Commissioning Plan Preparation Guide. Version 2.0 (Replaces Project Test Plans Preparation Guide, Version 1.0, September 2012)

Transcription

1 Commissioning Plan Preparation Guide Version 2.0 (Replaces Project Test Plans Preparation Guide, Version 1.0, September 2012) September 2013

2 Commissioning Plan Preparation Guide Contents 1.0 Introduction Purpose Relationship with Other District Design Standards Commissioning General Description Roles and Responsibilities Commissioning Plan Overview Data Management System and Document Control Testing Commissioning Team Contractor District Design Consultant Pre-Commissioning Pre-Commissioning Tests and Tasks Pre-Commissioning Deliverables Clean Water Commissioning Functional Acceptance Tests Performance Acceptance Tests Startup Reliability Acceptance Tests Performance Acceptance Tests Activation Training General Content Contractor Design Consultant Schedule Commissioning Plan Commissioning Activities Tables Table 2-1. Commissioning Activities Table 2-2. Design Consultant s Tasks and Deliverables Table 2-3. District Construction and Commissioning Tasks Table 3-1. Commissioning Plan Outline Table 3-2. Pre-Commissioning Tests, Tasks, and Responsibilities Table 3-3. Pre-Commissioning Deliverables and Responsibilities Table 3-4. Clean Water Commissioning Tests, Tasks, Deliverables, and Responsibilities Table 3-5. Functional Acceptance Test Plan Outline Table 3-6. Startup Tests, Tasks, Deliverables, and Responsibilities Table 3-7. Reliability Acceptance Test Plan Outline Table 3-8. Activation Tasks, Deliverables, and Responsibilities Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013 i

3 Commissioning Plan Preparation Guide Appendices Appendix A. Examples of Technical Specifications Tests Appendix B. Examples of Functional Acceptance Tests Appendix C. Examples of Reliability Acceptance Tests Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013 ii

4 Commissioning Plan Preparation Guide Abbreviations Acronym Description AR Access Request BIM Building Information Model CAD Computer Aided Draing CCTV Closed Circuit Television CM Construction Management CMMS Computerized Maintenance Management System CPM Critical Path Method DS Design Submittal I/O Input/output FAT Functional Acceptance Test FDT Factory Demonstration Test HMI Human-Machine Interface HVAC Heating, Ventilation, & Air Conditioning MCRT Mean Cell Residence Time MEL Mechanical Equipment List MMI Maintenance Managed Item NETA International Electrical Testing Association NPDES National Pollutant Discharge Elimination System O&M Operations and Maintenance OMTG Operator Manual and Training Guide P&ID Process and Instrumentation Diagrams PA Public Address PAT Performance Acceptance Test PCC Plant Control Center PCCS Plant Computerized Control System PLC Programmable Logic Controller PMO Program Management Office RAT Reliability Acceptance Test RCD Reliability-Centered Design RFI Request for Information RFP Request for Proposals RWQCB Regional Water Quality Control Board SRCSD VFD Variable Frequency Drive Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013 iii

5 Commissioning Plan Preparation Guide 1.0 Introduction 1.1 Purpose This document establishes the requirements for the Design Consultant to prepare a Commissioning Plan for the (District). The Commissioning Plan shall be developed by the Design Consultant in an effort to plan, organize, and document commissioning activities. Inclusion of the Commissioning Plan with the Contract Documents shall provide Contractor awareness of the level of effort the District requires to implement and document equipment and system preparedness. The Commissioning Plan shall be included as an appendix to the Technical Specifications (Specifications), Section Commissioning. Due to the magnitude of the, separate contracts shall be awarded for various portions of the project. During the project lifecycle, coordination between the various Design Consultants and District staff will be critical for ensuring cohesion amongst the various projects Commissioning Plans. 1.2 Relationship with Other District Design Standards This document is one in a suite of District Design Standards (Standards). These Standards are created and maintained to provide consistency and efficiency among design projects within the District. The Standards clearly document requirements, issues, decisions, products, procedures, etc., that have been widely agreed upon by District staff. The documents comprising the Standards include: Design Contract Requirements Presents the content requirements for contract documents prepared for design projects. Design Guidelines Describes discipline-specific District design preferences above and beyond applicable codes and standards. Guide Specifications A library of technical specifications available for project use. CAD and BIM Standards Standards to be used on computer aided draing (CAD) drawings and Building Information Model (BIM) requirements for data and file management. Standard Drawings and Typical Details A library of CAD drawings and typically used details common across all projects available for use by the Designer. Operator Manual and Training Guide Development Describes the level of effort the District requires of the Design Consultant to develop an Operator Manual and Training Guide (OMTG) specific to their respective project. The OMTG shall be used as a teaching and reference tool for the Design Consultant s portion of the training courses. Additional requirements related to execution of the design, project deliverables, and designer coordination with the EchoWater Program Management Office (PMO) and District staff shall 1-1 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

