Test Commissioning Plan Rev 1 Al Ri

Testing & Commissioning Plan

RTC/082/2013 Document No.:

M009

REI

MEP

PLN

00001

Document Type

PLN - Plan

Reason for Issue

03 - Issued for Approval

T&C Manager

0.2

Revision

Signature

Date

Signature

Date

Signature

Date

Signature

Date

Prepared by: Burak Oral

Engineering Manager Checked by: Tauqeer Ansari

QA/QC Manager Reviewed by: Raul Go

Approved by:

Project Manager Wessam Alahmedy

Revision History Rev. No.

Description of Revision

Date of Revision

0.1

First Issue

9 July 2017

0.2

Second Issue

4 Oct 2017

M009-REI-MEP-PLN-00001 M009-REI-MEP-PLN-00001 Rev 0.2 Testing & Commissioning Plan

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Controlled copy Issue Log: NB: This is only applicable to copies issued outside EDMS

This document has been issued in a controlled manner to the following recipients: (In the event of a revision, the parties listed are to be issued i ssued with the updated version) Copy No.

Company Name

Representative

1 2 3 4 5 6


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Table of Contents

1.

2

3

INTRODUC INTRODUCTION TION ............................... ................................................ .................................. ................................. .................................. .......................... ........ 6

1.1

Purpose Purpose ................................. .................................................. ................................. ................................. .................................. ............................... .............. 6

1.2

Descripti Description on............................... ................................................ .................................. .................................. .................................. ............................ ........... 6

1.3

Objectiv Objectives es ................................. ................................................. ................................. .................................. .................................. ............................ ........... 6

1.4

References, Definitions & Abbreviation ................................................................... 7

1.4.1

Reference References s ................................ ................................................. ................................. ................................. .................................. .................... ... 7

1.4.2

Definitio Definitions ns ............................... ................................................ .................................. ................................. ................................. ....................... ...... 8

1.4.3

Abbreviations Abbreviations ................... ......... ................... ................... ................... .................. ................... ................... ................... ................... ............ ... 12

1.4.4

Regulatory/Utilities Authorities ....................................................................... 13

SCOPE & LIST OF SYSTEMS................... .......... ................... ................... .................. ................... ................... .................. ................... .......... 13 2.1

General General.................................. ................................................... ................................. ................................. .................................. ............................. ............ 13

2.2

Commission ability Assurance .............................................................................. 15

2.3

Commissioning Phase Scope ............................................................................... 16

COMMISSIONING RESPONSIBILITIES & OBLIGATIONS ......................................... 17 3.1

SPH Responsibilities ............................................................................................. 17

3.2

Commissioning Team ........................................................................................... 17

3.2.1 3.3

4

Members Appointed by MEP Sub-Contractor: Sub-Contractor:.................. ......... ................... ................... .................. ........... .. 17

Responsibilities ..................................................................................................... 18

3.3.1

MEP Commissioning Commissioning Authority Responsibilities: Responsibilities: ................... .......... .................. .................. ................ ....... 18

3.3.2

Manufacturer/Vendors/Special Manufacturer/Vendors/Specialist ist Responsibilities ................... ......... ................... .................. .............. ..... 19

3.3.3

Planning and Scheduling Scheduling FAT Activities.................. ........ ................... ................... ................... ................... ............ 19

3.3.4

RAMS Demonstration Report ......................................................................... 19

3.3.5

FRACAS (Failure Reporting, Analysis & Corrective Action System)............... ........ ....... 20

3.3.6

Change Management System ........................................................................ 20

3.4

Commissioning Management Process .................................................................. 21

3.5

Verification & Validation ........................................................................................ 22

3.6

Organizational Chart ............................................................................................. 24

3.7

RACI RACI Matrix Matrix ................................. ................................................. ................................. ................................. .................................. ........................ ...... 24

PROGRESS REPORTING .......................................................................................... 24 4.1

T&C Schedul Schedule e........................................... ............................................................ .................................. ................................. .......................... .......... 24

4.2

Commissioning Commissioning Process Monitoring Monitoring (CPM) Log ................... .......... ................... ................... .................. .............. ..... 25

4.3

Commissioning Commissioning Inspection Monitoring Monitoring (CIM) Log ................... ......... ................... .................. ................... ............. ... 25

4.4

Commissioning Meeting’s ............................... ................................................ .................................. ................................. .................... .... 26


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5

6

4.5

Witnessing ............................................................................................................ 26

4.6

GSAS Requirement’s Validation ........................................................................... 26

OVERVIEW OF COMMISSIONING STRATEGY ......................................................... 28 5.1

Testing Strategy .................................................................................................... 28

5.2

Safety during T&C (Lock Out Tag Out & Permit to Work) ...................................... 28

5.3

Phases of the Project ............................................................................................ 29

5.4

Stages of the Project............................................................................................. 29

5.5

Test Before Completion ........................................................................................ 29

5.5.1

Design Stage: ................................................................................................ 29

5.5.2

Manufacture Stage – FAT Test (Stage 1):...................................................... 29

5.5.3

Installation Testing (IT) (Stage 2): .................................................................. 30

5.5.4

Partial Stand-Alone Test (PSAT) (Stage 3): ................................................... 30

5.5.5

Stand Alone Testing (SAT) (Stage 4) ............................................................. 30

5.6

Test on Completion ........................................................................................ 31

5.6.1

Integration Testing (Stage 5).......................................................................... 31

5.7

Test After Completion .................................................................................... 31

5.7.1

System Performance Testing (Stage 6) ......................................................... 31

DOCUMENTATION ..................................................................................................... 31 6.1

Test Procedures & Method of Statements for Tests: ............................................. 31

6.2

Check List & Test Sheet:....................................................................................... 32

6.3

Installation Test Reports: ...................................................................................... 33

6.4

Certificates:........................................................................................................... 33

6.5

Test Pack: ............................................................................................................. 34

7 SYSTEM DESCRIPTIONS, TESTING & COMMISSIONING PROCEDURES, STRATEGY, & INTERFACES. ............................................................................................ 35 7.1

HVAC System ...................................................................................................... 35

7.1.1

Installation Completion & Preparation ......................................................... 35

7.1.2

TAB Agency .................................................................................................. 35

7.1.3

References ................................................................................................... 36

7.1.4

Air Handling Units/Fresh Air Handling Units/Fan Coil Unit/Fans ..................... 36

7.1.5

Water Balancing ............................................................................................ 37

7.1.6

Air Balancing.................................................................................................. 37

7.1.7

Chemical Dosing Unit/Stream Filtration Unit .................................................. 37

7.1.8

Primary Chilled Water Pumps ........................................................................ 38

7.1.9

SRAC/CRAC Units......................................................................................... 38

7.1.10

Leakage Detection System for CHW Pre-insulated Pipe ................................ 39

7.1.11 Air Cooled Chiller ........................................................................................... 40

M009-REI-MEP-PLN-00001 Rev 0.2 Testing & Commissioning Plan

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7.2

Plumbing System .................................................................................................. 40

7.2.1

Installation Completion & Preparation ................................................................ 40

7.2.2

Booster Pump and Circulation Pumps......................................................... 41

7.2.3

Sump Pumps ................................................................................................ 41

7.2.4

Water Heater ................................................................................................ 42

7.2.5

Sand Filter .................................................................................................... 42

7.2.6

Chlorination of Portable Water System ....................................................... 42

7.2.7

Packaged Water Softener ............................................................................ 43

7.3

Fire Fighting System ............................................................................................. 43

7.3.1

Installation Completion & Preparation ................................................................ 43

7.3.2

Fire Pump...................................................................................................... 44

7.3.3

Fire Hose Cabinets ........................................................................................ 44

7.3.4

Zone Control Valve & Sprinkler System ......................................................... 45

7.3.5

Clean Agent FM 200 System ......................................................................... 45

7.3.6

Fire Damper Drop Test .................................................................................. 45

7.4

Electrical System .................................................................................................. 46

7.4.1

Earthing ......................................................................................................... 46

7.4.2

MCC panels ................................................................................................... 47

7.4.3

Distribution boards ......................................................................................... 47

7.4.4

Variable Frequency Driver (VFD) ................................................................... 48

7.4.5

Automatic Transfer Switch (ATS) ................................................................... 49

7.4.6

Lightning Protection System .......................................................................... 49

7.4.7

Lighting System ............................................................................................. 50

7.4.8

Fire Alarm System ......................................................................................... 51

7.5

Interface Test........................................................................................................ 52

7.5.1

Cause and Effect Testing ............................................................................... 52

7.5.2

Black-out Testing ........................................................................................... 53

8

CLIENT TRAINING ...................................................................................................... 53

9

FINAL DOCUMENTATION & HANDOVER .................................................................. 54

9.1 Equipment Data Sheets ............................................................................................... 55 9.2 O&M Manuals .............................................................................................................. 55 9.3 Manufacture Commissioning Report & Calibration Certificates .............. ...................... 56 9.4 Drawings...................................................................................................................... 56 10 ANNEXURE................................................................................................................. 56 11 NFPA CODES and OTHER STANDARD REFRENCE............................................... 133


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1. INTRODUCTION 1.1 Purpose This plan defines the method that will be used to ensure proper commissioning of t he General MEP Works of Qatar Rail, Green Line Elevated & At Grade Project. This plan reflects the requirements of the Contract Documents and the obligation of the Qatar Rail Stations Green Line Elevated and At Grade project team, the Design, the Consultants, the Commissioning Authority, the relevant Main Contractors, MEP Contractors, and Supplier/Vendors as well as a streamlined approach to allow for complete testing of the systems while maintaining the necessary requirements associated with the works which is in the Employer’s requirement ,D+B Contractor, MEP Subcontractor and the Third Party T&C ( MECON) & TAB Agencies. 1.2 Description Commissioning is the systematic process of ensuring all site and building components, equipment, systems, and interfaces among systems perform in accordance with the design intent, Employers Requirements and the contract documents. The commissioning process encompasses and supplements the traditionally separate functions of system, equipment, and component installation, checkout, startup, calibration, operational testing, adjustment and balancing, functional performance testing, development of O&M manuals, development of system manuals, development of as-constructed drawings, operation and maintenance training, final acceptance testing, and deferred functional performance and seasonal testing. 1.3 Objectives 

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









Ensure applicable equipment ’s, systems, and components that are properly installed and adequately checked out according to the manufacturer’s recommendations, industry accepted standards, and the contract documents, prior to startup. Ensure applicable equipment, systems, and components are started up, calibrated, operationally tested (statically and dynamically), adjusted and balanced, and functionally tested per the contract documents, prior to initiating operation and maintenance training and final acceptance testing. Ensure operation and maintenance manuals, system manuals, as-constructed drawings, and other required documentation are developed, updated, and submitted in accordance with the design intent and the contract documents. Ensure Client operation and maintenance personnel are adequately train prior to substantial completion of the work to provide routine operation and maintenance. Ensure that the plan is developing document to attain score “1” and to achieve an overall score of minimum “4” stars certification under GSAS (which shall be fro m 3rd party and shall be as per latest revision 2010 and updated). Ensure that T&C activities commenced according to the full complaint T&C plan and T&C results shall validate this score. GSAS provides direction for the commissioning process and ensure that commissioning team should be fully aware and addressed during all phases of the building process from pre-design to post-occupancy.


