covered & anticipated
duration.

???? 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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 Review, comment, assist contractors, sub contractors & specialist /


suppliers in finalising training manuals.
 Produce a register identifying all personnel / teachers who will be
undertaking the various training courses.
 Ensure that approved Operation & Maintenance manuals are available
for each element of the training
 Ensure that relevant as built schematic drawings & network diagrams
are available for each element of the training
 Produce forms covering attendance & client satisfaction with training
 Co-ordinate with the employer to ensure minimum disruption to services
provision for “hands on” field training
 Produce a bibliography of reference publications to be utilised for Client
Training.

(See Appendix 7.3 for the Training Manual Template)

5.2.3.7 ISSUE OF FINAL TESTING & COMMISSIONING


DOCUMENTATION
???? will collate all final commissioning documentation & ensure it is
incorporated into the final Operating & Maintenance manuals, which will be
submitted to the Clients Representative in accordance with the contract
documents.

???? will ensure that all test and commissioning results, comments and
tabulations are signed and approved prior to incorporation.

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6.0 SYSTEM DESCRIPTIONS, TESTING & COMMISSIONING


PROCEDURES / STRATEGY / INTERFACES

6.1 MECHANICAL SYSTEM

6.1.1 HYDRAULIC PRESSURE TESTING OF PIPE WORK


6.1.1.1 SYSTEM DESCRIPTION
These tests have been carried out previous to ????’s appointment ???? will
review all previous test sheets and if within acceptable limits file the paperwork
and comment if necessary.

6.1.1.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.1.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


There is no commissioning of Pipe Work systems but there is pressure testing
this will be as per the project specifications (Section to be added) and is usually
1.5 times working pressure. The pressure testing will not commence until the
installation mechanical checklists are signed off. The pipe work pressure
testing will be contained within method statement.

6.1.1.4 ACCEPTANCE STRATEGY


The system acceptance for pressure testing is that pressure is held for a period
specified in the project specification (Section to be added). Pipe work pressure
testing will be offered by the subcontractor and witnessed by the Resident
Engineer; ???? will monitor & collate the documentation.

6.1.1.5 INTERFACES/REQUIREMENTS

 Water Supply (Permanent/Temporary/Tanker)


 Drainage (Permanent/Temporary/Tanker)

6.1.2 CHILLED WATER PUMPS


6.1.2.1 SYSTEM DESCRIPTION
6 Chilled water pumps serving the main hospital, accommodation blocks,
morgue and mosque with chilled water.

6.1.2.2 FACTORY TEST REQUIREMENTS


One of each pump model will have a “detailed functional test”, or as per the
contract specification.

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6.1.2.3 TEST & COMMISSIONING PROCEDURES/ STRATEGY


The initial pre-commissioning, pump alignment and setting to work is to be
carried out by the pump manufacturer/supplier. The pump commissioning will
not commence until the installation mechanical & electrical checklists are signed
off. The pump pre-commissioning, alignment & setting to work will be contained
within method statement.

NOTE: The pump final commissioning will form part of the VAC Testing &
Balancing section.

6.1.2.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the pump alignment and
operation are within acceptable limits, this is to be verified by ???? prior to
being offered for witness by the Resident Engineer.

6.1.2.5 INTERFACES/REQUIREMENTS
 Water Supply (Permanent/Temporary/Tanker)
 Drainage (Permanent/Temporary/Tanker)
 Power (Permanent/Temporary)
 BMS

6.1.3 FLUSHING & CHEMICAL TREATMENT OF CHILLED WATER PIPE


WORK
6.1.3.1 SYSTEM DESCRIPTION
Chilled water serving the main hospital, morgue and Mosque.

6.1.3.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.3.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The flushing of the chilled water will follow guidelines as set out in BSRIA
Application guide 1-2001 and will include:

 Constant water analysis


 A system static flush.
 A fresh water dynamic flush.
 Velocity proving (110% of Design or BSRIA flushing velocity which ever
is greater).
 Chemical Cleaning.
 Chemical dynamic flush.
 Addition of Inhibitor & Biocide.
 Back flushing of equipment & plant.
 Final laboratory report.

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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.

6.1.3.4 ACCEPTANCE STRATEGY


The flushing will be offered for witness by the Resident Engineer through out all
stages of the flushing, with at least 24 hours notice prior to inspection, at no
stage will the process be delayed due to the Engineer not being available. The
parameters for acceptance are that the velocities are obtained, that water
quality is within acceptable limits after both flushes and that Inhibitor and
Biocide levels are correct.

6.1.3.5 INTERFACES/REQUIREMENTS
 Water Supply (Permanent/Temporary/Tanker)
 Drainage (Permanent/Temporary/Tanker)
 Power (Permanent/Temporary)
 Chemicals

6.1.4 CHILLED WATER PRESSURISATION UNITS


6.1.4.1 SYSTEM DESCRIPTION
2 pressurisation units, located in the main plant building providing the CHW
system with a constant system pressure.

6.1.4.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.4.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The initial pre-commissioning and setting to work is to be carried out by the
pressurisation unit manufacturer/supplier. The pressurisation commissioning
will not commence until the installation mechanical & electrical checklists are
signed off. The pressurisation unit pre-commissioning & setting to work will be
contained within method statement.