6 Commissioning Plan Preparation Guide be contained in the Request for Proposals (RFP). Particular reference is made to the Reliability- Centered Design (RCD) process to be implemented on projects involving treatment facilities and appurtenant equipment. 1-2 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

7 Commissioning Plan Preparation Guide 2.0 Commissioning 2.1 General Commissioning is the final stage of the project life cycle in which the objective is to validate the performance of the new equipment/systems/processes per the design intent and the required service levels of the District. In addition, District staff classroom and field training are provided by the equipment vendors and the Design Consultant to prepare them to operate and maintain the facilities. 2.2 Description Commissioning shall consist of the following stages: Pre-Commissioning: Includes pre-operational testing of the completed structural, mechanical/hvac, electrical, instrumentation and control systems as defined in the Specifications. Pre-operational testing includes activities such as structural leakage tests, cycling valves, pipe system pressure and leakage tests, instrument calibration, loop testing, control and logic testing, NETA tests, manufacturer installation certifications, etc. The objective of Pre-Commissioning shall be to confirm the equipment s readiness to operate as a system. Clean Water Commissioning: Functional acceptance testing of the hardware and soware to verify all PLC control narratives, PCCS control strategies, and interaction with other new or existing systems. In conjunction with the system testing, loops shall be tuned to obtain the desired process control response and individual equipment performance tests shall be conducted to confirm operational parameters as defined in the Specifications. District staff training from the Contractor and Design Consultant is also provided during this stage. Startup: Reliability acceptance testing of the integrated facility to demonstrate the continuous and reliable operation of the equipment and systems under normal process water conditions. This stage includes shutdowns and tie-ins to the existing plant processes, seeding the biological process (if required), process optimization, additional loop tuning, and individual equipment performance tests requiring process water. Activation: Initiated aer granting the Contractor substantial completion. District O&M staff assumes control of the facility/site and the warranty period begins aer releasing Notice of Field Acceptance to the Contractor. This stage includes completion of the Contractor s punch list items, process optimization, and plant wide optimization. Each stage of commissioning must be completed, witnessed, and documented to the satisfaction of the District before initiating the next stage of commissioning. At the minimum, the commissioning stages and associated tests, tasks, and deliverables are presented in Table Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

8 Commissioning Plan Preparation Guide Table 2-1. Commissioning Activities Construction/Pre-Commissioning Clean Water Commissioning Startup Activation 1. Equipment submittals received and approved 1. Functional Acceptance Tests (FAT) 1. Reliability Acceptance Tests (RAT) 1. Contractor s punch list completed and field accepted 2. Equipment performance guarantees and warranty letters received and 2. Verification of all PLC control 2. Verification of remaining PLC 2. District Notice of Field Acceptance approved narratives and PCCS control strategies control narratives and PCCS control strategies 3. RFIs and responses up-to-date 3. Loop tuning 3. Cont d loop tuning 3. Commencement of warranty period 4. Equipment O&M manuals received and approved 4. Clean water equipment Performance Acceptance Tests 4. Process water equipment PATs 4. Process optimization (PAT) 5. Factory Demonstration Tests (FDT) 5. Certificate of Occupancy received 6. Delivery Acceptance Inspections 6. District staff training 7. Storage and maintenance of equipment 7. Maintenance of equipment 8. Verification of installed assets per design database 9. Structural tank leakage tests per Specifications 10. Mechanical equipment pre-operational tests per Specifications (equipment, valves, HVAC) 11. Piping system pressure and leakage tests and pipe cleaning/flushing per Specifications 12. Instrumentation equipment preoperational tests per Specifications (instrument calibration, loops, PLC and PCCS controls and logic, public address system, CCTV system, fire alarm system, and fiber optic cables) 13. Electrical equipment pre-operational tests per Specifications (NETA, conductors, and motors) 14. Equipment manufacturers installation certifications 15. Contractor s edits to Commissioning Plan received and approved 16. Design Consultant s dra and final Operator Manual and Training Guide (OMTG) received and approved 17. Record CAD drawings and BIM models (includes Master Equipment List [MEL] and Maintenance Managed Items [MMI] design database) received and approved 18. Equipment vendors and Design Consultant s training lesson plans and course schedules received and approved 5. Maintenance of equipment 6. Site clean-up 7. District field inspection 8. Final Contractor s punch list 9. District Notice of Substantial Completion 5. Plant wide optimization 2-2 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