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Ensure the T&C Plan is a “LIVE” document and such as will be subject to constant review during the construction phase through the handover of Green Line Elevated & At Grade project as the process of material approval and shop drawing production and equipment/system installation continues. A full commissioning management team shall be appointed to manage, co-ordinate, monitor, witness, including system sign-off and verifying all the testing and commissioning of station/tunnel engineering services. The commissioning activities shall be undertaken and carried out by the commissioning management team generated within Green Line Elevated & At Grade Project & by the team of subcontractor (Redco). The Green Line Elevated & At Grade Project MEP tests shall be carried out at all the associated stations including their interconnecting tunnels, Trough, Cross passages, Switch boxes, Emergency Exits etc.

1.4 References, Definitions & Abbreviation 1.4.1

References The following other Contract Documents may contain requirements that relate to this section of contract documents submittals: INTERNATIONAL STANDARDS UNI EN ISO 9001:2008

Quality Management system -Requirement

UNI EN ISO 9000:2005

Quality Management system -Fundamental and Vocabulary

UNI EN ISO 14001:2004

Environmental Management

OHSAS 18001:2007

Occupational Health and Safety Management System

BSI/BS

British Standard Institute BS 7671

NFPA

National Fire Protection Association

IEC

International Electro Technical Commission

IEEE

Institute of Electrical and Electronics Engineers

ANSI

American National Standard Institute

NEMA

National Electrical Manufacture Association

IES

Illuminating Engineering Society

ASTM

American Standards Testing and Materials

SMACNA

Sheet Metal & Air Conditioning Contractor’s National Association

UL

Underwriters Laboratory, Inc.


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National Standards QCS 2010

Qatar National Construction Standards

QCDD

Qatar Civil Defense Standards

KAHRAMAA

Qatar General Electricity and Water Corporation

BASE DOCUMENATION FOR TESTING AND COMMISSIONING PLAN

CMS Ref: TM-201-PP01, Rev-

Qatar Rail Program Testing and Commissioning Management Plan

05,15/12/15

Rev-05

Volume 4: ER’s-General

Section 17 T&C & Section 18 O&M Manuals (18.1)

Volume 5: ER’s-Particular

Section 3 (3.7-3.8) and Section 4

Volume 6: ER’s-Design Spec

Section 13 & Section 15

Volume 7: ER’s-Material’s and

Appendix A -MEP Specifications addendum to QCS

Workmanship Specification

1.4.2

Definitions A. Commissioning Lots (CmLot) The Smallest functioning units are referred as commissioning Lots (CmLot). A commissioning Lot is a basic geographical section of one or more sub systems or functional units, which constitutes an independent, coherent, functional and isolated assembly. B. No Objection with Comments (NOWC) For documents that have been reviewed in accordance with project review procedure and have the status of No Objection with Comments. No Objection to use this document, but the document is to be revised by incorporating the comments. Subject to the comments, the document can be used. C. Statement of No Objection (SONO) For documents that have been reviewed in accordance with project review procedure and have the status of Statement of No Objection. The document can be used without amendment.


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D. Commissioning Plan: An overall plan, developed during the construction that provides the structure, schedule and coordination planning or the entire testing and commissioning process. E. Pre-Commissioning Certificate (PCC): PCC is a certificate issued by the MEP Contractor for Supervision Engineer approval when a Commissioning Lot is completely tested. F. Factory Acceptance Tests (FAT) These tests are Qualification Tests and/or Routine Tests undertaken during Stage 1 of Testing and Commissioning. Separate FAT Procedures shall be submitted for each equipment. G. Installation Release Notice (IRN) IRN is the document formalizing the transfer of responsibility for part of a system (Commissioning Lots) from the REDCO MEP Contractor installation team to the REDCO MEP commissioning team. H. Non-conformance Non-conformance is a defect that may occur during the various setting up and testing phases that may result in design changes. When a Non-conformance becomes apparent, the nonconformance procedure is followed to ensure that the Defect is properly remedied. I.

Non-conformance Report (NCR) Non-conformance report is a report for recording the non-conformance.

J. Partial Acceptance Certificate (PAC) Partial Acceptance Certificate is a certificate issued by the MEP Contractor and supported by a Supervision Engineer approval when a sub-system or system is completely tested. K. Test Readiness Review (TRR) (Check list of Readiness) Test Readiness Review is the permit to start stage 4 activities that are Stand Alone Tests. The TRR assesses test objectives, test methods and procedures, scope of tests, and safety and confirms that required test resources have been properly identified and coordinated to support planned tests. The TRR verifies the traceability of planned tests to program requirements and user needs. L. Certificate of Completion (COC) Certification that show all systems are commissioned and all system under MEP Scope as per Subcontract works together as a whole and there are no interfaces or functional issues between other disciplines.


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M. Commissioning Process Monitoring (CPM) Log Commissioning Process Monitoring Log includes all activity logs for the services, equipment’s, and devices identified system by system divided into various test . N. Commissioning Inspection Monitoring (CIM) Log Commissioning Inspection Monitoring Log shows the status of inspections to reflect the actual commissioning IRE status and approval. O. Factory Acceptance Test Certificate (FATC) Factory Acceptance Test Certificate (FATC) is a certification that show all FATs are successfully performed. P. Stages 1. Factory Acceptance Test (FAT) (Stage 1): The FAT stage is defined as the testing of equipment and equipment components during production in the factory or in similar conditions and it confirms that the supply of individual components and equipment is according to the design and the overall project requirements. 2. Installation Test (IT) Stage (Stage 2): The Installation Test stage is the testing stage following the installation of civil works, equipment or sub systems on site within the defined commissioning lot. The goal of the IT is to demonstrate that the relevant equipment or sub systems have been correctly installed. After successful Installation Test, an Installation Release Note (IRN) is issued for the relevant CmLot. Equipment are visually inspected and non-energized equipment are tested (air leakage testing, light test, pressure test etc.) 3. Partial Stand-Alone Test (Stage 3): Once an Installation Release Note (IRN) has been issued for the CmLot then a third step of testing takes place on the defined CmLot, this time in an energized state, to prove functionality of CmLot. If permanent power supply is not available during any step of testing and commissioning activities, it is Redco responsibility to provide details of power requirement to Design and Built (D+B) contractor adequate parameters to allow T&C activities to be undertaken. Stage 3 tests shall be completed by the issuance of Pre-Commissioning Certificates (PCC) to be submitted to the Engineer for comment/review and acceptance. 4. Stand Alone Test (Stage 4): A Test Readiness Review (TRR) shall be held prior to the start of the Stand-Alone Tests. This test aims to prove that all MEP sub-systems can work independently in autonomous mode. Continuity, isolation and grounding tests shall be done on all electrical cables and wires in addition to the functional tests required following the installation of such equipment for those items within contractor scope. 5. System Integration Testing (SIT) (Stage 5):


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This state shall demonstrate that all system works together as a whole and there are no interfaces or functional issues between other disciplines. Improves various stand – alone system into a coordinated set of integrated systems functioning together with other systems. During this phase, Integration Testing shall be conducted using permanent power supply. 6. System Performance Test (SPT) (Stage 6): This phase is to prove the overall inter-operability of all independent precommissioned systems. This includes the proof of compliance with the overall system specifications. At the end of the successful System Performance Verification Test, Completion Certificate will be issued. Q. Commissioning Handover Certificate (CHOC) For each section is issued by the Engineer when all As-Built documentation, operations manuals, punch lists of outstanding items and test reports are provided by the contractor to the engineer after the successful completion of Phase 4 dynamic testing. R. Commissioning Logic Is when the Commissioning test activities have been listed on Test data sheets and linked together in a logical manner ensuring that the sequence and interdependences of activities are recognized. S. Commissioning Schedule When the Commissioning Logic is established, each test activity is given an estimated duration and is reviewed from the resource viewpoint. By analyzing the results and carrying out a number of reconciliations to decide on the optimum number of, inter alia, personnel, test sites, items of plant and materials, the Commissioning Logic is converted into the Commissioning Schedule by the Contractor. T. Dynamic Testing Are test requiring the use of Test trains and are carried out during the Phase 4 of Testing and Commissioning. U. Engineering Safety Case Is a document produced by the MSI Contractor to demonstrate that t he infrastructure and system is acceptably safe . V. Construction/Commissioning Railway Rule Book Is the rulebook developed by the MSI Contractor to manage the transition from a construction site into an integrated operating railway.


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1.4.3

Abbreviations

ARCH AC BS CCW CHOC CCRRB CmLOT CWK CRAC DVE E&M EMC FAT FATC HVAC H&S SDR IAT ICD IRN IOR ISA IFC IT ITP LV MEP MS MSI MSDS MTC NOWC NCR OCC O&M PCA PM PMC PPE PSH QA / QC QCS QMS QND RAMS SCADA SCIL SHA


Project Archive Acceptance Certificate British Standard Certificate of Completion of Works Commissioning Handover Certificate Construction Commissioning Railway Rulebook Commissioning Lot Civil Works Computer Room Air Conditioner Design Verification Engineer Electrical & Mechanical Equipment Electromagnetic Compatibility Factory Acceptance Tests Factory Acceptance Test Certificate Heating, Ventilation & Air Conditioning Health, Safety Surveillance Deficiency Report Installation Acceptance Tests Interface Control Document Installation Release Note Internal Observation Report Independent Safety Assessor Issued for Construction Information Technology Inspection and Test Plan Low Voltage Mechanical, Electrical & Plumbing Method Statement Main System Integrator Material Safety Data Sheet Maintenance Certificate No Objection with Comments Non-Conformance Report Operation Control Centre Operation & Maintenance Partial Acceptance Certificate Project Manager Project Management Consultant Personal Protective Equipment Joint Venture of PORR, Saudi Binladin Group and HBK Quality Assurance / Quality Control Qatar Construction Specification Quality Management System Qatar National Datum Reliability, Availability, Maintainability and Safety Supervision Control and Data Acquisition Safety Critical Item List Safety Hazard Analysis

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SAT SIL SIT SONO SRAC T&C TAB TRR V&V WAD TP RIL

1.4.4

Site Acceptance Test Safety Integrity Level Static Integration Tests Statement of No Objection Split Room Air Conditioner Testing & Commissioning Test Adjusting & Balancing Test Readiness Review Verification and Validation Work Authorization Document Test Pack Redco International

Regulatory/Utilities Regulatory/Utilities Authorities KAHRAMAA Qatar Rail QCDD MOI ASHGAL

Qatar General Electricity & Water Corporation Client Qatar Civil Defense Department Minister of interior Public Works Authority of Qatar

2

SCOPE & LIST OF SYSTEMS

2.1

General The Redco MEP T&C Team is responsible for the commissioning process and shall plan, execute, and document the commissioning commissioning work specified herein. Systems to be commissioned: The scope of this Testing and Commissioning Plan covers all testing that shall be performed during the installation and commissioning of the Mechanical, Electrical, Public Health, and Firefighting/Fire suppression systems within the Green Line Elevated & At Grade Metro Project. Systems, equipment, components, and the interface between the systems specified in the following systems shall be Tested, Verified, Commissioned and Demonstrated according according to the contract. Systems to be commissioned shall include: A.

Mechanical Systems Air Cooled Chiller Fans (Smoke extract, Pressurization, Pressurization, Supply and General Extract Fans) Air Handling Units Fan Coil Units Chilled Water Pumps SRAC Units CRAC Units

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       

B.