NOTE: The pressurisation final settings will be dictated by the system design.

6.1.4.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the pressurisation unit
operation is within the correct pressure settings, this is to be verified by ????
prior to being offered for witness by the Resident Engineer.

6.1.4.5 INTERFACES/REQUIREMENTS
 The chilled water system
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 Power (Permanent/Temporary)
 BMS

6.1.5 CHILLED WATER DOSING SYSTEM


6.1.5.1 SYSTEM DESCRIPTION
Dosing system located in the main plant building providing the required
chemicals to the chilled water system.

6.1.5.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.5.3 TEST & COMMISSIONING PROCEDURES/ STRATEGY


The initial commissioning of the chemical dosing system will be carried by the
system manufacturer/supplier. The commissioning of the chemical dosing
system will not commence until the flushing, as described in Section 6.1.3, and
the pressurisation unit commissioning, as described in Section 6.1.4, are
signed off. The chemical dosing system commissioning will be contained within
method statement.

6.1.5.4 ACCEPTANCE STRATEGY


If the correct levels of chemical are set, then the system should maintain the
correct water dosing levels. The dosing system will be set and monitored over
a 4 week period and acceptance will be based on correct levels at the end of
this period.

6.1.5.5 INTERFACES/REQUIREMENTS
 Power (Permanent/Temporary)
 BMS
 Chemicals

6.1.6 DUCTWORK LEAKAGE TESTING


6.1.6.1 SYSTEM DESCRIPTION

6.1.6.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.6.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


There is no commissioning of Duct Work systems but there is leak testing this
will be as per DW 145. The leak testing will not commence until the installation
mechanical checklists are signed off. The duct work leak testing will be
contained within method statement.

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6.1.6.4 ACCEPTANCE STRATEGY


The system acceptance for duct work testing is that the leakage is within the
limits as prescribed by . Duct work leakage testing will be offered by the
subcontractor and witnessed by the Resident Engineer; ???? will monitor &
collate the documentation.

6.1.6.5 INTERFACES/REQUIREMENTS
 A duct work leakage test kit.

6.1.7 FIRE DAMPER DROP TESTS


6.1.7.1 SYSTEM DESCRIPTION
Fusible link fire dampers located throughout the entire project.

6.1.7.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.7.3 TEST & COMMISSIONING PROCEDURES/ STRATEGY


The fire damper drop tests will be a 100% witness check for accessibility,
operation & reset of every unit. The drop testing will not commence until the
installation mechanical checklists are signed off. The fire damper drop testing
will be contained within method statement.

6.1.7.4 ACCEPTANCE STRATEGY


The system acceptance for the fire damper drop testing is that all the dampers
are accessible, close correctly with no leakage and can be reset from the
access provided. The drop testing will be carried out by the subcontractor and
verified by ????.

6.1.7.5 INTERFACES/REQUIREMENTS
 Duct work complete

6.1.8 CENTRIFUGAL FANS & AXIAL FANS


6.1.8.1 SYSTEM DESCRIPTION
21 AHU’s located throughout the building providing supply air to various HVAC
systems, 279 extract fans mainly located in kitchens and bathrooms.

6.1.8.2 FACTORY TEST REQUIREMENTS


One of each unit type will have a “detailed functional test”, or as per the contract
specification.

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6.1.8.3 TEST & COMMISSIONING PROCEDURES/ STRATEGY


The initial pre-commissioning, drive alignment and setting to work is to be
carried out by the unit manufacturer/supplier. The fan commissioning will not
commence until the installation mechanical & electrical checklists are signed off.
The fan pre-commissioning, drive alignment & setting to work will be contained
within method statement reference **.

NOTE: The fan final commissioning will form part of the VAC Testing &
Balancing section.

6.1.8.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the drive alignment and
operation are within acceptable limits, this is to be verified by ???? prior to
being offered for witness by the Resident Engineer.

6.1.8.5 INTERFACES/REQUIREMENTS
 Duct work complete
 Power (Permanent/Temporary)
 BMS

6.1.9 REFRIGERANT PIPING

6.1.9.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.9.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


There is no commissioning of this system but there is pressure testing. The
procedures for the refrigerant pipe work pressure testing will be contained within
the split AC commissioning method statement.

6.1.9.4 ACCEPTANCE STRATEGY


All pipe work will be tested by the installer, a sample will be offered for witness
at the discretion of the Resident Engineer. The tests will be accepted if there
are no leaks from the pipe work & no drop in pressure during the tests.

6.1.9.5 I NTERFACES/REQUIREMENTS
 Split AC

6.1.10 SPLIT SYSTEM AIR CONDITIONING UNITS


6.1.10.1 SYSTEM DESCRIPTION
Split AC systems located throughout the project providing tempered,
conditioned air.
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6.1.10.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.10.3 TEST & COMMISSIONING PROCEDURES/ STRATEGY


The initial pre-commissioning and setting to work is to be carried out by the unit
manufacturer/supplier or subcontractor. The fan commissioning will not
commence until the installation mechanical & electrical checklists and
refrigerant leak detection, as described in section 6.1.9, are signed. The fan
pre-commissioning & setting to work will be contained within method statement.