9 Commissioning Plan Preparation Guide 2.3 Roles and Responsibilities Preparation of the Commissioning Plan, followed by the implementation and witnessing of construction/pre-commissioning and commissioning test activities shall be a collaborative effort by representatives from the Design Consultant, Contractor, and District. Table 2-2 provides a list, at the minimum, of the Design Consultant s tasks and deliverables during the design, construction, and commissioning project phases. Design 1. Submit design CAD drawings and BIM models (includes MEL/MMI design database) Table 2-2. Design Consultant s Tasks and Deliverables Construction/Pre-Commissioning Clean Water Commissioning, Startup, & Activation 2. Review equipment performance guarantees and warranty letters 1. Review equipment submittals 1. Engineering support services (i.e. review of test results, oncall and on-site support, and process optimization) 2. Submit Specifications 3. Respond to RFIs 2. Conduct required training 3. Submit Project Design 4. Review equipment O&M manuals courses Manual 4. Submit Commissioning 5. Review FDT results Plan 6. Review Contractor s edits to Commissioning Plan 7. Submit Dra and Final OMTG 8. Prepare and submit training course lesson plans and training materials 9. Review the Contractor s training course lesson plans and training materials 10. Maintain and update record CAD drawings and BIM models throughout construction (via Contractor red-lines, District approved equipment submittals, and District CM documentation) Table 2-3 provides the District s tasks during the construction and commissioning stages and identifies the responsible party from the District. Table 2-3. District Construction and Commissioning Tasks Construction/Pre-Commissioning Clean Water Commissioning, Startup, & Activation Task 1. Review and approve equipment submittals, performance guarantees, and warranty letters. 2. Review and approve equipment O&M manuals. 3. Review and approve RFI s and responses. District Responsibility Task Engineering/PMO 1. Witness, review, and approve Functional Acceptance Tests (FAT). Engineering/O&M/PMO 2. Witness, review, and approve verification of all PLC control narratives and PCCS control strategies. Engineering/PMO 3. Witness, review, and approve loop tuning. District Responsibility O&M/PMO O&M/PMO O&M/PMO 2-3 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

10 Commissioning Plan Preparation Guide Construction/Pre-Commissioning Clean Water Commissioning, Startup, & Activation Task 4. Witness, review, and approve FDT results. 5. Witness Delivery Acceptance Inspections. 6. Confirm Specification requirements for the storage and maintenance of equipment by the Contractor. 7. Verification of installed assets per design database. 8. Witness and approve structural tank leakage tests per Specifications. 9. Witness and approve mechanical equipment pre-operational tests per Specifications. 10. Witness and approve piping systems pressure and leakage tests and piping system cleaning/flushing per Specifications. 11. Witness and approve valve preoperational tests per Specifications. 12. Witness and approve HVAC preoperational tests per Specifications. 13. Witness and approve instrumentation calibration tests per Specifications. 14. Witness and approve analog loop end-to-end testing at PLC and PCCs per Specifications. 15. Witness and approve analog loop end-to-end testing at PCCS. 16. Witness and approve digital control and logic end-to-end testing at PLCs and PCCs per Specifications. 17. Witness and approve digital control and logic end-to-end testing at PCCS. 18. Public address system preoperational tests per Specifications. 19. CCTV system pre-operational tests per Specifications. 20. Fire alarm system pre-operational tests per Specifications. District Responsibility Task Engineering/PMO 4. Witness, review, and approve clean and process water equipment Performance Acceptance Tests (PAT). CM 5. Confirm Certificate of Occupancy from Cosumnes Fire District Fire Marshall. CM 6. Receive Design Consultant and Contractor training. CM 7. Confirm Specification requirements for the maintenance of equipment by the Contractor throughout each stage. CM 8. Witness, review, and approve Reliability Acceptance Tests (RAT). CM 9. Confirm Contractor site cleanup District Responsibility O&M/PMO CM O&M/PMO CM O&M/PMO CM CM 10. Conduct field inspection. CM/O&M/PMO CM CM CM CM 11. Release Notice of Substantial Completion to Contractor. 12. Develop final Contractor s punch list. 13. Field accept Contractor s punch list. 14. Release Notice of Field Acceptance. CM/O&M CM/O&M/PMO CM/O&M/PMO CM/O&M O&M 15. Document commencement of O&M warranty period. CM 16. Process optimization. O&M/PMO O&M 17. Plant wide optimization O&M/PMO CM CM CM 2-4 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

11 Commissioning Plan Preparation Guide Construction/Pre-Commissioning Clean Water Commissioning, Startup, & Activation Task District Responsibility Task District Responsibility 21. Fiber optic cable pre-operational tests per Specifications. CM 22. Witness and approve NETA tests per Specifications. CM 23. Witness and approve conductor tests per Specifications. CM 24. Witness and approve motor preoperational tests per Specifications. CM 25. Witness equipment manufacturers installation certifications. CM 26. Review and approve Contractor s edits to Commissioning Plan. O&M/PMO 27. Review and approve Dra and Final OMTG. O&M/PMO 28. Review and approve training course lesson plans and training materials. O&M/PMO 29. Review and approve record CAD drawings and BIM models (includes MEL/MMI design database) based on Contractor red-lines. Engineering/O&M/PMO 2-5 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