Duct accessories (Motorized Damper, Fire Damper & Volume control Damper) Air Balancing of HVAC System Flushing, Cleaning and Passivation of Chilled Chilled Water System Water Balancing for Chilled Water System Chemicals Dosing System Chilled Water Pressurization Pressurization Unit and Expansion Tank CHW Pipework Pipework accessories Air Distribution devices (Diffusers, Grilles, Nozzles, etc.)

Electrical Systems LV Panels LV Distribution Network (Cables and Final Circuits) LV Motor Control Centers (MCCs) Lighting Fixtures Small Power and associated final DBs Variable Frequency Drives and Motor Starters Lighting Control System Emergency Lighting System Fire Alarm Functional Test Panel Boards Functional Test Earthing, Bonding and Lightning Protection BACS Interfacing

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C.

Plumbing Systems        

D.

Water Storage Tanks Booster Pumps Sand Filter Chlorination of water System Electric Water Heaters Thermostatic Mixing Valve Sump Pumps (Drainage) Drainage System Functionality Functionality (Sewage, (Sewage, Storm water and roof drainage drainage and water force main)

Fire Fighting System        

Fire Pumps Zone Control Valves Assembly Wet Type Sprinkler System Functional Tests Fire Hydrant System Fire Hose Cabinet and Fire Hose Station FM 200 Gas Suppression System Fire Extinguishers


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2.2

Commission ability Assurance To enable a degree of services familiarization, Redco T&C Team 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 requirement are incorporated. Commission ability study for MEP commissioning works includes following but not limited to, under project specification requirements: a) Examine Contract Documents Contract Documents are defined in the Conditions of the Contract.  Verify the equipment, such as gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, manual volume dampers, fire dampers, detectors, sensors, isolators required by the Contract Documents. Verify that quantities and locations of these equipment are accessible and appropriate for effective commissioning and for efficient system and equipment operation. b) Examine approved submittal data of systems and equipment. c) Examine design data, including system descriptions, statements of design assumptions for environmental conditions and system's output, and statements of philosophies and assumptions about systems and equipment controls. d) Examine equipment performance data, including fan and pump curves. e) Examine system and equipment installations to verify that they are complete and that testing, cleaning, adjusting, and commissioning specified in individual Specification Sections have been performed. f) Examine system and equipment test reports. g) Examine systems for functional deficiencies that cannot be corrected by adjusting and balancing. h) Examine air-handling equipment to ensure clean filters have been installed, bearings are greased, belts are aligned and tight, and equipment with functioning controls is ready for operation. i) Examine plenum ceilings, utilized for supply air, to verify that they are airtight. j) Examine equipment for installation and for properly operating safety interlocks and controls. k) Examine noise and vibration mitigation. l) Examine the sub-main distribution board(SMDB), distribution board (DB), Mechanical Control Center (MCC), Variable frequency driver (VFD) etc. to ensure that all the associated accessories/components are working properly and all the test which are explained in the testing and commissioning method statements are performed and are ready for operation. m) Report deficiencies discovered before and during performance of testing, adjusting, and balancing procedures. 


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2.3

Commissioning Phase Scope Commissioning includes setting to work, testing & balancing and performance testing to demonstrate adequacy of the system, and complete verification of 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. Inspection, Testing & Commissioning The process of inspection, testing and commissioning is divided in to various stages as follows. Stage 1 Factory Acceptance Test (FAT)  Stage 2 Installation Test (IT)  Stage 3 Partial Stand-Alone Test (PSAT)  Stage 4 Stand Alone Test (SAT)  Stage 5 MEP System Integration Test (SIT)  Stage 6 System Performance Test (SPT)  Testing & Commissioning Certificate Stage 3 Partial Completion Certificate  Stage 4 Partial Acceptance Certificate  Stage 5 Acceptance Certificate  Stage 6 Certificate of Completion  Testing & Commissioning Handover Documentation The sign off of individual test and commissioning activities / demonstrations will take place on a Progressive / logic sequence basis during the construction of the project. Redco will coordinate with SPH for archiving purposes. Redco T&C team will prepare the test packs as a result of all relevant tests for every equipment and will organize a general test pack for each sub-system including each separate test packs. After the completion of all final commissioning documentation, Redco T&C shall provide the test packs. These test packs will subsequently be included within the Operation and Maintenance Manuals (O&M) for the project. The following must be included as a minimum within each test pack; • A project standard commissioning completion certificate. • All relevant testing and commissioning documentation, each having been individually signed by the relevant specialist, sub-contractor, Redco, SPH and Client team to confirm that these works have been undertaken successfully. • Appropriate calibration certification for the instrument used during the test and commissioning process.


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• Related installation IRN having been individually signed by the specialist/subcontractor, Redco, SPH and Client team to confirm that installation of the works has been undertaken successfully.

3

COMMISSIONING RESPONSIBILITIES & OBLIGATIONS

3.1

SPH Responsibilities SPH to co-ordinate a l l activities of the commissioning schedule, so that completion, testing, and commissioning of the systems is carried out without hindrance and in a safe and satisfactory manner by the appointed sub-contractors and also SPH to arrange Power, Water and suitable temperature for any testing and commissioning activity.

3.2

Commissioning Team

3.2.1 Members Appointed by MEP Sub-Contractor: Commissioning Manager and Commissioning Engineers from MECON as a third party shall manage all the commissioning activities, coordinate and implement testing and commissioning process. This consists of the following: Commissioning Manager / Engineer Foreman Skilled Worker Helper

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Schedule of Key Personnel from QR, SPH and Redco (MEP Subcontractor) Company

Contact Name

Contact Details

EMPLOYER PRIMARY CONTACT QATAR RAIL

TBC

Mobile:

Email:

ENGINEER ASSISTANT PRIMARY CONTACT/PSH COMMISSIONING MANAGER SPH

TBC

Mobile:

Email:

Sub-CONTRACTOR PRIMARY CONTACT/MECON COMMISSIONING MANAGER REDCO

Jaffer Ibrahim

Mobile: 33194898

Email: [email protected]

MECON

Burak Oral

Mobile: 31579429 Email: [email protected]

The above schedule details are of the Main Commissioning Team Members. The members representing each contractor, vendor, supplier, subcontractor, installer and specialist required as a part of Commissioning team shall be detailed as below.


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3.3

Responsibilities

3.3.1 MEP Commissioning Authority Responsibilities: To manage and execute the commissioning activities in liaison with the specialist vendors, and all related subcontractor. Organize and lead the testing and commissioning teams. Coordinate and update the commissioning programs. 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 the arranging for facilities, preparing agenda and attendance lists, and notifying participants. Prepare testing and commissioning procedure, which includes checklists, test reports and risk assessment for all MEP related works. Coordinate with HSE for necessary safety procedure implementation. Identify the requirement of special agency for commissioning as per project specifications. Identify testing and commissioning team member responsibilities, by name, firm, and trade specialty, for performance of each testing and commissioning task. Verify ensure the commission ability of the system and sub-system. Agree actions required and follow action implementation on site. Enable the permit to work system, implement safety signage & LOTO procedure to ensure the safe operation coordination with HSE officer. Schedule, direct, coordinate, execute, witness and document testing, commissioning, inspections and other related activities. Complete the test report duly signed by commissioning engineer, specialist of vendors/manufacturers commissioning certificate, equipment data sheet, equipment schedule and final drawings for the producing test pack, verify the test results and necessary documentation prior to submission for consultant verification. Prepare and maintain commissioning risk register to log and update the commissioning risk, which may affect the system performance and non-compliance to the project requirement/authority’s requir ement. Compile test and commissioning data, inspection reports, and include in the system manual, commissioning reports and O&M manuals. Certify date of test acceptance and commissioning for each item of equipment for start of warranty periods. Provide required information for O&M manual preparations. Prepare and conduct operation and maintenance training including the formulation of training programmed, all in accordance with the contract requirements. Preparation of Test Packs upon completion of tests. Prepare regular testing and commissioning reports, for each phase and segments activities. Assemble the final test and commissioning documents, test pack including the test and commissioning reports and in collaboration with the entity responsible for system/equipment supply/performance of corrective action.

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Participate in the final review at acceptance meeting and review/approve final test and commissioning documentation. 3.3.2 Manufacturer/Vendors/Specialist Responsibilities 

As directed by MEP commissioning manager, assign representative 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:   

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Participate in maintenance orientation and inspections. Participate in procedures meetings for testing and commissioning. Verify test and commissioning activities for all system equipment as directed by MEP commissioning managers and in accordance with test and commissioning procedures and programed. Participate in final review and acceptance meetings. Preparation of test packs including test sheets, manufacturer’s recommendation, and material submittal approvals, etc. Give input to planning for operation and maintenance data submittals, equipment startup, and testing to contractor for incorporation into the O&M plan and documentation. Participate in training sessions for Client’s operation and maintenance personnel. Provide update project record documents to the Supervision Management. Submit O&M manuals for all systems as specified in project contracts documents. Provide technicians who are familiar with construction and operation of installed systems. Develop specific test procedures and participate in testing and installed systems, subsystems, and equipment.

3.3.3 Planning and Scheduling FAT Activities 

FAT activities like procedure, FAT Test and record of FAT Test shall be carried as per approved Methodology.

3.3.4 RAMS Demonstration Report Upon commence of T&C a period of RAM requirements monitoring will be carried out during (SPT with permanent power in place) in order to demonstrate that the RAM targets are met. The RAM demonstration process comprises of the following main stages  Preparation of a RAM Demonstration Report.  Collecting RAM performance failure data as part of a FRACAS system  Carrying out tests and demonstration during a RAM Demonstration Period.  Implementation of Corrective action for remedial measure for any identified deficiencies.  Analyzing the failure data to demonstrate that the Sub-system meets the RAM performance targets, with extension of the RAM Demonstration Period, should RAM performance targets not be achieved during this period. RAM Demonstration report shall be forwarded by sub-contractor (Redco) and will be part of T&C report (sub-construction package). During the T&C phase, every failure will be registered, and in case of failure random will be ‘counted in the calculation of RAM parameter.


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3.3.5 FRACAS (Failure Reporting, Analysis & Corrective Action System)

If the failure is due to equipment failure, then FRACAS shall be applied. FRACAS is applied to ensure all failures and incidents are accurately and consistently categorized as to cause, significance, frequency and chargeability. 3.3.6 Change Management System 

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A systematic approach to proposing, evaluating, approving, implementing and reviewing changes. The scope of change management is much broader than change control, which was typically applied to one change. Change management includes the oversight and management of the entire portfolio of changes and the change process, including all the components of change control. An evaluation of the change should be undertaken after implementation to confirm the change objectives were achieved.


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3.4 Commissioning Management Process MEP WORKS MANAGEMENT SYSTEM

Design Lifecycle Stages

Stage Discription Milestone Stage g

Stage 1 Manufacture Stage

Stage 2 Installation Testing

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Installation Release Note (IRN)

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Defects Notification Period (DNP)

3.5 Verification & Validation T&C process objective is to carry out all the activities which are necessary in order to ensure and to demonstrate the complete system and sub-system Integration Verification and Validation. There are five possible Verification methods which can be used on the project a) Analysis b) Inspection c) Review d) Test e) Similarity Each project requriement is verified according to one or more of the aformentioned methods.