NOTE: The fan final commissioning will form part of the VAC Testing &
Balancing section.

6.1.10.4 ACCEPTANCE STRATEGY


There will be no acceptance required at this stage.

6.1.10.5 INTERFACES/REQUIREMENTS
 Ductwork
 Power (Permanent/Temporary)

6.1.11 FAN COIL UNITS


6.1.11.1 SYSTEM DESCRIPTION
Fan Coil Units located throughout the project providing a mixture of fresh and
Conditioned air via grille outlets.

6.1.11.2 FACTORY TEST REQUIREMENTS


One of each unit type will have a “detailed functional test”, or as per the contract
specification.

6.1.11.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The testing of these units will form part of the VAC Testing & Balancing method
statement.

6.1.11.4 ACCEPTANCE STRATEGY


The FCU commissioning will be offered for sample test of the FCU’s and
controls operation.

6.1.11.5 INTERFACES/REQUIREMENTS
 Power (Permanent/Temporary)
 Chilled Water
 BMS

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6.1.12 COMPUTER ROOM AIR CONDITIONING

6.1.12.2 FACTORY TEST REQUIREMENTS


One of each unit type will have a “detailed functional test”, or as per the contract
specification.

6.1.12.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The initial pre-commissioning and setting to work is to be carried out by the unit
manufacturer/supplier. The fan commissioning will not commence until the
installation mechanical & electrical checklists are signed. The fan pre-
commissioning & setting to work will be contained within method statement.

NOTE: The fan final commissioning will form part of the VAC Testing &
Balancing section.

6.1.12.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the units perform to their
specified duty, control and alarm points they will be considered acceptable
limits, this is to be verified by ???? prior to being offered for witness by the
Resident Engineer.

6.1.12.5 INTERFACES/ REQUIREMENTS


 Power (Permanent/Temporary)
 Chilled Water
 BMS

6.1.13 AIR TERMINALS


6.1.13.1 SYSTEM DESCRIPTION

6.1.13.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service, unless otherwise stated in the contract
documents.

6.1.13.3 TEST & COMMISSIONING PROCEDURES/ STRATEGY


The commissioning of the terminals will form part of the air system
commissioning, in summary the following checks will take place, with all boxes
set to full flow (any diversity is to be applied by setting the appropriate number
of boxes to Vmin) test each air terminal for volumetric performance at V max & Vmin.
The terminal commissioning will form part of the VAC Testing & Balancing
method statement.

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6.1.13.4 ACCEPTANCE STRATEGY


The units will be deemed acceptable if they perform within the specified design
criteria each system will be verified by ???? prior to being offered for witness by
the Resident Engineer.

6.1.13.5 INTERFACES/ REQUIREMENTS


 Power (Permanent/Temporary)
 AHU’s
 Ductwork
 BMS

6.1.14 TESTING & BALANCING OF VAC SYSTEMS


6.1.14.1 SYSTEM DESCRIPTION
The contract specification tolerance for unit and outlet performance is to be
added here i.e.
AHU’s to achieve between -5% & + 10% of design
Terminals to achieve between -5% & + 10% of design

6.1.14.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.14.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The testing & balancing of the ventilation & air conditioning systems shall follow
the codes as stipulated in the contract documents i.e. CIBSE, BSRIA, ASHRAE
or AABC and shall be carried out by the subcontractors 3 rd party specialist. All
tests are required including the following:

 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.

6.1.14.4 ACCEPTANCE STRATEGY


The units and systems will be deemed acceptable if they perform within the
specified design criteria, each system will be verified by ???? prior to being
offered for partial witness by the Resident Engineer.

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6.1.14.3 INTERFACES/REQUIREMENTS
 Power (Permanent/Temporary)
 AHU’s
 Ductwork
 BMS

6.1.15 WATER STORAGE TANKS

6.1.15.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.15.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The tanks will all be tested for leaks and only offered for witness when they
have passed their own internal Sub Contractor tests, the period of the test will
be as per the contract documents. The water storage tank leak test will be
contained within the method statement.

6.1.15.4 ACCEPTANCE STRATEGY


If the tanks do not leak they will be deemed acceptable.

6.1.15.5 INTERFACES/REQUIREMENTS
 Water Supply (Permanent/Temporary/Tanker)
 Drainage (Permanent/Temporary/Tanker)
 BMS

6.1.16 POTABLE WATER TRANSFER & BOOSTER PUMPS

6.1.16.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service, unless otherwise stated in the contract
documents.

6.1.16.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The initial commissioning, pump alignment (if required) and setting to work is to
be carried out by the pump manufacturer/supplier. The pump commissioning
will not commence until the installation mechanical & electrical checklists are
signed off. The potable water pump commissioning, alignment & setting to work
will be contained within method statement reference **.

6.1.16.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the pump alignment and
operation are within acceptable limits, this is to be verified by ???? prior to
being offered for witness by the Resident Engineer.
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6.1.16.5 INTERFACES/REQUIREMENTS
 Water Supply (Permanent/Temporary/Tanker)
 Drainage (Permanent/Temporary/Tanker)
 Power (Permanent/Temporary)
 BMS

6.1.17 CHLORINATION OF POTABLE WATER SYSTEM

6.1.17.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.17.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The potable water chlorination will follow contract specification and will include:

 Constant water analysis


 A fresh water flush.
 Chlorinating the system to 50PPM or more depending on specification
requirements
 Holding for 24 hours
 Flush of the system to remove chlorine.
 Achieving less than 0.5PPM
 Final laboratory report.