12 Commissioning Plan Preparation Guide 3.0 Commissioning Plan The Commissioning Plan shall include the requirements for planning, scheduling, coordinating, executing, and documenting Pre-Commissioning, Clean Water Commissioning, Startup, and Activation activities. The main objective of the Commissioning Plan is to provide an organized and thorough approach to the validation of the equipment, systems, and processes to be completed by the Contractor. Through the Commissioning Plan, the Design Consultant prepares detailed test plans and procedures for commissioning the equipment and systems, and prepares a preliminary schedule of commissioning test and training activities. Provided in Table 3-1 is an example outline of a Commissioning Plan for the Design Consultant to use as a reference. The table identifies and briefly describes the various sections and nominates the responsible party for preparing the initial content. Aer notice to proceed, the Contractor shall review, edit, or modify the Commissioning Plan to account for items such as changes to the construction schedule, purchased equipment, safety procedures, identification of the commissioning team, etc. The Contractor must ensure the overall objectives set forth in the commissioning plan are met. Edits to the Contractor s commissioning plan shall be reviewed by the Design Consultant and District O&M/PMO. Final acceptance of the Commissioning Plan shall be provided by the District to the Contractor. Table 3-1. Commissioning Plan Outline Heading Section Subsection Description Responsibility 1. Overview a. Introduction A brief introduction to the Commissioning Plan describing the overall intent and objectives. b. Overview of the project A brief description of the facility/project. c. Safety i. Quality control and safety procedures ii. Proper personal protective equipment iii. Lock-out/Tag-out procedures iv. Other District safety requirements Contractor to provide safety related documentation. d. Data management system and document control Prepare the framework of a database to manage and document test activities associated with each asset. 2. Testing a. Commissioning Team Prepare a preliminary organization chart illustrating the relationship between the design consultant, District, construction management (CM) team, and contractor during commissioning. (Note that the District will prepare the PCCS control strategies and facilitate the Contractor s end-toend tests verifying the PCCS end.) Design Consultant Contractor Design Consultant Design Consultant/ District 3-1 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

13 Commissioning Plan Preparation Guide Heading Section Subsection Description Responsibility b. Pre-Commissioning i. Introduction Provide a description of the Pre- Commissioning tests, tasks, deliverables, and responsibilities. c. Clean Water Commissioning ii. Pre-Commissioning Tests Since these tests shall already be developed and included in the Specifications, this section shall provide a description of any specialized tests requiring extensive design development (i.e. complex subsystem PLC factory test that requires simulated outputs, mixer dye testing, large tank leakage test, etc.) Acceptance criteria for a successful test shall also be provided. i. Introduction Provide a description of the Clean Water Commissioning tests, tasks, deliverables, and responsibilities. ii. FATs Provide a description of the FAT, followed by each FAT test plan and procedures. Each FAT test plan shall identify the required resources, prerequisites, and acceptance criteria. iii. PATs Provide a description of the equipment PAT, followed by a list of equipment (with equipment numbers) requiring clean water PATs and then each PAT test plan and procedures. Each PAT test plan shall identify the required resources, acceptance criteria, and test forms. d. Startup i. Introduction Provide a description of the Startup tests, tasks, deliverables, and responsibilities. i. RATs Provide a description of the RAT, followed by each RAT test plan and procedures. Each RAT test plan shall identify the required resources, prerequisites, and acceptance criteria. ii. PATs Provide a description of the equipment PAT, followed by a list of equipment (with equipment numbers) requiring process water PATs and then each PAT test plan and procedures. Each PAT test plan shall identify the required resources, acceptance criteria (i.e. mechanical and process related, if required), and test forms. e. Activation Provide a description of the Activation tasks, deliverables, and responsibilities. Design Consultant 3-2 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

14 Commissioning Plan Preparation Guide Heading Section Subsection Description Responsibility 3. Training a. Contractor training courses For training requirements, refer to the Specifications, Section Training. Provide a description of the training requirements and a table of Contractor (equipment vendor) required training courses with number of sessions and duration of each session as per the requirements of the Specifications. The Contractor shall submit formal lesson plans prior to Clean Water Commissioning. b. Design Consultant training courses Provide a description of the training requirements and a table of number of sessions and duration of each session as per the requirements of the Specifications. The Design Consultant shall submit formal lesson plans prior to Clean Water Commissioning. 4. Schedule a. Introduction i. Up-to-date schedules Provide a description of the Contractor s schedule requirements during commissioning. ii. Three-week lookahead schedules iii. Daily schedules iv. Master schedule of access requests (ARs), shutdowns, and tie-ins b. Initial commissioning baseline schedule Prepare a preliminary schedule of commissioning test and training activities. This schedule shall be consistent with the Design Consultant s construction operations sequencing plan. Design Consultant to identify Contractor and Design Consultant required training sessions. Design Consultant Design Consultant 3.1 Overview The Design Consultant shall provide an introduction to the Commissioning Plan and a description of the facility/project. The Contractor shall include a section detailing safety requirements that must be complied with during commissioning. This shall include, but not be limited to, quality control and safety procedures, proper personal protective equipment, lockout/tag-out procedures, and other District safety requirements Data Management System and Document Control The District s PMO shall be responsible for maintaining a data management and document control system (PMWeb) for commissioning activities. This includes the collection of test plans, procedures, test forms, checklists, worksheets, and test results required for and resulting from commissioning test activities. The objective of this system is to provide an organized and efficient approach for tracking the progression of equipment/system test activities, collecting 3-3 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