* Figure 6 from 6.2.3 V&V Method section of Qatar Rail Program Test & Commissioning Management

NOTE: Test reports to be available and in coordination to the Engineering Safety Validation Plan as part of the necessary validation criteria


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3.6 Organizational Chart The Organizational Chart applicable to this work is attached in Annexure G. 3.7 RACI Matrix

(Please refer to Appendix H For the whole process RACI Chart)

4 PROGRESS REPORTING

(Please refer to Appendix J for the 3 WLA and Progress report)

4.1 T&C Schedule Redco T&C department will produce an integrated Commissioning Program for approval incorporating all services, project sectors, segments and zone requirements, including device and sub-system tests. The Program will show all key milestones together with all inter relationships and all interface between systems and external services. The schedule is to be programmed in a manner that includes all tests to be conducted on site in every stage of commissioning plan. Every testing and commissioning activities shall be identified on this schedule and will be tracked in the “T&C Process Tracker ” such as;       

FAT tests and planned schedules Static test schedules SAT tests and planned schedules Testing equipment certification and availability A three-week schedule updated weekly Standalone test schedules Dynamic Systems testing schedules


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T&C milestones are shown in the Contract Schedule Expending the schedule with the discussion of relevant stakeholders for integrated testing.

A. Production of T&C System Management Procedure Redco T&C will produce or obtain commissioning system management procedure from specialist/vendors for special systems and testing will review that procedure fully complies with the project specification & client requirements this will include but not be limited to: 1. 2. 3. 4. 5. 6. 7. 8.

Scope Purpose Definitions Resources Testing and Commissioning Methodology Risk Assessment Job Safety Analysis Attachments (Check List & Test Sheets)

4.2 Commissioning Process Monitoring (CPM) Log Redco will prepare a Commissioning Process Monitoring Log, which includes all the services, equipment’s, and devices identified system by system divided into various test with predetermined weight-age. The same is to be updated on a weekly basis. Moreover, reported to Supervision, Management on a weekly basis to track the actual process. CPM will report on the status of testing and commissioning as system and subsystem. Redco will submit the CPM tool skeleton review and approval. This CPM log will generate only the actual percentage. The final plan percentage is to be matched from Commissioning Program, which is being updated by Redco Planner / Commissioning team. 4.3 Commissioning Inspection Monitoring (CIM) Log Redco will prepare an Inspection status-monitoring log to reflect the actual commissioning documentation status and approval. Documents projection to be made system wise and status of Submission, Approval and Rejection to be updated on daily basis. CIM log will reflect the commissioning documents percentage system wise, as follows     

Electrical Systems HVAC System Plumbing & Public Health System Fire Fighting System Fire Alarm System


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CIM log will highlight the Total Commissioning document system wise, Submitted, Approved, Rejected and Under Review. Redco commissioning team will submit the CIM summary and Graph on weekly basis. 4.4 Commissioning Meeting’s Redco T&C will arrange and administer meetings to agree and submit all relevant documentation for testing and commissioning and ensure meeting agenda covers all relevant topics such as:      

Health & Safety Documentation Progress - Method statements and test procedure. Production test pack. Installation Progress affecting Commissioning. Testing and Commissioning Progress (after commencement). Coordination and interface

4.5 Witnessing With the self-certification system, all tests are to be witness and signed-off as per T&C procedure shown in Section 7. Despite the self-certification, every test (Off-site) shall be formally notified to each of the validating entities with sufficient time to let interested people planning their participation if needed, independently of the fact they are willing to witness the test or not. The test notification will identify the test purpose and various other information such as person in charge of the test, the test procedure reference, the location of the test, etc. The Redco shall perform all necessary testing and commissioning activities which takes place on the defined CmLot, the smallest functioning units, in order to ensure satisfactory operation of the completed works and compliance with the Contractor Requirements. Tests shall be witnessed by the SE, the Contractor and Engineer’s Assistant as required and where identified in the Inspection and Test Plan. Tests are to be carried out following the below indicated stages and including the documentation associated related to its witnessing as indicated in point 5.3: 4.6 GSAS Requirement’s Validation Once the mentioned system commissioned, all system test packs shall be signed off by the PMC, evidence to the GSAS Log (GSAS by 3 rd Party) shall be forwarded to Sub contractor Redco, who shall verify the accuracy and then forwarded to Sustainability team to validate that the requirement is been met in terms of commissioning process.


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Activities Design Review

Review Responsible Design

Outcomes

WORK FLOW

Tracker

De artment MEP Review

MEP Department

Material Submittal Tracker

Equipment Installations Activities

Responsible

Outcomes

FAT - Factory

QA/QC -

FAT Acceptance

Acce tance Test

Procurement – T&C

Certificate

Installations

QA/QC

IRN

Testin

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Installation Method Statements

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Commissioning Activities

Responsible

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Commissioning

Stand Alone Test

De artment

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Commissioning

Test

SIT – System Inte ration Test

Outcomes PCC

Stage 3 - PSAT

PAC

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De artment

Commissioning

Test Before Completion

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De artment

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Commissioning Method Statement

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Energized State (Temporary / Permanent Power Supply)

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Commissioning System Procedure

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Test On Completion

activities etc. shall be performed at this stage.

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Performance Test

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CofC Stage 6 - SPT

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Test Packs shall be updated as per AC

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Commissioning System Procedure

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Test After Completion

5 OVERVIEW OF COMMISSIONING STRATEGY 5.1 Testing Strategy The fundamental testing strategy is that during different phases of the work, such as manufacturing, construction and commissioning, system requirements as detailed in the technical specifications and in accordance to the validation plan, 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. Use of Spare Parts during Testing and Commissioning 

a) Suitable Testing and Commissioning spares shall be available in order to be able to replace faulty equipment during Testing and Commissioning period. Strategy for Test Failure A test may fail due to number of reasons a) The sub system works as designed but the Test Procedure was incorrect. b) The Test Procedure was correct but the expected values (design values) were not within tolerance or were inconsistent. c) Most of the test passed but a specific part or component failed. d) The equipment does not work as designed If the failure is due to equipment failure, then FRACAS shall be applied. FRACAS is applied to ensure all failures and incidents are accurately and consistently categorized as to cause, significance, frequency and chargeability. 

5.2 Safety during T&C (Lock Out Tag Out & Permit to Work) Procedure M009-SPH-HMS-PLN-00009 & M009-SPH-QMS-PLN-00029 cover Redco scope of works. This includes associated test equipment and temporary piping and power installations. This procedure is intended to provide authorize employees with a level of protection equal to that, which would be afforded to them by the use of personal lock. The preferred method for providing this type of protection involves the use of locks and key control as described further in this procedure. When an energy-isolating device is not capable of being locked out, the energy control program shall have utilized tag out (s). A personal sign-in/sign-out log or permit is acceptable and considered a “personal tag out device” as long as (1) it identifies each authorized employee being protected and (2) the person in charge can reliably account for each individual authorized employee who is being protected. This procedure Explains the procedures for Lockout I T ag out specified in the project H&S plan: M009-SPH-HMS-PLN-00009 and also refers to doc. M009-SPH-QMS-PLN-00029 "Lock-out I Tag-out Procedure".


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5.3 Phases of the Project MEP T&C testing activities are to be divided into the following main phases:   

Test Before Completion Test on Completion Test After Completion

5.4 Stages of the Project For the phases mentioned above, T&C activities and certification of the work will be considered in 6 main stages.      

Manufacture Stage – FAT Test (Stage 1) Installation Testing Stage (Stage 2) Partial Stand-Alone Stage (Stage 3) Stand Alone Stage (Stage 4) Integration Testing Stage (Stage 5) System Performance Testing (Stage 6)

Detailed descriptions are outlined in the following sections. 5.5

Test Before Completion

5.5.1 Design Stage: The milestone for starting the T&C activities shall be the design stage. Completion of sub system shop drawings will form a basis to T&C activities for preparing verification documentation and in line to the validation criteria. 5.5.2 Manufacture Stage – FAT Test (Stage 1): Manufacturing Stage mainly consists of Factory Acceptance Test (FAT). This Stage is defined as the testing of equipment and equipment components during production in a factory or testing laboratories. The aims of these tests are to confirm that the supplied loadout complies with declared specifications and capacities on equipment data sheets. In this stage verification of design and overall project, requirements are also considered. FAT Tested equipment shall be stated as a list and a schedule for tests and dates will be established and provided. In this list, it should also be remarked which equipment will be fully tested or randomly tested for a portion of t he total system. The engineer will be notified with Factory Acceptance Tests. These will all be identified in the Testing and Commissioning Schedule. Before the FAT test in the factory a Testing Program including details of inspection and testing shall be informed to the Engineer. The program shall include: Agenda FAT attendees contact details FAT Procedure

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Responsibilities Calibration test records of instruments Sample test records

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At the conclusion of the FAT test, a Factory Acceptance Test Certificate (FATC) will be issued by the supplier indicating how the item have been rigorously tested. FAT will be issued for review and approval to Engineer. A Certificate of Conformity shall be required for propriety equipment, and a Certificate of Compliance to ensure its compliance with the relevant standards. 5.5.3 Installation Testing (IT) (Stage 2): The aim of installation testing stage is to demonstrate the equipment, or the sub-systems have been installed correctly. After successful installation tests; Installation Release Note (IRN) is to be issued for the relevant CmLot. IRN is to be prepared by the QA/QC department and handed over to the T&C Department. T&C department will only support to the QA/QC Team for this stage. IT Tests will be considered as non-energized tests conducted in construction phase. 5.5.4 Partial Stand-Alone Test (PSAT) (Stage 3): Once an (Installation Release Note) IRN has been issued for the identified/selected CmLot then a third step of testing takes place, this time in an energized state, to prove the functionality of CmLot. If permanent power supply is not available during any step of testing and commissioning activities, it is SPH responsibility to provide details of power requirement to Design and Built (D+B) contractor adequate parameters to allow T&C activities to be undertaken. The Partial Stand-Alone Test (PSAT) shall demonstrate that the MEP System or installations works/were installed correctly as individual parts not as a whole system. Equipment and installations will be tested part by part. Partial Stand-Alone Test will be excluded from integration of other internal MEP sub-systems. Stage 3 tests shall be completed by the issuance of Pre-Commissioning Certificates (PCC) to be submitted to the Supervision Engineer for comment/review and acceptance. 5.5.5 Stand Alone Testing (SAT) (Stage 4) Test Readiness Review is the permit to start stage 4 activities which are Stand Alone Tests. The TRR assesses test objectives, test methods and procedures, scope of tests, and safety and confirms that required test resources have been properly identified and coordinated to support planned tests. The TRR verifies the traceability of planned tests to program requirements and user needs. This testing stage aims to prove that all MEP sub-systems can work independently in autonomous mode with its all system components. During testing of equipment’s and components, permanent power shall be provided for all the testing activities in order to prevent any harm in the system.