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 **.

6.1.17.4 ACCEPTANCE STRATEGY


The chlorination will be offered for witness by the Resident Engineer through
out all stages of the flushing, with at least 24 hours notice prior to inspection, at
no stage will the process be delayed due to the Engineer not being available.
The parameters for acceptance chemical levels are achieved and that the final
water quality is within acceptable limits.

6.1.17.5 INTERFACES/REQUIREMENTS
 Water Supply (Permanent/Temporary/Tanker)
 Drainage (Permanent/Temporary/Tanker)
 Power (Permanent/Temporary)
 Sanitary ware

6.1.18 SEWAGE & SUMP PUMPS

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6.1.18.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service, unless otherwise stated in the contract
documents.

6.1.18.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The initial setting to work and commissioning is to be carried out by the pump
manufacturer/supplier. The pump commissioning will not commence until the
installation mechanical & electrical checklists are signed off. The sewage/sump
pump setting to work & commissioning work will be contained within the method
statement.

6.1.18.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the pump operation
(including float switches) and volumetric flow are within acceptable limits, this is
to be verified by ???? prior to being offered for witness by the Resident
Engineer.

6.1.18.5 INTERFACES/REQUIREMENTS
 Water Supply (Permanent/Temporary/Tanker)
 Drainage (Permanent/Temporary/Tanker)
 Power (Permanent/Temporary)
 BMS

6.1.19 ABOVE & BELOW GROUND DRAINAGE SYSTEMS

6.1.19.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service.

6.1.19.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


There is no commissioning of drainage systems but there is pneumatic pressure
testing this will be as per the project specifications (Section to be added). The
pressure testing will not commence until the installation mechanical checklists
are signed off. The pipe work pressure testing will be contained within the
method statement.

6.1.19.4 ACCEPTANCE STRATEGY


The system acceptance for pressure testing is that pressure is held for a period
specified in the project specification (Section to be added). The drainage
pressure testing will be offered by the subcontractor and witnessed by the
Resident Engineer; ???? will monitor & collate the documentation.

6.1.19.5 INTERFACES/REQUIREMENTS
 A Pneumatic pressure test kit

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6.1.20 FIRE FIGHTING PUMPS

6.1.20.2 FACTORY TEST REQUIREMENTS


All units will have a “detailed function test”.

6.1.20.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The fire pump commissioning will be performed by the manufacturer/supplier in
accordance with the contract specifications and will include:

 A certain number of manual and automatic starts.


 Flow tests
 Closed head tests
 A full pump test
 Bearing temperatures
 Auto transfer (in both directions)

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.

6.1.20.4 ACCEPTANCE STRATEGY


The full fire pump tests will be verified by ???? prior to being offered for witness
by the Resident Engineer.

6.1.20.5 INTERFACES/REQUIREMENTS
 Water Supply (Permanent/Temporary/Tanker)
 Drainage (Permanent/Temporary/Tanker)
 Power (Permanent/Temporary)

6.1.21 FIRE FIGHTING – FIRE SUPPRESSION PIPING SYSTEM

6.1.21.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service, unless otherwise stated in the contract
documents.

6.1.21.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The fire suppression system commissioning will not commence until the
installation mechanical QC checklist, pipe work pressure tests, as described in
Section 6.1.1, and fire pump tests, as described in Section 6.1.2, are signed
of. The system commissioning will include the following:

 Setting and recording pressures for the system PRV’s


 Proving of all tamper switches
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 Proving of all flow switches


 Hose reel pressure & throw tests

The fire suppression system commissioning will be contained within the method
statement.

6.1.21.4 ACCEPTANCE STRATEGY


The full fire suppression system tests will be verified by ???? prior to being
offered for witness by the Resident Engineer.

6.1.21.5 INTERFACES/REQUIREMENTS
 Water Supply (Permanent/Temporary/Tanker)
 Drainage (Permanent/Temporary/Tanker)
 Fire Pumps
 Power (Permanent/Temporary)
 Fire Alarm System

6.1.22 FIRE FIGHTING – CLEAN AGENT EXTINGUISHING SYSTEM


(FM200)

6.1.22.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service, unless otherwise stated in the contract
documents.

6.1.22.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The system supplier will fully test & commission the system, the commissioning
will include the following:

 Pneumatic pipe pressure tests


 Room integrity tests
 Cable testing (Digital Continuity & Analogue Megger tested)
 Panel programming
 Device testing
 Interface testing

The FM200 system commissioning will be contained within the method


statement.
6.1.22.4 ACCEPTANCE STRATAGY
The full FM200 system tests will be verified by ???? prior to being offered for
witness by the Resident Engineer.