15 Commissioning Plan Preparation Guide data, reviewing and approving commissioning test results and deliverables, and ultimately transferring select data to the District s Computerized Maintenance Management System (CMMS). The Design Consultant shall be responsible for preparing the framework of the commissioning testing database within PMWeb. This involves identifying the association with an asset-type (i.e. pump, modulating electric control valve, magnetic flow meter, etc.) and its respective test activities per the requirements of the Specifications. For example, the associated tests for a mixed liquor pump shall include: FDT, delivery inspection acceptance, pre-operational tests, manufacturer s installation certification, and PATs (mechanical, vibration, and noise) for clean and process water operating conditions. This database will serve as the starting point for managing and tracking the flow of data, documents, and testing during commissioning. The preliminary framework of the database shall be included with Design Submittal No. 2 (DS-2). The final framework of the database shall be included with DS-3. Prior to construction, assets (by equipment tag numbers) from the BIM models will be extracted and uploaded to PMWeb (by the PMO) where the assets will be automatically assigned (based on asset-type) to the framework of the database. The intent shall be to develop a process within PMWeb where the selection of an individual asset lists all the associated tests and provides the electronic test forms for the Contractor to document all the test results. 3.2 Testing As part of the Commissioning Plan, the Design Consultant shall develop FAT, PAT, and RAT test plans and procedures. These test plans and procedures detail the coordinated, sequential testing of each system component and piece of controlled equipment installed under the Contract. Test plans and procedures shall identify, by system and specific tag number, each device or control station to be manipulated or observed during the test procedure and the specific results to be observed or obtained. Test plans also shall be specific as to the support systems required to complete the test work, temporary systems required during the test work (including any temporary construction needed for testing), representatives to be present, and expected test duration Commissioning Team The commissioning team shall be made up of representatives from the Contractor, Design Consultant, and the District (CM, O&M, and PMO). The Contractor shall assemble a commissioning team under the direction of a Commissioning Coordinator, duly authorized to commit the Contractor s personnel and resources Contractor The Contractor shall engage a Commissioning Coordinator to be responsible for planning, coordinating, conducting, and documenting commissioning test activities. The Commissioning Coordinator shall use a team consisting of representatives of the Contractor s mechanical, electrical, and instrumentation subcontractors. The Commissioning Coordinator shall have a minimum of ten years of experience in operations and commissioning of facilities, equipment, electrical equipment and plant controls of similar type, size, and capacity, and shall be a 3-4 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

16 Commissioning Plan Preparation Guide Grade V Operator who is experienced in all aspects of commissioning and testing. The Commissioning Coordinator and his/her team shall be available during all commissioning activities at the work site during normal working hours and shall be available within 2 hours notice at all other times upon notice by telephone. During the RATs, a Contractor s representative shall be on site 24 hours per day. Additional requirements for the Contractor and the Commissioning Coordinator shall be located in the Commissioning Specification District Unless directed otherwise, the District shall have the option to witness all commissioning test activities for compliance with the Contract requirements. The District CM team shall witness the majority of the pre-commissioning testing and inspections. The District O&M/PMO team shall witness the majority of the commissioning (Clean Water Commissioning and Startup) testing. During Startup and under the supervision of the Commissioning Coordinator, District O&M staff shall operate the facility, conduct daily rounds, provide sampling and testing, perform maintenance, and note any abnormal observations. Additional District involvement prior to and during commissioning is to prepare the PCCS control strategies and facilitate the Contractor s end-to-end tests verifying the PCCS end, respectively Design Consultant The Design Consultant shall provide engineering support throughout pre-commissioning and commissioning (i.e. reviewing the Contractor s edits to the Commissioning Plan, submitting the Dra and Final OMTG, maintaining and submitting the record CAD drawings and BIM models, reviewing test results, conducting District staff training, process control, process optimization, on-call support, etc.) and shall be available for on-site assistance when requested by the District. The Design Consultant shall also review the proposed Commissioning Coordinator s qualifications and experience for compliance with the Specifications. The Design Consultant, with input from the District, shall prepare a preliminary commissioning organization chart which shall be updated by the Contractor aer notice to proceed. The organization chart shall illustrate the relationship between members of the Design Consultant, District (CM, O&M, or PMO), and Contractor during commissioning. It shall also identify the resources from the Contractor and District (CM, O&M, or PMO) to conduct and witness the testing within the time constraints of the schedule and budget. As noted previously, each test plan (FAT, PAT, and RAT) shall clearly define the personnel required to perform and witness each test and the estimated amount of time to complete the test Pre-Commissioning Pre-Commissioning includes pre-operational testing of the completed structural, mechanical/hvac, electrical, instrumentation and control systems and concludes with the Manufacturer s Installation Certification. The testing verifies that the installed hardware and soware conforms to the requirements of the Specifications and is ready for operation Pre-Commissioning Tests and Tasks The completion of Pre-Commissioning shall be an indication that all equipment in the system has been properly inspected, installed, lubricated, cleaned, checked for foreign materials, 3-5 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