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After ensuring that all the necessary equipment has been tested and that the snag lists do not contain any items that may invalidate the test, Partial Acceptance Certificates (PAC) shall be issued. 5.6

Test on Completion

5.6.1 Integration Testing (Stage 5) System integration tests demonstrate that the system works together as per design and there are no interfaces or functional issues between the MEP, Civil, Track, Transit and Operations. During this phase, Integration Testing shall be conducted using permanent power supply, only where applicable temporary power is to be used. During this phase of the testing, a comprehensive set of integration testing shall be conducted for station systems. All Testing, Adjusting and Balancing actions, cause & effect checks, black-out test and activities etc. shall be performed at this stage. All specific integration testing will be the responsibility of Main Contractor. However, for BACS and Railway System testing, MSI will take the lead on integration supported by Redco. At the end of each successful System Integration test, an Acceptance Certificate (AC) will be issued. 5.7

Test After Completion

5.7.1 System Performance Testing (Stage 6) Within this stage, construction phases are to be considered as finished, and studies for proving that the system is suitable for operating with all independent pre-commissioned systems. The stage includes performance testing to demonstrate that the integrated equipment and systems meet contract performance requirements. By the end of a successful System Performance Verification Test Completion Certificate will be issued.

6 DOCUMENTATION 6.1 Test Procedures & Method of Statements for Tests: Redco T&C will produce or obtain from manufacturer/vendor/specialist for their dedicated commissioning method statements. Testing shall be performed according to approved test methods. 

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.


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Produce a comprehensive commissioning documentation structure so that all system records can be easily field retrieved and reproduced.

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All these procedures must be submitted to the Main Contractor in advance for approval. The data will indicate that the test fully complies with the project specifications & client requirements, which will include but not limited to: Objective, Purpose, Scope Definitions Resources / Calibrated Devices Testing and Commissioning Methodology

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Format of Recording    

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Initial and Final Conditions Detailed Description Results Expected

Results Obtained on Site Immediate on-site analysis Immediate conclusions and actions to be taken Pass/Fail Criteria

Risk Assessment Job Safety Analysis Attachment (Check List & Test Sheet)

In these procedures contractor will take into proper account the test procedures and constraints of any other Interfacing Parties, the external railway networks, and the external facility networks. The test results conducted on site will be noted and reported with a specific procedure. These reports are to be signed with the person in charge of testing, and those who have witnesses the test as part of piece of Self Certification. All procedures are to be consistent with the general arrangements defined in the document above. MSI is the Test Lead Contractor and is in charge of carrying out the tests such as Site Integration & Dynamic Testing within the scope of MSI. Redco to provide support at this stage ensuring that all its equipment works as per project specification. 6.2 Check List & Test Sheet: For each test conducted on site, a test data sheet (checklist) shall be provided. This test has to contain all necessary data for the test such as followings;  

Title and the number of the test Phase and sub-phase of Testing and Commissioning


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Brief description of the test Objectives of the test Location Duration Requirement regarding items such as equipment, staff, facilities Requirements in the form of availability of other metro line assets Satisfactory space, whether the test is passed or failed. If the test fails, provide the criteria and the parameter of the failure Space for any additional comments.

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The data sheets will be available for every particular test and will be implemented with the relevant test M&S. 6.3 Installation Test Reports: For every result of each test conducted on site, it should be reported in its proper methods. Results should be analyzed carefully and conclusions must be indicated properly. The contractor is responsible for complying and submitting Test Reports in accordance with the Contractor’s Test Procedure. Partial test reports can be submitted in the continuum of project, but must be reported after completion of a sub-system or full system test as a Test Pack. Same process will be necessary for every type of equipment located to one specific architectural area (Station, Trough, and Evacuation Shaft etc.) The Test Report shall contain as a minimum, the following: 

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Test Checklist or Test Sheet including; Date, time and location o Description of the system/sub-system tested o Test Configuration o Measured Parameters o The Pass/Fail Indication o The Derivations (if any) o Drawing of system/sub-system tested Material Submittal Approval Reference QA/QC Installation Approval Reference ITP (Inspection Test Plan) HSE Assessment & Job Hazard Analysis IRE (Inspection Request) Calibration Certificates and Fit Reports for test equipment.

6.4 Certificates: Certificates shall be used to confirm that equipment or sub-system meets requirements for related Stage. Certificates are based on results from the test and the check sheets in the t est reports. Each discipline requirements are outlined in further items.


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MEP Certificate

*: Table 5 from 6.5.3 Certificate section of Qatar Rail Program Test & Commissioning Management 6.5 Test Pack: For every individual equipment, Redco will prepare type of a significant CmLot or a sub-system a test pack. These Test Packs will be reported to Supervision Engineer. Results will be analyzed carefully and conclusions will be indicated properly. The Sub contractor is responsible for compiling and submitting Test Pack in accordance with the Contractor’s Test Procedure. Same process will be necessary for every type of equipment located or appeals to the one specific architectural area (Station, Trough, Evacuation Shaft etc.) The Test Pack shall contain as a minimum, the following: MIR (Material Inspection Request) Material Submittal Approval Reference (MAR) FAT IRE for Installation Test Reports for Installation Stage Installation Release Note (IRN) PSAT and/or SAT Checklist including; Date, time and location o Description of the system/sub-system tested o Test Configuration o Measured Parameters o The Pass/Fail Indication o The Derivations (If Any) o ITP o

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HSE Assessment & Job Hazard Analysis Drawing of system/sub-system tested Equipment Data Sheet Calibration Certificates and/or Fit Reports for test equipment’s

o   

7 SYSTEM DESCRIPTIONS, TESTING & COMMISSIONING PROCEDURES, STRATEGY, & INTERFACES. Complete MEP system will be tested and commissioned by Redco T&C Specialist (MECON) and functionality of the system performance will be verified prior to Supervision Engineer verification. Stages of testing and inspection are defined below for clear understanding of commissioning strategy and step-by step procedures. Detailed testing and commissioning procedure will be submitted for each system and subsystem to detail the commissioning methodology including standards, codes and project specification references. 7.1

HVAC System

7.1.1 Installation Completion & Preparation Complete system readiness checks and prepare system readiness report. Verify the following: A. B. C. D. E.

F. G. H. I. J. K. L. M.

N.

Installation of ductwork are completed. Installation of piping completed. Installation of equipment are completed. Ductworks are cleaned out of dust. Pipework leakage test are performed and passed according to related Method Statement. Isolation and control valves are installed. IRN has issued. Permanent electrical power wiring is complete. Hydronic systems are filled, clean, and free of air. Equipment and duct access doors are securely closed. Balance, Motorized smoke, and fire dampers are open. Isolating and balancing valves are open and control valves are operational. Ceilings are installed in critical areas where air – pattern adjustments are required and access to balancing devices is provided. Windows and doors can be closed so design conditions for system operations can be met.

7.1.2 TAB Agency MECON is appointed T & C supervision and TAB Agency.


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7.1.3 References HVAC system testing, adjusting and balancing will be performed according to the following specification and standards.    

7.1.4

Project specifications for Testing, Adjusting and Balancing of HVAC systems. QCS 2010 for Testing, Adjusting and Balancing of HVAC systems. Associated Air Balance Council (AABC) and National Environmental Balancing Bureau - Standard Testing & Balancing (TAB) Procedures. Sheet Metal and Air Conditioning Contractors’ National Association (SMACNA).

Air Handling Units/Fresh Air Handling Units/Fan Coil Unit/Fans A. Pre - Commissioning & Start up The initial pre-commissioning, fan alignment and setting to work is to be carried out by Redco T&C in liaison with the unit manufacturer/supplier prior to start-up. Note: Equipment will not be started until the installation of mechanical and electrical is signed off. Pre-commissioning will be carried out for the equipment, associated duct works, dampers and control devices including air terminals. B. Functional Test & TAB Functionality including electrical performance, fan performance, terminal air balancing and noise level measurement. Vibration test will be carried out for major equipment’s . Redco T&C will verify and ensure test results then offer for Supervision Engineer verification. Note: Water balancing will be a separate inspection for complete secondary water distribution network. It will not be a part of HVAC system functionality test. Note: Air balancing for grills and diffusers will be a separate inspection for complete secondary air distribution network. It will not be a part of HVAC system functionality test. Note: Function test will not be commenced before permanent or appropriate temporary electrical power provided. C. System Performance Test After the complete building envelope, unit cooling performance will be verified and submitted for Supervision Engineer verification. Verification & Validation activities will be finalized with as documentation. D. Interface Test BACS interfaces will be tested by the specialist and separate inspection will be offered for Supervision Engineer verification. Fire Alarm interface test will be carried out as per


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approved Cause & Effect matrix as part of integration test and offered for verification with complete third-party integration. 7.1.5

Water Balancing A. Pre – Pre – Commissioning Commissioning Pre-commissioning of the piping network, regulating valves, control valves and strainers will be checked for proper and right installation. Ensure that system is flushed and clean prior to start balancing. Ensure that pumps are started and operational. Note: Balancing will not be commenced until the system installation and flushing is signed off. Pre-commissioning by TAB agency will be carried out as per approved commissioning procedure. Note: Flushing to be treated separately as it is considered part of the construction phase/activities. B. Water Balancing Water balancing will be carried out by as per approved commissioning procedure and standard requirements. Test includes terminal flow, total flow of the pump and head. Redco T&C will verify the test results then offer for Supervision Engineer verification.

7.1.6

Air Balancing A. Pre – Pre – Commissioning Commissioning Pre-commissioning of the duct network, regulating dampers, grilles and diffusers will be checked for proper and right installation. Ensure that system is clean prior to start balancing. Ensure that fans are started and operational. operational. Note: Balancing will not be commenced until the system installation and duct cleaning is signed off. Pre-commissioning will be carried out as per approved commissioning procedure. B. Air Balancing Air balancing Management Management will be carried out by MECON as per approved commissioning procedure and standard requirements. Test includes air flow, volume damper fixation, grill and diffuser calibrations. Redco T&C will verify the test results then offer for f or Supervision Engineer verification.

7.1.7

Chemical Dosing Unit/Stream Filtration Unit A. Pre – Pre – Commissioning Commissioning Pre-commissioning and setting to work will be carried out by Redco T&C in liaison with unit manufacturer/supplier. manufacturer/supplier.


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Note: Commissioning Note: Commissioning will not be commenced until the installation of mechanical and electrical is signed off. B. Functional Test Functional test will be done as per approved procedure by Redco T&C in liaison with unit manufacturer/supplier. Water analysis report will be obtained from laboratory. Redco T&C will verify the test results then offer for Supervision Engineer verification. C. Interface Test BACS Interface Test Interface shall be performed by BACS Contractor. Note: Interface test will be offered separately for Supervision Engineer verification as part of BACS functionali f unctionality. ty. 7.1.8

Primary Chilled Water Pumps A. Pre - Commissioning & Start-up Start-up Pre-commissioning, pump alignment and setting to work is to be carried out by Redco T&C in liaison with t he pump manufacturer/supplier manufacturer/supplier prior to start-up. Note: Pump Note: Pump commissioning will not be commenced until the installation of mechanical and electrical is signed off. Pre-commissioning will be carried out for the pump and distribution network. B. Functional Test Functional test will be carried out by Redco T&C as per approved procedure liaison with Manufacturer/Supplier. Test includes electrical and mechanical operation, pressure setting and safety protections. Redco T&C will verify the results and offer for SE verification. Note: Note: Function test will not be commenced before permanent electrical power provided. C. System Performance Test Performance test will be carried out as per approved procedure. Test will include Electrical and Mechanical Performance, Design flow and Pump Head verification. Redco T&C will verify the test results then offer for Supervision Engineer verification.