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6.1.22.5 INTERFACES/REQUIREMENTS
 Power (Permanent/Temporary)
 Fire Alarm System

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6.2 ELECTRICAL SYSTEMS

6.2.1 HV POWER SUPPLY DISTRIBUTION NETWORK.

6.2.1.2 FACTORY TEST REQUIREMENTS


Tests carried out at the factory on switch and transformers will include, but not
limited to, the following:

 Bus bar resistance testing.


 Hypot testing.
 Verification of CTs and VTs polarity, winding resistance and ratio tests.
 Protective relay testing primary injection, normal inverse curve, definite
time stages, final settings.
 Transformer insulation and polarisation, ratio, magnetising current and D
vector group.
 BMS interfaces.

6.2.1.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


All the above tests will be carried out again at site save that the hypot tests will
be carried at a reduced value of 80% and protective relay testing will be
carried out using secondary injection. The HV system commissioning will be
contained within the method statement.

6.2.1.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the results are in
accordance with limits set out in BS 4776, 7244, IEC 60439 standards and the
project 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.

6.2.1.5 INTERFACES/REQUIREMENTS
 Test Instrumentation

6.2.2 HV CABLE DISTRIBUTION.


6.2.2.1 SYSTEM DESCRIPTION
Awaiting Full information cables

6.2.2.2 FACTORY TEST REQUIREMENTS


There is no FAT for this service

6.2.2.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


All cables will be insulation tested and hypot tested to the BS 6622 standard
and the site specific specification. The HV Cable testing will be contained within
method statement reference **.

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6.2.2.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the cable hypot results are
in accordance with limits set out in BS 6622, 7888, IEC 60502. The testing will
be offered for witness by the Resident Engineer through out all stages with at
least 24 hours notice prior to inspection.

6.2.2.5 INTERFACES/REQUIREMENTS
 Test Instrumentation

6.2.3 LV BOARDS (MDB’s, MCC’s, SMDB’s and final DB’S).

6.2.3.2 FACTORY TEST REQUIREMENTS


All MDB’s, MCC’s and SMDB’s will be factory tested whilst final DB’s will be
batch tested. The manufacturer will issue documentation prior to the factory test
including the relevant GA and single line drawings to enable the visiting
witnessing personal to have complete knowledge of the board/boards to be
tested. The following tests will be carried out to the relevant BS standards and
site specification but not limited to:

 Insulation tests of the bus bar.


 Pressure test of bus bar.
 Insulation tests of the bus bar.
 Primary injection of all protection relays
 Functional and interlock testing.
 Interface proving for BMS and fire points.

6.2.3.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


All LV panels that are dismantled to be transported to site will require re testing
on completion of installation as follows:
 Torque of all bus bar transit connections.
 Insulation tests of the bus bar.
 Pressure test of bus bar at 80%.
 Insulation tests of the bus bar.
 Secondary injection of all protection relays.
 Milli volt drop test.
 Functional and interlock testing.
 Interface proving for BMS and fire points.

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.

6.2.3.4 ACCEPTANCE STRATEGY

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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)

6.2.4 CAPACITOR BANKS.

6.2.4.2 FACTORY TEST REQUIREMENTS


Tests carried out at the factory on the capacitor banks will include, but not
limited to, the following:

 Calibration of meters
 Load Test
 Proving of Harmonic Filtering

6.2.4.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections will be carried.

 Field inspection and testing shall be carried out after installation is


complete, feeders and terminated.
 Test control wiring and metering
 Meter calibration.
 System earthing.
 Perform functional tests and compile test reports for each capacitor
bank and over current protective device.

The Capacitor Bank commissioning will be contained within the method


statement.

6.2.4.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the Capacitor Bank results
are in accordance with limits set out in BS 1650 & IEC 70. The testing will be
offered for witness by the Resident Engineer through out all stages with at least
24 hours notice prior to inspection.

6.2.4.5 INTERFACES/REQUIREMENTS
 Power (Permanent)
 MDB’s
 Site Load

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6.2.5 VARIABLE FREQUENCY DRIVES.

6.2.5.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

6.2.5.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections will be carried out but not limited to:

 Field inspection and testing shall be carried out after installation is


complete, feeders and terminated.
 Test motor wiring.
 Set and record setting and parameters.
 Perform functional tests and compile test reports for each VFD.

The VFD commissioning will be contained within the method statement.

6.2.5.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the VFD’s perform to the
correct set points and unit operation is observed. The VFD unit tests will be
verified by ???? prior to being offered for witness by the Resident Engineer.

6.2.5.5 INTERFACES/REQUIREMENTS
 Power (Permanent/Temporary)
 Associated Units
 BMS

6.2.6 BUS BAR.

6.2.6.2 FACTORY TEST REQUIREMENTS


The factory test consists of a unit type test or as required in the contract
documents

6.2.6.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections will be carried:

 Field inspection and testing shall be carried out after installation is


complete, feeders and terminated.
 Torquing of all bus bar connections using a calibrated torque wrench.
 Insulation test.
 Milli volt drop test.

The Bus Bar system commissioning will be contained within the method
statement.