17 Commissioning Plan Preparation Guide anchored, grounded, and, in general, ready for Clean Water Commissioning. At a minimum, listed and described in Table 3-2 are the required Pre-Commissioning tests and tasks with the associated Design Consultant and District responsibilities. Contractor responsibilities and scope of work during construction and commissioning shall be located within the Specifications. The District s previous requirements for Pre-Commissioning tests and associated test forms are referenced from the Specifications and are listed in Appendix A. The Design Consultant shall provide any additional project-specific equipment test requirements and add/modify the test forms to suite. In general, the Pre-Commissioning tests and tasks shall be defined in the Specifications. Table 3-2. Pre-Commissioning Tests, Tasks, and Responsibilities Tests and Tasks Description Responsibility 1. Factory Demonstration Tests Factory tests customized specific to Design Consultant to review test results. the equipment being factory tested and demonstrates compliance with District Engineering/PMO to witness, the Specifications. review, and approve. 2. Delivery Acceptance Inspections Inspections to verify delivered equipment conforms to approved equipment submittals and are suitable for installation. District CM to inspect and document. 3. Equipment storage and maintenance records up-to-date 4. Verification of installed assets per design database Verify equipment storage, maintenance, installation, and servicing logs and records are properly documented and kept up-todate as per manufacturer s instructions. Equipment installation dates to be documented in the BIM model; thus the ability to track installation of all assets. 5. Structural leakage tests Hydrostatic pressure tests for water retaining structures. Mechanical Equipment Tests 6. Mechanical pre-operational tests Pre-operational tests customized specific to the equipment to verify the equipment s readiness to startup for the first time by confirming the installed equipment is in compliance with the Specifications. 7. Piping system pressure and leakage tests 8. Piping system cleaning and flushing Pressure and water leakage tests for isolated portions of piping systems. Piping shall be cleaned followed the pressure and leakage tests. Method of cleaning is dependent on the type of pipe and application as per the Specifications. 9. Valve pre-operational tests Testing of valve operators to ensure proper cycling. 10. HVAC pre-operational tests Verify the HVAC equipment s readiness to startup for the first time by confirming the installed equipment is compliance with the Specifications. District CM to confirm. District CM to confirm. District CM to witness. District CM to witness. District CM to witness. District CM to witness. District CM to witness. District CM to witness. 3-6 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

18 Commissioning Plan Preparation Guide Tests and Tasks Description Responsibility Instrumentation Equipment Tests 11. Instrument calibration tests Prior to field testing, all District CM to witness. instrumentation will be calibrated to accurately read and record operating data. 12. Analog loop end-to-end testing at PLCs and PCCs District CM to witness. 13. Analog loop end-to-end testing at PCCS 14. Digital control and logic end-toend testing at PLCs and PCCs 15. Digital control and logic end-toend testing at PCCS 16. Public address system preoperational tests Every signal circuit connected to the computer input/output (I/O) terminals shall be tested to verify that it is properly wired and functions as specified to send or receive signals from the computer system and its I/O equipment. Verify the proper operation of each discrete control loop to insure the proper operation of hand switches, interlocks, solenoid valves, other auxiliary devices, status lights, and alarms. Demonstrates the operation of the speaker and horn. District O&M to prepare PCCS control strategies and facilitate the Contractor s end-to-end tests verifying the PCCS end. District CM to witness. District O&M to prepare PCCS control strategies and facilitate the Contractor s end-to-end tests verifying the PCCS end. District CM to witness. 17. CCTV system pre-operational tests 18. Fire alarm system preoperational tests 19. Fiber optic cable pre-operational tests Demonstrates the operation of the CCTV system. Inspection and acceptance testing shall include a visual inspection of all fire system components, and a complete functional test to demonstrate the operation of each device following installation. Tests shall demonstrate that the entire fire alarm system functions as intended. All circuits shall be tested: automatic sprinkler (pre-action), elevator recall, equipment shutdown and alarm devices. Each optical fiber shall be tested for end-to-end OTDR trace and attenuation for each installed span aer cable installation. Electrical Equipment Tests 20. International Electrical Testing Newly-installed power systems tests. Association (NETA) tests 21. Conductor tests Continuity and insulation resistance measurements shall be made on conductors. The test specified herein shall be performed prior to energizing. 22. Motor pre-operational tests Verify that all fixtures and devices operate and are correctly polarized, that motors have correct rotation, and that all three-phase receptacles have correct phase sequence and polarity. District CM to witness. District CM to witness. District CM to witness. District CM to witness. District CM to witness. District CM to witness. 3-7 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