7.1.9

SRAC/CRAC Units A. Pre - Commissioning & Start-up Start-up Pre-commissioning and setting to work is to be carried out by Redco T&C in liaison with manufacturer/supplier. manufacturer/supplier.


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Note: Commissioning Note: Commissioning will not be commenced until the installation of mechanical and electrical is signed off. B. Functional Test Functional test will be carried out by Redco T&C as per approved procedure in liaison with manufacturer/supplier. Test includes electrical and mechanical operation, pressure setting and safety protections. Redco T&C will verify the results and offer for SE verification. Note: Note: Function test will not be commenced before permanent electrical power provided. C. System Performance Test Performance test will be carried out by Redco T&C in liaison with manufacturer/supplier as per approved commissioning procedure. Test includes fan operation, controls and room temperature measurement. Redco T&C will verify the operation and test results then offer for SE verification. D. Interface Test (as Applicable) Applicable) BACS interfaces test shall be performed by BACS Contractor. 7.1.10 Leakage Detection Detection System for CHW Pre-insulated Pipe A. Pre - Commissioning & Start-up Start-up Pre-commissioning and setting to work is to be carried out by Redco T&C in liaison with manufacturer/supplier. manufacturer/supplier. Note: Commissioning Note: Commissioning will not be commenced until the installation of mechanical and electrical is signed off. B. Functional Test Functional test will be carried out by Redco T&C as per approved procedure in liaison with manufacturer/supplier. Test includes electrical and mechanical operation and safety protections. Redco T&C will verify the results and offer for consultant verification. Note: Note: Function test will not be commenced before permanent electrical power provided. C. System Performance Test Performance test will be carried out by Redco T&C in liaison with manufacturer/supplier as per approved commissioning procedure. Test includes


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functional checks and test. Redco T&C will verify the operation and test results then offer for consultant verification. D. Interface Test (as Applicable) BACS interfaces shall be performed by BACS Contractor. 7.1.11 Air Cooled Chiller E. Pre - Commissioning & Start up Pre-commissioning and setting to work will be carried out by Redco T&C in liaison with unit manufacturer/supplier. Note: Equipment will not be started until the installation of mechanical and electrical is signed off. Pre-commissioning by TAB agency will be carried out for the equipment, associated all connections. F. Functional Test & TAB Functionality including electrical performance, unit performance, and performance measurements. Redco T&C will verify and ensure test results then offer for consultant verification. Note: Function test will not be commenced before permanent or appropr iate temporary electrical power provided. G. System Performance Test After the complete building envelope, unit performance will be verified and submitted for consultant’s verification. Verification & Validation activities will be finalized with as documentation. H. Interface Test BACS interfaces will be tested by the specialist and separate inspection will be offered for consultant verification. Fire Alarm interface test will be carried out as per approved Cause & Effect matrix as part of integration test and offered for verification with complete third-party integration. 7.2

Plumbing System

7.2.1

Installation Completion & Preparation Complete system readiness checks and prepare system readiness reports. Verify the following: A. Installation of piping completed and pressure tested. B. Installation of tanks and equipment’s are completed.


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C. Isolation and control valves are installed. D. IRN has issued. E. Permanent Electrical power wiring is complete. F. Ensure that continuous water source available. G. Pipes are filled, clean, and free of air. H. IRN has issued. I. Adequate access is available.

7.2.2 Booster Pump and Circulation Pumps A. Pre - Commissioning & Start-up Pre-commissioning, pump alignment and setting to work will be carried out by Redco T&C in liaison with the pump manufacturer/supplier prior to startup. Note: Pump commissioning will not be commenced until the installation of mechanical and electrical is signed off. B. Functional Test Functional test will be carried out by Redco T&C as per approved procedure in liaison with manufacturer/supplier. Test includes electrical and mechanical operation, pressure setting and safety protections. Redco T&C will verify the results and offer for SE verification. Note: Function test will not be commenced before permanent electrical power provided. C. Interface Test The specialist will test BACS interfaces and separate inspection will be offered for Supervision Engineer verification. D. System Performance Test Capacity testing will be performed for displaying pumps meet contract performance requirements. Verification & Validation activities will be finalized with as documentation. BACS interfaces test. 7.2.3 Sump Pumps A. Pre – Commissioning Redco T&C will carry out Pre-commissioning and setting to work prior to start-up in liaison with manufacturer/supplier.


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Note: Commissioning will not be commenced until the installation of mechanical and electrical is signed off. B. Functional Test Functional test will be carried out by Redco T&C team as per approved procedure. Test includes mechanical operation, electrical operation, controls and volumetric performance. Redco T&C will ensure the operation then offer for SE verification. C. Interface Test BACS interfaces test. 7.2.4 Water Heater A. Pre – Commissioning Pre-commissioning and setting to work will be carried out by Redco T &C prior to startup in liaison with manufacturer/supplier .Note: Commissioning will not be commenced until the installation of mechanical and electrical is signed off. B. Functional Test Redco T&C will carry out the functional test as per approved procedure. Test includes electrical, mechanical performance and water temperature. Redco T&C will ensure the performance and offer for SE verification. 7.2.5 Sand Filter A. Pre – Commissioning Pre-commissioning and setting to work will be carried out Redco T&C in liaison with manufacturer/supplier. Note: Commissioning will not be commenced until the installation is signed off. B. Functional Test Functional test will be carried out by Redco T&C liaison with manufacturer/supplier as per approved procedure and witness by Redco T&C. Test includes mechanical and functional operation. Redco T&C will verify the results t hen offer for SE verification. 7.2.6 Chlorination of Portable Water System Disinfection will be carried out by in-house team under the specialist supervision. After commissioning the pumps and water distribution system the entire water supply network to


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be disinfected as per project specification and to meet Kahramaa water quality requirement. Disinfection process includes the following steps but not limited to:  Fresh

Water  Chlorination  Disinfect  De – Chlorination  Sample Analysis  Report (Lab Analysis Report) Final water quality: Inspection will be offered to SE for sample collection during the process and final t est results will be provided for verification and approval. 7.2.7 Packaged Water Softener A. Pre – Commissioning Pre-commissioning and setting to work will be carried out Redco T&C in liaison with manufacturer/supplier. Note: Commissioning will not be commenced until the installation is signed off. B. Functional Test Functional test will be carried out by Redco T&C in liaison with manufacturer/supplier as per approved procedure and witness by Redco T&C. Test includes mechanical, functional operation and water quality. Redco T&C will verify the results then offer for consultant verification.

7.3

C. Interface Test BACS interfaces test. Fire Fighting System

7.3.1

Installation Completion & Preparation Complete system readiness checks and prepare system readiness reports. Verify the following:

a) b) c) d) e) f) g) h)


Installation of piping completed and pressure tested. Installation of tanks and pumps are completed. Isolation and control valves are installed. Relief, reducing and check valves are installed. Installation of hose, cabinets, hydrants and sprinklers are completed. IRN Issued. Permanent electrical power wiring is complete. Ensure that continuous water source available.

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i) Pipes are filled and clean. j) Ensure that interfaces are completed with fire alarm system. k) Adequate access is available. 7.3.2

Fire Pump A. Pre - Commissioning & Start-up Pre-commissioning and setting to work will be carried out Redco T&C in liaison with manufacturer/supplier. Note: Commissioning will not be commenced until the installation of mechanical and electrical is signed off. B. System Performance Test Performance test will be carried out by the manufacturer representative approved by authority having jurisdiction in compliance to approved procedure and code NFPA 20 (Standards for Stationary Pumps) to ensure that system performance meets the codes and local authority's (QCDD) requirements. Field test will include Electrical, Mechanical performance, design flow, close head, system pressure and controller functionality verification. Redco T&C will ensure the satisfactory performance and record the field test data then offer for SE verification. C. Interface Test BACS Interface shall be performed by BACS Contractor. Fire Alarm Interface Cause & Effect Matrix

7.3.3

Fire Hose Cabinets A. Pre – Checks Redco T&C will carry out pre-checks and Pressure Release Valve (PRV) setting prior to functional test. Note: Commissioning will not be commenced until the installation is signed off. B. Functional Test Redco T & C will perform flow test to ensure that project specification and NFPA 14, 2013 edition requirements are met. Test includes static pressure, residual pressure and flow through. Redco T&C will ensure that requirements are met then for SE verification.


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7.3.4

Zone Control Valve & Sprinkler System A. Pre – Checks Redco T&C will carry out pre-checks and setting to work prior to functional test. Note: Test will not be commenced until the installation is signed off. B. Flow Test PRV setting, test drain, flow test will be performed by Redco T&C to ensure that project specification and NFPA 20 requirements are met for fire alarm interfaces. Sprinkler burst test will be performed to ensure the sprinkler coverage. Redco T&C will ensure that requirements are met then offer for SE verification. C. Interface Test BACS Interface shall be performed by BACS Contractor. Fire Alarm interface Cause & Effect Matrix

7.3.5

Clean Agent FM 200 System A. Pre – Checks Pre-checks, programming and setting to work is to be carried out by a specialist vendor prior to functional test. Room integrity test will be carried out by specialist to and offered for SE verification. Note: Functional test will not be commenced until the installation is signed off. However, functionality will be tested and demonstrated to consultant irrespective of integrity test. B. Functional Test Functional test will be performed by specialist to ensure that project specification and NFPA 2001 (Standard on Clean Agent Fire Extinguishing System) requirements are met. Test includes detector simulation and functionality of all field devices. Redco T&C will ensure the system operation then offer for SE verification. C. Interface Test BACS Interface shall be performed by BACS Contractor. Fire Alarm interface Cause & Effect Matrix

7.3.6

Fire Damper Drop Test


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The fire damper accessibility will be verified and drop test will be carried out as per project specification. The drop test will not be commenced until the installation is signed off. The system acceptance for the fire damper drop testing is that all dampers are accessible, identified and fusible links are provided and drop completely. Drop test will be carried out by Redco construction team and witnessed by Redco T&C and SPH. Redco T&C will witness the test and offer for SE verification. Stakeholder will be invited to witness fire damper drop tests. 7.4

Electrical System

7.4.1

Earthing A. Pre- Test Earthing to be visually checked for terminal, connection and to be tested by Redco Commissioning Team on completion of installation.        

Visual Check Earthing copper tape of adequate size. Installation work is as per acceptable standard Look for any incorrect positioning of copper tape. Location of each joint above ground and its type (e.g. weld, bolted etc.). Location, material, size and type of connection made above to equipment and structures Location of test points. A test link provided at the main Earthing terminal.

B. Measurements On the completion of any Earthing construction work the applicable measurements from the list below shall be carried out by in-house commissioning team for the following Parameters:  Continuity  

test. Earth resistance test at different points Earthing resistance measurement of main electrodes using a clamp meter

C. Assessment A report shall be provided to demonstrate that the design has been satisfied. The report shall include:   

Continuity Test report Earth resistance test report Confirmation that all design recommendations have been implemented.

Above field, test results and factory test reports will be submitted for verification and sign off.


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7.4.2

MCC panels A. Pre- Test MCC panels to be visually checked for proper installation and termination by panel Fabricator/Supplier and in-house commissioning team on completion of installation prior to energization as follows:      

Visual checks Protection relays, controls termination and Earthing. Torque of all connections Insulation resistance tests for panel bus bar Mechanical operation of breakers and interlocks if applicable. Breaker and protection relay setting.