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6.2.6.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the results are in
accordance with limits set out in the 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

6.2.6.5 INTERFACES/REQUIREMENTS
 Test Instrumentation

6.2.7 LV DISTRIBUTION & FINAL CIRCUITS.


6.2.7.1 SYSTEM DESCRIPTION
Low voltage panels located in the LV plantroom providing low voltage power to
the project.

6.2.7.2 FACTORY TEST REQUIREMENTS


 There is no FcAT for this service

6.2.7.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections will be carried two stages. Insulation testing
carried out on all out going circuits on completion of second fix. Live testing
carried out after permanent power has been made available.

 Insulation tests and continuity of all circuits including the final


termination using a calibrated instrument.
 Earth loop impedance tests of all circuits using a calibrated instrument.
 Prospective short circuit current test.
 Residual current device test.
 Phase rotation of three phase panels.
 Polarity tests of all single phase circuits.

The LV Distribution commissioning will be contained within the method


statement.

6.2.7.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the results are in
accordance with limits set out in BS 7671, DEWA and the contract specification.
The LV Distribution tests will be verified by ???? prior to being offered for
witness by the Resident Engineer.

6.2.7.5 INTERFACES/REQUIREMENTS
 Test Instrumentation
 Power (Permanent)

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6.2.8 EMERGENCY GENERATOR SET


6.2.8.1 SYSTEM DESCRIPTION
2 Generators providing emergency power to the project in the event of mains failure.

6.2.8.2 FACTORY TEST REQUIREMENTS


All units will have a “detailed function test” this will include:

 Tests proving the satisfactory performance of all safety controls shall be


carried out. These shall include the overspeed and oil pressure cut outs,
and such other safety devices and automatic alarms as per the
specification.
 Governor trails to be carried out as per BS 5514.
 Preliminary electrical tests shall include but not limited to the following:
insulation resistance.
 Stator, rotor and exciter windings to earth, stator – between windings.
 Prove efficiency of radio interference suppression equipment.
 Performance tests as per the specification.
 Sound levels.
 Vibration survey.
 Exhaust emission survey.
 Interface with BMS points.

6.2.8.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections will be carried out but not limited to:

 Electrical tests in line with BS 7671.


 Mechanical inspection of the installation.
 Shaft alignment verification where required.
 Site load test to the specification.
 Phase rotation test.
 Safety device tests.
 Remote monitoring tests.
 Auxiliary contact tests.
 Functional test on simulated loss of mains power.
 Sound & Vibration Levels

The Generator commissioning will be contained within the method statement.

6.2.8.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the generator results are in
accordance with limits set out in BS 5514, 2613 & 7671 and the 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.

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6.2.8.5 INTERFACES/REQUIREMENTS
 Test Instrumentation
 Load Banks
 Power (Temporary/Permanent)
 Final Site Loads
 BMS
 FAS

6.2.9 AUTOMATIC TRANSFER SWITCH

6.2.9.2 FACTORY TEST REQUIREMENTS


All units will have a “detailed function test” this will include:

 Each switch will be factory tested in accordance with circuit breaker


standards BS EN 60898, BS EN 60947-2, BS 5419, BS 5486 and BS
4293. In addition the manufacturer will perform the following tests.
 Insulation tests to ensure the integrity of insulation and continuity of the
entire system.
 Visual inspection to ensure that the switch matches the specification
requirements and to verify that the quality standards have been met.
 Mechanical tests to confirm compatibility of switch logic and power
sections and to verify that there is no mechanical hindrance. Switches
shall be cycled through a minimum of 50 operations by alternately
removing normal and emergency power sources.
 Electrical tests to verify the complete electrical operation of the switch
and to set up time delay and voltage setting of the logic.
 Interface with BMS points.

6.2.9.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections will be carried out but not limited to:

 Electrical tests in line with BS 7671.


 Mechanical inspection of the installation.
 Mechanical tests of the switch to ensure free mechanical movement.
 Functional test on simulated loss of mains power.
 Electrical tests to verify the complete electrical operation of the switch
and to set up time delay and voltage setting of the logic.

The ATS commissioning will be contained within the method statement.

6.2.9.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the ATS’ operate as
required and within the limits as prescribed in the relevant BS standards and

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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 EARTHING SYSTEM


6.2.10.1 SYSTEM DESCRIPTION

6.2.10.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

6.2.10.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections will be carried two stages. Earth pits and
equipotenial bonding:

 Earth pit electro tests.


 Insulation and continuity tests of equipment bonding.

The earthing system commissioning will be contained within the method


statement.

6.2.10.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the IR & continuity results
are in accordance with limits set out in BS 6622, 7888, IEC 60502. The full
Earthing tests will be verified by ???? prior to being offered for witness by the
Resident Engineer.

6.2.10.5 INTERFACES/REQUIREMENTS
 Test Instrumentation

6.2.11 LIGHTNING PROTECTION SYSTEM.


6.2.11.1 SYSTEM DESCRIPTION
Lightening protection system serving the entire project to protect all mechanical,
electrical and architectural assets in the event of a lightening strike.

6.2.11.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

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6.2.11.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections will be carried two stages. Earth pits and
equipotenial bonding:

 Earth pit electro tests.


 Insulation and continuity tests of equipment bonding.

The lightning protection system commissioning will be contained within method


statement reference

6.2.11.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the IR & continuity results
are in accordance with limits set out in BS 6622, 7888, IEC 60502. The full
Earthing tests will be verified by ???? prior to being offered for witness by the
Resident Engineer.