19 Commissioning Plan Preparation Guide Tests and Tasks Description Responsibility 23. Manufacturer s Installation Certification Aer completion of equipment preoperational tests, the Contractor shall arrange for the manufacturers representatives to inspect and certify installation and operation. District CM to witness. Factory Demonstration Tests Equipment FDTs are customized specific to the equipment being factory tested and shall be referenced and described in the individual equipment Specifications. If required for particular equipment, the FDTs shall include the required performance for a successful test, method of simulation, and test sheet. Documentation for the completion of a successful FDT must be completed during Pre-Commissioning. FDTs shall also include timing requirements for fixing a failed test, resuming/aborting, and rescheduling the FDT. District Engineering/PMO shall have the option to witness the FDTs and will review and approve the test results. The Design Consultant shall provide a review of the test results and submit any comments to the District PMO representative. Delivery Acceptance Inspections Delivery acceptance inspections shall be performed on items delivered at the site or to any authorized place of storage. District CM shall verify equipment and materials are of the specified quantity, conforming to approved submittals, suitable for installation, and include installation and maintenance recommendations from the manufacturer. Equipment Storage and Maintenance Once new equipment is shipped from the manufacturer, whether immediately installed or stored in the warehouse, it is the Contractor s responsibility to properly store, maintain, and service the equipment until it has been accepted and turned over to the District (commencement of Activation). This shall also include electrical gear and instrumentation, which may have special storage requirements. Prior to installation of the equipment, the Contractor shall provide and use lubricating oil, hydraulic oil, grease and other substances required to clean, blow out, flush, lubricate, and initially charge the equipment for use per the manufacturer s recommendations. Equipment storage, installation, maintenance, and servicing shall be recorded and kept up-to-date by the Contractor and confirmed by the District CM throughout commissioning. Service records shall be attached to the equipment for District CM verification of compliance. Verification of Installed Assets The District CM shall log the equipment installation dates for entry into the BIM models and shall verify that all the equipment has been installed per the design database. The Design Consultant shall maintain and update the CAD drawings and BIM models with the installation dates and any discovered discrepancies. 3-8 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

20 Commissioning Plan Preparation Guide Structural Leakage Tests Concrete tanks, channels, and other structures which have walls or slabs that are exposed or common with areas occupied by equipment or personnel and subjected to hydrostatic pressure shall be tested for water tightness. Testing consists of filling the tank with water to the maximum operating water surface for at least 24 hours and documenting any loss of water or noticeable leaks. District CM shall witness the structural leakage tests. Mechanical Equipment Tests Mechanical Pre-Operational Tests. The mechanical pre-operational tests are customized specific to the equipment to verify the equipment s readiness to startup for the first time. These tests are used for large complex equipment or where factory authorized technicians are required to inspect and perform the first startup. Prior to the manufacturer installation certifications, the equipment items will be inspected by the Contractor to verify that the installations are in compliance with the Specifications and manufacturer s recommendations. The Design Consultant shall prepare equipment preoperational test forms for inclusion in the Specifications (if not currently provided by the District). In some cases, the test forms provided by the manufacturers in their equipment submittals shall be used to document the tests. The manufacturer s representative shall also sign-off on the test forms during their visit for installation certification. District CM shall witness the mechanical equipment pre-operational tests as well as the manufacturer s installation certification. Piping System Tests. Process piping and related fittings, gaskets, and seals shall be hydrostatically tested per the requirements of the Specifications. Pipe test reports shall be filled out and filed for all sections of piping in the system. Aer successful completion of piping system pressure and leakage tests, the piping system shall be cleaned and flushed per the requirements of the Specifications. District CM shall witness the piping system pressure and leakage tests and the cleaning and flushing. Valve Pre-Operational Tests. Per the Specifications, manual valves and control valves shall be tested to demonstrate proper opening, closure, and proper timing using manual controls. District CM shall witness the valve pre-operational testing. HVAC Pre-Operational Tests. The HVAC equipment and control systems shall be tested to conform to the requirements of the Specifications. Aer the successful completion of individual HVAC equipment testing, the complete HVAC system shall be tested, adjusted, and balanced. District CM shall witness the HVAC pre-operational testing. Instrumentation Equipment Tests Instrument Calibration Tests. Prior to field testing, all instrumentation shall be calibrated to accurately read and record operating data. The Contractor shall check instruments for correct operation and perform calibration tests for position, pressure, level, flow, speed, and temperature as per the requirements of the Specifications. The 3-9 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