ACB, MCCB and other protection relays to be set as per discrimination study as provided in the drawings or load requirements. B. Energization & Live Test Upon completing, the pre-test panel will be energized and following parameters will be verified:  Power sources such as Voltage, Frequency and Phase sequence will be recorded.    

VFD setting parameters to be recorded. Operation of metering devices and indication Electrical interlock test. Breaker trip test using test buttons. Fire interface and BACS points to be verified by simulation

Above field test results and factory test reports will be submitted for SE verification and sign off. 7.4.3 Distribution boards A. Pre- Test All switch boards to be visually checked for terminal, connection and to be tested by panel builder I supplier on completion of installation prior to energization as follows. Visual checks. Protection relays, termination and earth continuity test.  Torque of all connections  Breaker and protection relay setting  ACB, MCCB and other protection relays to be set as per discrimination study as provided in the drawings. B. Energization


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Upon completing the pre-test, panel will be energized and power source will be verified by in-house commissioning team. Such as Voltage, Frequency and Phase sequence will be recorded. C. Live Test Live test will be carried out by in-house commissioning team after permanent power has been made available. Test includes the following:    

Earth fault impedance. Residual current device test. Polarity test. Power source and Phase sequence test.

Above field, test results and factory test reports will be submitted for SE verification and sign off. 7.4.4 Variable Frequency Driver (VFD) A.

Pre- Test All VFD to be visually checked for terminal, connection and to be tested by VFD builder supplier on completion of installation prior to energization as follows.

 

Visual checks. Termination and continuity test. VDF study as provided in the drawings.

B. Energization Upon completing the pre-test, VDF will be energized and power source will be verified by in-house commissioning team. Such as Voltage, Frequency and Phase sequence will be recorded. C. Live Test Live test will be carried out on cable connected to the VFD by in-house commissioning team after permanent power has been made available. Test includes the following:        

Insulation Resistance test Earth fault impedance. Prospective earth fault current Prospective short current Polarity test. Power source and Phase sequence test. Frequency Voltage drop


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Above field, test results and factory test reports will be submitted for SE verification and sign off. 7.4.5 Automatic Transfer Switch (ATS) A. Pre- Test All ATS to be visually checked for terminal, connection and to be tested by ATS builder supplier on completion of installation prior to energization as follows.    

Visual checks. Termination and earth continuity test. Torque of all connections Transfer Switch setting

Rating of ATS shall study as provided in the drawings. B. Energization Upon completing the pre-test, ATS will be energized and power source will be verified by in-house commissioning team. Such as Voltage, Frequency, Voltage drop and Phase sequence will be recorded. C. Live Test Live test will be carried out on cable connected to the VFD by in-house commissioning team after permanent power has been made available. Test includes the following:        

Insulation Resistance test Earth fault loop impedance. Prospective earth fault current Prospective short current Polarity test. Power source and Phase sequence test. Frequency Voltage drop

Above field, test results and factory test reports will be submitted for SE verification and sign off. 7.4.6 Lightning Protection System A. Pre- Test All Lightning Protection system to be visually checked for terminal, connection and to be tested by Lightning Protection system builder supplier on completion of installation prior to connected to the earth rod as follows. 

Visual checks.


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

Termination and copper tape continuity test.

Lightning Protection system shall study as provided in the drawings. B. Commissioning Upon completing the pre-test, Lightning Protection system will be verified by in-house commissioning team. Such as Continuity, earth resistance test will be recorded. Above field, test results and factory test reports will be submitted for SE verification and sign off. 7.4.7

Lighting System Complete system testing and commissioning will be carried out by Specialist/Vendor in liaison with Redco commissioning team. A. Pre- Commissioning Complete system testing and commissioning will be carried out by Specialist/Vendors in liaison with Redco commissioning team. 1. Redco will be held responsible for the physical adjustment of all fixtures after they have been installed and connected. Redco will provide all labor, materials and equipment to complete this task. 2. Upon completion of the electrical works and energization of the system, Redco shall carry out all checks as considered necessary as to the correctness of the aiming in accordance with both the lighting design parameters and the accepted final design illuminance plots. All adjustments that are found necessary shall be carried out at this stage by Redco at no additional cost, under the requirements of the Contract. 3. Upon satisfactory completion of all testing and rectification work (if required), Redco shall submit a detailed lighting test report to the Supervision Engineer advising the status of the installation and incorporating sufficient information to substantiate the claim. 4. After physical completion of the entire Contract and other works associated with the project and in addition to the contractual obligations outlined above, Redco will be required to attend and to assist in the final commissioning and testing of the completed installation. 5. All final adjustments to the luminaires found necessary by the Supervision Engineer to achieve the tendered performance or to correct irregularities in the installation, shall be carried out by Redco during the final programmed commissioning period. 6. The above provision shall be in addition to all attendance and work required to satisfy the same objectives up to the completion of the Contract works prior to final commissioning (as described in above Clause) for which full allowance shall be made in the tendered offer. 7. During this period, Redco shall carry out all necessary tests, in company with the Supervision Engineer, as may be necessary to demonstrate compliance with the


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specification and the tendered offer. Any corrective measures necessary to achieve the specified requirements shall be carried out by Redco within the above allowance.

7.4.8

B. Commissioning Network Checks Control System Checks Performance Check Continuity Test of Cables Fire Alarm System A. Pre- Test All Fire Alarm Panels, detectors to be visually checked for terminal, connection and to be tested by Fire Alarm subcontractor on completion of installation prior to energization as follows.  Visual inspection of all fire alarm detector, devices etc. connected to the fire alarm.  Installation work is as per acceptable standard.  Look for any incorrect positioning of sensors or other devices.  Continuity & Insulation Resistance of FP200 Cable.  Detectors and other components addressed. B. Function Test Function of system is tested in accordance with job specifications, manufacturer recommendations and authorities' requirements and adjusted as required. Test of panel functionality, LED's, fuses, etc.  Test panel battery charger  Battery discharge test  Test of horns, strobes, & bells etc.  Test of smoke detectors  Test of heat detectors  Test of duct smoke detectors  Pull stations 

C. Live Test Live test will be carried out by subcontractor commissioning team after permanent power has been made available. Test includes the following:     

Interface Equipment Lamps/LEDs Primary Power Supply Trouble Signals Disconnect Switches


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

Ground Fault Monitoring

System will be commissioned and maintained to ensure correct operation in accordance with relevant standards, and manufacturer and job specifications Above field, test results and factory test reports will be submitted for Supervision Engineer verification and sign off. D. Interface Test

7.5

System

Action

Fire Pump

Supervisory Signal

Fire Water Flow Switch

Alarm Activation

Sprinkler Valve – Tamper Switch

Supervisory/Alarm Signal

FM 200 System


HVAC Equipment’s


WC Ventilation Fan


Smoke Extract System


Stairwell Pressurization


Interface Test Redco shall take all necessary steps to ensure that the work under the Subcontract are coordinated and integrated with the works of the Interfacing Parties and shall comply with any directions which the Contractor may give for the integration and/or coordination of the Works with the work of the Interfacing Parties. For interface test a dedicated method statement will be prepared by Redco T&C team. After internal interfaces accomplished, BACS & MSI scope interface tests will take the lead. Redco will provide support for these integration tests where necessary.

7.5.1

Cause and Effect Testing The objective of the test is to ensure, system integration between fire alarm, fire detection, firefighting, air conditioning, ventilation, smoke extract, all life safety related systems are responding as per approved cause and effect matrix incompliance to local authority (QCDD) requirements. Redco T&C will conduct the t est liaison with Specialist/Vendors to ensure the system interface as detailed above then offer for Supervision Engineer verification.


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Stage 5 Integration Testing In Lead of Redco Internal Integration Testing

In Lead of BACS

In Lead of MSI

Couse Effect Testing



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Black-out Testing

The main tests, aims and objectives are limited only for Interface tests of follows, mains power failure tests with system health. By definition to prove Switchgear/Generator switching matrix systems, together with the BACS interfacing/monitoring. Above to be proven in a fire condition, verifying alarm cause and effect matrix including all plant and equipment involved in life safety system are to be operational. Note it is not the intention to repeat any of the tests that must be completed as prerequisites prior to commencement of these tests. The principle aim is to assess the overall impact of the system operation and failure on the fully loaded facility. 8 CLIENT TRAINING After completion of testing and commissioning, each system's and sub system's trainings shall be provided to the operator/owner to demonstrate the proper manner of operating the Equipment, making adjustments, responding to alarms and emergency signals, and maintaining the systems. Each system will include a training as defined in the ElectroMechanical Specifications Parts or as with the Employer's Representative. Training procedures and O&M manuals are to be submitted separately to this T&C plan to specify all its particularities and specific methodology.


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A. Training Manual Training manual for each system and sub-system will be submitted for each training course covering both classroom and on-the-job training for client review and approval as specified in the Electro-Mechanical specifications parts ( M007-MML-MEP-SPE00004_REV5.0 (1 )). In the training manual, it will include valuable source of information to the operator & maintainer about the equipment or the system. The following will be taken in consideration in the training manual; Content – topics, tasks, procedures and other information arranged in a logical sequence and broken down into small units; Overview of Equipment/System Operating Operating Directories o Emergency Operation o Considerations & General Advices for Operator o Problems & Solutions o Security Precautions o Related Parties Contact Details o Maintenance Maintenance Directories o Considerations & General Advices for Maintainer o Troubleshoots o Periodic Maintenances o Security Precautions o Related Parties Contact Details o



 



B. Training Schedule Training schedule will be provided for owner I operator attendance with at least 7 days of notice. C. Training Execution Training session will be divided into class room lecture training or "on-the job" training shall be provided as per approved training manual and schedule. Class room training shall not exceed maximum of 2 hours. "On-the-job" training shall be scheduled for entire 8-hour shift. Note: The detailed training plan and manual shall be submitted separately as part of handing over documentation. 9 FINAL DOCUMENTATION & HANDOVER After Acceptance Certificates (AC) are issued also Handover mechanism shall be started and operational staff will be involved in the activities. In parallel with the completion of System


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Performance Tests Redco T&C will start providing all final commissioning documentation including Validation & Verification to Redco "Close Out" team for incorporating into the final dossier and Operation & Maintenance Manual. Final documentation consists of compilation of test pacts which consists of;  

     

Equipment Data Sheets Manufacturer commissioning report Calibration certificates Drawings IRN PCC PAC AC C of C

This documentation will be available as part of the O&M Manuals and in coordination to BIM requirements. Redco “Close Out Team” will provide a Handover Plan for clarifying the procedures, schedules. Detailed information for this documentation are followings; 9.1 Equipment Data Sheets This part shall be comprised of equipment data sheet provided by the manufacture for every installed system: A datasheet, or spec sheet is a document that summarizes the performance and other technical characteristics of a product, machine, component (e.g., an electronic component), material, a subsystem (e.g., a power supply) or software in sufficient detail to be used by a design engineer to integrate the component into a system. Typically, a datasheet is created by the component/subsystem/software manufacturer and begins with an introductory page describing the rest of the document, followed by listings of specific characteristics, with further information on the connectivity of the devices. Depending on the specific purpose, a datasheet may offer an average value, a typical value, a typical range, engineering tolerances, or a nominal value. The type and source of data are usually stated on the datasheet. 9.2 O&M Manuals The following equipment data content shall be available for in Operating and Maintenance Manuals:     

Description of Equipment Record Product Submittals Parts List. Recommended Spare Parts List. Normal Operating Instructions.