6.2.11.5 INTERFACES/REQUIREMENTS
 Test Instrumentation

6.2.12 UPS/BATTERY SYSTEMS.


6.2.12.1 SYSTEM DESCRIPTION
UPS battery system providing emergency power to all systems in the event of
mains power failure before generator power is enabled.

6.2.12.2 FACTORY TEST REQUIREMENTS


All units will have a “detailed function test” this will include:

 Full load and half load efficiency test.


 Frequency and voltage limits over whole range of load
 Overload Voltage & short circuit protection
 Voltage and frequency regulation during sudden load application
 Overload performance
 Instrument Calibration
 Output tests whilst being supplied by battery only
 Battery discharge
(This would usually only be required on bespoke systems)

6.2.12.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections will be carried out:

 Electrical tests to BS 7671.


 Inspection of the interior of enclosure for integrity of mechanical and
electrical connections, component type and labelling, verification and
ratings of installed component of the central battery inverter system.

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 Test manual and automatic operation with full load.


 Test alarms and shutdowns.
 Test communication system.

The fire suppression system commissioning will be contained within the method
statement.

6.2.12.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: the results are in
accordance with limits set out in the relevant BS standards and contract
specification. The UPS tests will be verified by ???? prior to being offered for
witness by the Resident Engineer.

6.2.12.5 INTERFACES/REQUIREMENTS
 Test Instrumentation
 Site Load/Load bank
 Power (Permanent/Temporary)
 BMS

6.3 EXTRA LOW VOLTAGE SYSTEMS

6.3.1 FIRE ALARM & PAVA SYSTEMS.


6.3.1.1 SYSTEM DESCRIPTION
Fire alarm system serving the entire project, including sounders, public address
system and full integration with the BMS system.
6.3.1.2 FACTORY TEST REQUIREMENTS
 Graphic Demonstration.

6.3.1.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The following site inspections/tests will be carried out:

 Cable testing to BS 7671.


 100% device tests.
 Testing of interfacing.
 Test alarms and shutdowns.
 Test communication system.
 Fire panel battery back up system tests.
 Cause and effect testing.
 Sound level testing of PAVA systems

The fire alarm commissioning will be contained within the method statement.

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6.3.1.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: that all tests listed in
Section 6.3.1.3 are carried out, these to be verified by ???? the Resident
Engineer will be offered to witness any part of the testing at time of test repeat
test will not be carried out except where part(s) of the system fail.

6.3.1.5 INTERFACES/REQUIREMENTS
 Power (Permanent)
 As per Cause & Effect Matrix & site specification

6.3.2 BUILDING MANAGEMENT SYSTEM.


6.3.2.1 SYSTEM DESCRIPTION
BMS system serving the entire project, controlling and monitoring all aspects of the
electrical and mechanical systems contained within the project.

6.3.2.2 FACTORY TEST REQUIREMENTS


 Testing of hardware and software will be carried out in accordance to
the specification.
 Graphic demonstration.

6.3.2.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The site inspections will be carried out at the following defined levels:

 Cable testing to BS 7671.


 Point to point testing.
 Calibration tests.
 Building testing.
 Graphic verification.
 Specifically orient acceptance test procedures to demonstrate the
satisfactory operation of all aspects of operation and interfaces.
 Real time performance testing logged ensuring correct control.
 Perform a complete and detailed calibration and operational test for
each individual BMS point and control function contained within the
supplied system. Ensure that all equipment, software, network elements,
modules and circuits provided are functioning to meet the specification
and record on log sheets.

The BMS suppression system commissioning will be contained within the


method statement.

6.3.2.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: that all tests listed in
Section 6.3.2.3 are carried out, these to be verified by ???? the Resident
Engineer will be offered to witness any part of the testing at time of test.

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6.3.2.5 INTERFACES/REQUIREMENTS
 Power (Permanent)
 As per I/O Schedule & site specification

6.3.3 BUILDING SECURITY & ACCESS CONTROL SYSTEM.


6.3.3.1 SYSTEM DESCRIPTION
Building security and access control system serving the entire project and
monitored via the BMS system.

6.3.3.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

6.3.3.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The site inspections will be carried out at the following defined levels:

 Cable testing to BS 767


 Individual Component/Equipment tests
 Sub System Functional test
 Hard ware testing.
 Soft ware testing.
 System testing.
 Building testing.

The SACS commissioning will be contained within the method statement.

6.3.3.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: that all tests listed in
Section 6.3.3.3 are carried out, these to be verified by ???? the Resident
Engineer will be offered to witness any part of the testing at time of test.

6.3.3.5 INTERFACES/REQUIREMENTS
 Power (Permanent)
 As per I/O Schedule and site specification

6.3.4 CLOSED CIRCUIT TELEVISION SYSTEM.


6.3.4.1 SYSTEM DESCRIPTION
CCTV system monitoring the entire site via 57 camera’s

6.3.4.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

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6.3.4.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The site inspections will be carried out at the following defined levels:

 Cable testing to BS 7671.


 Point to point testing.
 Hard ware testing.
 Soft ware testing.
 System testing.
 Building testing.
 VCR testing.

The CCTV system commissioning will be contained within the method


statement.