21 Commissioning Plan Preparation Guide Contractor shall follow a standard calibration procedure, complete standard calibration forms, and place a calibration sticker on the calibrated instruments. Set points for each instrument shall be recorded and tracked in the System Set Point List (located in the FATs and RATs). District CM shall witness instrument calibration testing. Analog loop end-to-end testing at PLCs, PCCs, and PCCS. Each analog loop shall be tested as an integrated system. This test shall be designed to verify that indicators or recorders operate correctly, function modules provide proper signal conditioning, alarms operate correctly, final elements move in the correct direction, and control trips cause proper action in interlocking of control circuits. As part of loop testing, every signal circuit connected to the computer input/output (I/O) terminals shall be tested to verify that it is properly wired and functions as specified to send or receive signals from the computer system and its I/O equipment. District CM shall witness loop testing for the PLCs and PCCs. District O&M shall prepare the PCCS control strategies and facilitate the Contractor s end-to-end tests verifying the PCCS end. Digital control and logic end-to-end testing at PLCs, PCCs, and PCCS. The logic test verifies the proper operation of each discrete control loop to insure the proper operation of hand switches, interlocks, solenoid valves, other auxiliary devices, status lights, and alarms. The controls and logic shall be demonstrated in a step by step fashion that the discrete circuits and logic operate according to the control strategies. Discrete inputs shall be tested to verify proper state when the field device is switched between states. Discrete outputs shall be tested to verify field equipment responds properly (start, stop, etc.). District CM shall witness digital control and logic testing for the PLCs and PCCs. District O&M shall prepare the PCCS control strategies and facilitate the Contractor s digital control and logic tests verifying the PCCS end. Public Address System Pre-Operational Tests. Aer the installation of the public address system components, the Contractor shall demonstrate the operation of each speaker and horn for the District CM. CCTV Pre-Operational Tests. Aer the installation of the CCTV system components, the Contractor shall verify the network components, DC power supplies, operability of the cameras, operability of the existing District digital video recorders, and operability with the existing District operator workstations. District CM shall witness all CCTV testing. Fire Alarm System Pre-Operational Tests. Inspection and acceptance testing shall include a visual inspection of all fire system components, and a complete functional test to demonstrate the operation of each device following installation. Tests shall demonstrate that the entire fire alarm system functions as intended. All circuits shall be tested: automatic sprinkler (pre-action), elevator recall, equipment shutdown and alarm devices. District CM shall witness fire alarm system testing Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013

22 Commissioning Plan Preparation Guide Fiber Optic Cable Pre-Operational Tests. All fibers shall be tested for breaks, abnormalities, and overall attenuation characteristics to ensure that the cable system meets the attenuation specifications. District CM shall witness all testing and final checkout of the fiber optic system to determine fiber optic cable system acceptability. Electrical Equipment Tests NETA Tests. The requirements of the International Electrical Testing Association (NETA) include tests on newly-installed power systems and apparatuses before being energized. These tests verify the equipment and installation comply with the Specifications as well as with regulatory and safety requirements. District CM shall witness all NETA tests. Conductor Tests. Continuity and insulation resistance measurements shall be made on conductors aer wire pulling and prior to connecting equipment. Conductor to conductor and conductor to ground insulation resistance shall be measured for all circuits 120V and above except lighting and receptacle circuits. District CM shall witness all conductor tests. Motor Pre-Operational Tests. Pre-operational testing of all devices and control circuits shall be adjusted and made operative prior to energizing. The testing shall consist of energizing each control circuit and operating each control, alarm or malfunction device and each interlock in turn to verify that the specified action occurs. Contractor shall verify that all fixtures and devices operate and are correctly polarized, that motors have correct rotation, and that all three-phase receptacles have correct phase sequence and polarity. Verification may be accomplished by momentarily energizing the motor, provided that neither the motor nor the driven equipment will be damaged by reverse operation. District CM shall witness all motor tests Manufacturer s Installation Certification Aer the completion of equipment pre-operational tests, the Contractor shall arrange an inspection of the installation by each equipment manufacturer s qualified representative (per the requirements of the Specifications). The manufacturer shall start and run the equipment in the field for the first time to check for proper rotation, alignment, lubrication, abnormal vibration, abnormal temperature, abnormal amperage draw, abnormal operation and provide initial adjustments or calibrations as necessary for continuous operation. If necessary, the manufacturer shall resolve assembly or installation problems attributable to, or associated with their products and equipment. The time spent remedying defective work shall not reduce their contractual site visit obligations intended for making inspections and normal adjustments. The Contractor shall ensure the manufacturer s representative sign the equipment s pre-operational and startup summary test form for each equipment item. The District CM shall witness the inspections by the manufacturers. Since the manufacturer will operate the equipment to certify the installation, addition of clean water to the facilities shall be organized and conducted prior to the manufacturer s inspection. The Commissioning Plan shall include steps taken to fill all tested process systems, except 3-11 Z:\00. Program Management\B Engineering Standards Update\02 Work Products Archive\B Commissioning Plan Preparation Guide\Version 2\Commissioning Plan Preparation Guide_v2.0.docx October 23, 2013