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Emergency Operating Procedures.  Preventive Maintenance  Calibration  Trouble Shooting Procedures  Removal and Installation Instructions  Repair Instructions  System Drawings.  Special Tools and Test Equipment. 

Note: Redco T&C Team shall not produce these documents. Redco T&C Team will be responsible for leading to O&M manuals preparations. 9.3

Manufacture Commissioning Report & Calibration Certificates Manufacture Commissioning Report This Part shall be comprised of commissioning and validation reports provided by the manufacture for every installed system and shall include: Introduction to system/element and the activities that took place during testing/commissioning Factory Acceptance records





Calibration Certificate Detailed data on what to calibrate, how to calibrate, when to calibrate and procedures to enable checking the equipment for reliability or indications as well as data for test equipment, special tools and the location of test points. 9.4

Drawings   

10

An index shall be provided for all ‘as-built’ drawings as set. Numbers of copies and format for as-built records shall be as set out. As-built plans including services (CAD format). These are to be a measured full set at completion of the works

ANNEXURE Annexure A

- Commissioning Responsibility Matrix

Annexure B

- Commissioning Team Member Contact Details

Annexure C

- Authority Interface Matrix

Annexure D

-Testing & Commissioning Procedure Log

Annexure E

- Commissioning Deliverable Schedule


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Annexure F

- Corrective Action Flow Chart

Annexure G

- Commissioning Issue Log

Annexure H

- Process Flow RACI Chart

Annexure I

- FAT Tracker (Schedule)

Annexure J

- Progress Report

Annexure K

- Test Pack

Annexure L

- Test Report Tracker

Annexure M

- Organization Chart


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ANNEXURE A COMMISSIONING RESPONSIBILITY MATRIX


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Commissioning Responsibilities Matrix LEGEND A - Approval / Acceptance P - Prepare S - Supervise R - Review W - Witness / Monitor E - Execute

DESCRIPTION General Commissioning Requirements Commissioning Plan & Updates

R, A

R

E

R

P, E

Commissioning (Updates, Mitigati on Plans, Critical Path)

R, A

R

E

R

P, E

Production of T&C, Checklist, Procedure etc Templates

R, A

R

E

R

P, E

Develop Prefunctional Checklists

R, A

R

E

-

P, E

Develop Functional Performance Tests

R, A

R

E

-

P, E

Develop Integrated Systems Test

R, A

R

E

-

P, E

Tracking Report

R, A

R

-

-

P, E

Operations and Maintenance Manuals

R, A

R

P

P

P, E

Training O&M

W

S

P, E

S

W

Final Commissioning Close-out Report

A

R

-

-

P, E

P

-

Mechanical HVAC / Building Automation Systems Equipment Submittals

R, A

P

-

Ductwork Pressure Testing Plan

A

R

E

R

P

Field Ductwork Pressure Testing

A

R

E

W

S

Hydronic Piping Flushing and Testing Plan

A

R

E

W

P

Hydronic Piping Hydrostatic Testing

A

R

E

W

S

Supervision Engineer shall be responsible on behalf of the REDCO

Hydronic Piping Flushing

A

R

E

W

S


Equipment Prefunctional Checklists

A

R

E

R

P, E

A

R

E

W

S

A

R

E

W

S

A

R

E

W

S

Equipment Startup Testing, Adjusting and Balancing Functional Performance Testing


Supervision Engineer/Certified Manufacturer Representative shall be responsible on behalf of the REDCO Supervision Engineer/Certified Manufacturer Representative shall be responsible on behalf of the REDCO Supervision Engineer/Certified Manufacturer Representative shall be responsible on behalf of the REDCO

Electrical Systems Equipment Submittals

R, A

P

-

R

-

Coordination Study

A

P

P

R

R

Electrical Dead Testing

A

R

E

W

S


Electrical Cable Live Testing

A

R

E

W

S


Equipment Pre-Functional Checklists

A

A

E

R

P, E


A

R

E

W

S

A

R

E

W

S

A

R

E

W

S

Equipment Submittals

A

P

-

R

-


A

R

E

R

P, E

A

R

E

W

S

A

R

E

W

S

Submittals

A

P

E

R

-

Fire Alarm 3rd Party shall be responsible on behalf of the REDCO


A

P

E

R

S


System Startup

A

P

E

R

S


Functional Performance Testing

A

P

E

R

S


Fire Alarm Acceptance Testing

A

P

E

R

S


Submittals

A

P

E

R

-

Piping Pressure Testing and Flushing Plan

A

P

E

W

S

Hydrostatic Testing

A

P

E

W

S


A

P

E

W

P, E

A

P

E

W

S

A

P

E

W

S

A

P

E

W

S

Energize Equipment / Startup Functional Performance Testing Power Status and Monitoring System Verification


Plumbing Systems

Equipment Startup Functional Performance Testing

Supervision Engineer/Certified Manufacturer Representative shall be responsible on behalf of the REDCO Supervision Engineer/Certified Manufacturer Representative shall be responsible on behalf of the REDCO

Fire Alarm System

Fire Protection Systems

Equipment Startup Fire Pump Testing Functional Performance Testing




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ANNEXURE B COMMISSIONING TEAM MEMBER CONTACT DETAILS


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COMMISSIONING TEAM MEMBER CONTACT DETAILS Item No.

Name

Designation

System

Contact

Responsible 1.

2.

S. Burak Oral

T&C Manager

TBA

T&C Deputy Manager

3.

4.

TBA

TBA

6.

TBA

TBA


All systems

Senior Mechanical

Mechanical

Engineer

Systems

Senior Electrical Engineer

5.

All systems

Electrical Systems

Senior Public Health

Public Health

Engineer

Systems

Senior Fire Fighting

Fire Fighting

Engineer

Engineer Systems

[email protected] TBA

TBA

TBA

TBA

TBA

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COMMISSIONING TEAM MEMBER

Company

Contact Name

Contact Details

EMPLOYER PRIMARY CONTACT QATAR TBC Mobile: Email: RAIL ENGINEER ASSISTANT PRIMARY CONTACT/PSH COMMISSIONING MANAGER PMC

TBC

Mobile:

SPH

TBC

Mobile: Email:

Email:

Sub-CONTRACTOR Sub-CONTRACTOR PRIMARY CONTACT/MECON COMMISSIONING MANAGER REDCO

Jaffer Ibrahim

Mobile: 33194898 [email protected] [email protected]

MECON

Burak Oral

Mobile: 31579429 Email: burak.oral@mecoyappi [email protected] .com


Email:

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ANNEXURE C Authority Interface Matrix


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LOCAL AUTHORITIES INVOLVEMENT FOR FINAL INSPECTION AND APPROVAL

ASHGAL

KAHRAMAA

MOI

QATAR COOL

QCDD

OOREDOO

/ Water Meter Cabinet

QATAR FOUNDATION

Fire Fighting System

MV & LV Distribution Ventilation System

Earthing & Lightning Pressurization System

Energy Meter

Fire Alarm System

Cause and Effect

Green colored box just for information if needed and is not for approval.


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ANNEXURE D TESTING AND COMMISSIONING LOG (Sample)


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ANNEXURE E COMMISSIONING DELIVERABLE SCHEDULE


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(Annexure – E) MEP Commissioning Deliverable Schedule Item No.

1.

Deliverables

Remarks

Coordination Commissioning Plan

3.

Organizational Chart

4.

T&C Method Statement

5.

Issue Log

6.

Commissioning Program Schedule

8.

Date

Commissioning Kick-off Meeting and

2.

7.

Plan Submission

T&C Test Pack Tracker / Commissioning Process Monitoring (CPM) Log T&C Documentation Tracker / Commissioning Inspection Monitoring (CIM) Log

9.

Pre-Commissioning Certificate (PCC)

10.

Partial Acceptance Certificate (PCA)

11.

Acceptance Certificate (AC)

12.

Certificate of Completion (CofC)


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ANNEXURE F CORRECTIVE ACTION FLOW CHART


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PRE - COMMISSIONING

START – UP

RETEST

FUNCTIONAL /

FAIL Investigate the cause of

PERFORMNCE

Deficiency

TEST

Prepare Corrective

PASS

Action Report

Estimate the Time PREPARE TEST PACK

Required for Action

Carryout the QDC/SPH REVIEW &

recommended

ACCEPTANCE

Correction


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ANNEXURE G Commissioning Issues Log


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Date

System

Service


Level

Issue

Category

Raised By

Commissioning Issue Log Solution Assigned to Close Date

Page 72 of 133

Status

ANNEXURE H PROCESS RACI CHART


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KEY R A C I

Process Participants s

Responsible r c

ib

C o

P

Approve Contribute

n

itl ot i at s

Commissioning Plans & Deliverable. Preparing Updating the Commissioning Plane. Define/Preparing FAT Schedule and Procedure. Preparing/Updating the T&C Procedure(MES)& Log Producing Commissioning Program (T&C Tracker &2WLA) Preparing/Updating Commissioning issue log

M n

o p C s e R

informed

.t p

CommissioningAuthority ei

r o t c a r t n o C b u S

A

C

R

A

I

R

A

C

R

I

I

R

I

I

R

Tracking of Deliverable Flow

.t p m e et D s T

&

C y S

n e V / t s i l a i c e p S

g r

c

iot

n t

D p

ur

e D r

n in o

T

g n IV

E

C

C

A

C

C

R

C

A A

C

C

C Q D

e &

D e

s

C d

e p

e

o

p t.

ni

R

C

.t

e

.t

/ A

C Q

C

C C

C

C

I C

C

I

Commissioning Strategy(Inspection, Testing & Commissioning) Installation Inspection allowing T&C to Start

I

C

I

R

A

Installation test allowing T&C to start

I

C

I

R

A

Factory Acceptance Test

I

C

R

C

I

A

PSAT

I

R

C

A

R

C

SAT

I

R

C

A

C

I

C

Final Commissioning (SAT+SIT+SPT)

I

I

R

R

A

C

I

RAM Demonstration

I

I

R

R

A

C

I

Authorities Inspection (QCDD,Kahramaa)

C

I

R

R

C

C

C

I

R

C

A

C

I

RAM Demonstration Report.

I

R

R

R

A

C

FRACAS Report(In Case of Failure)

I

R

R

R

A

C

Completion Documents Preparation of Final Test Packs T&C IRE Submission.

C

CCP Submission for System/Station

I

C

R

A

I

I

CCP Submission for System/Tunnel

I

C

R

A

I

I

Validation of ER- Report

I

R

R

A

C

Hazard Log-Report

I

R

R

A

C

Interface Register -Report

I

R

R

A

C

GSAS Log -Report

I

R

R

A

C


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ANNEXURE I FAT Tracker (Schedule) Sample


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ANNEXURE J 3 WLA & Progress Report


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Progress Report


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ANNEXURE K DISTRIBUTION BOARD TEST PACK (Sample Shall be Submitted Separate)


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v


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Annexure L Test Report Tracker


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Annexure M Organization Chart


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Test Commissioning Plan Rev 1 Al Ri

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