6.3.4.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: tests listed in Section
6.3.4.3 are carried out; these to be verified by ???? the Resident Engineer will
be offered to witness any part of the testing at time of test repeat test will not be
carried out except where part(s) of the system fail

6.3.4.5 INTERFACES/REQUIREMENTS
 Power (Permanent)
 Cameras
 SACS

6.3.5 CO2. MONITORING & CAR PARK VENTILATION.


6.3.5.1 SYSTEM DESCRIPTION
Not applicable

6.3.5.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

6.3.5.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The site inspections will be carried out at the following defined levels:

 Cable testing to BS 7671.


 Calibration of detectors.
 Function tests of system.
 Function test of system during fire condition.

The CO2 Monitoring & Car Park Ventilation Control system commissioning will
be contained within the method statement..

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6.3.5.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: tests listed in Section
6.3.5.3 are carried out, these to be verified by ???? the Resident Engineer will
be offered to witness any part of the testing at time of test.

6.3.5.5 INTERFACES/REQUIREMENTS
 Power (Permanent/Temporary)
 Fans
 BMS
 FAS

6.4 MISCELLANEOUS SYSTEMS

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.

6.4.1.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service, unless otherwise stated in the contract
documents.

6.4.1.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The site inspections will be carried out at the following defined levels:

 Cable testing to BS 7671.


 The Units will be tested to BS 5655
 Third Party Certification to be carried out.
 Interface of equipment with building load shedding.
 Interface of equipment with building fire system.
 Function test of system during fire condition.

The fire suppression system commissioning will be contained within the method
statement.

6.4.1.4 ACCEPTANCE STRATEGY


The system acceptance will be carried out in accordance with the relevant BS
standards and the contract specification. Testing will be carried out by third
party and offered by the specialist for witnessed by the Resident Engineer; ????
will review and test interfaces.

6.4.1.5 INTERFACES/REQUIREMENTS
 As per site specification schedule.
 Fire alarm
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 Load shedding.

6.4.3 GARBAGE SYSTEM.


6.4.3.1 SYSTEM DESCRIPTION

6.4.3.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

6.4.3.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


The site inspections will be carried out at the following defined levels:

 Cable testing to BS 7671.


 Panel testing as LV panels.
 Door interlocking system.
 Automatic cleaning system.
 Fire deluge system.

The garbage system commissioning will be contained within the method


statement.

6.4.3.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: tests listed in Section
6.4.3.3 are carried out, these to be verified by ???? the Resident Engineer will
be offered to witness any part of the testing at time of test.

6.4.3.5 INTERFACES/REQUIREMENTS
 Power (Permanent/Temporary)
 Water
 Fire Fighting

6.4.4 PERMIT TO WORK.


6.4.4.1 SYSTEM DESCRIPTION
This is to be implemented on the project for safety.

6.4.4.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

6.4.4.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


???? can on request issue a tried and tested permit to work strategy for all
parties to work with.

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6.4.4.4 ACCEPTANCE STRATEGY


The system acceptance will be carried out in accordance with the relevant BS
and BSRIA standards and the project specification. Issued by the subcontractor
and requests signed by the designated party.

6.4.4.5 INTERFACES/REQUIREMENTS
 All mechanical and electrical systems related to the equipment requiring
the permit.

6.4.5 INTEGRATED SYSTEM TESTING PLAN (DOOMS DAY TESTING).


6.4.5.1 SYSTEM DESCRIPTION
 The main tests, aims and objectives are as follows, mains power failure
tests with system healthy. By definition to prove switchgear/ generator
switching matrix systems, together with the BMS interfacing/monitoring.
 Above to be proven in a fire condition, verifying alarm cause and effect
matrix including all plant, security, BMS etc interfaces particularly with
reference to impact on life safety equipment. Note it is not the intention
to repeat any of the commissioning / certification tests that must be
completed as prerequisites prior to the commencement of these tests.
The principal aim is to asses the overall impact of the system operation
and failure on the fully loaded facility.

6.4.5.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

6.4.5.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


???? will produce the method statement and issue the strategy for all parties to
agree and follow.

6.4.5.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: that all tests as stated in the
method statement all get carried out without any defects.

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 VIBRATION, SOUND & LIGHTING SURVEYS.


6.4.6.1 SYSTEM DESCRIPTION
As dictated by specifications.

6.4.6.2 FACTORY TEST REQUIREMENTS


There is no FcAT for this service

6.4.6.3 TEST & COMMISSIONING PROCEDURES/STRATEGY


These tests will be carried out as per the specification

6.4.6.4 ACCEPTANCE STRATEGY


The following parameters are used for acceptance: that all vibration and sound
level readings are within acceptable limits, that the lighting levels achieve the
correct lux levels. The results will be verified by ???? and offered to the
Resident Engineer for witness.

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

Method Statement Template

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Appendix 7.2

Operation & Maintenance Template

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Appendix 7.3

Training Manual Template

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Appendix 7.4

Commissioning Programme
(Sample)

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Appendix 7.5

Commissioning Activity Schedules


(Samples)

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Appendix 7.6

Commissioning Team Organisation Chart

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Appendix 7.7

Commissioning Team CV’s

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