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AfDB Field’s office in Abuja ‐ Nigeria
Lot 3: Vol 5 ‐ Commissioning Plan
Prepared by: Apave Liban s.a.r.l.
For : Aim Consultants Ltd.
AfDB Field office in Abuja
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Table of contents
Introduction …………………………… 3
I‐ Overview of the commissioning process …………………………… 4
II‐ Systems and assemblies included in the CA’s scope of
work
…………………………… 4
III‐ Commissioning team and its responsibilities …………………………… 4
IV‐ Description of management, communication and
reporting of commissioning process
…………………………… 7
V‐ Commissioning Plan …………………………… 8
VI‐ List of expected work products …………………………… 9
VII‐ Testing equipment …………………………… 10
VIII‐ Commissioning process milestones and schedules …………………………… 10
IX‐ Commissioning check‐lists and testing procedures …………………………… 11
Check‐lists annexes:
Annex 1: T&C for Electrical Installation
Annex 2: T&C for Generator Installation
Annex 3: T&C for Split Unit System
Annex 4: T&C for AHUs and VAVs
Annex 5: T&C for Chillers and Accessories
Annex 6: T&C for Cooling Pumps
Annex 7: T&C for Domestic Water System
Annex 8: T&C for FCU
Annex 9: T&C for Fans
Annex 10: T&C for BMS
Annex 11: T&C for Metering Systems
Annex 12: T&C for VRVs
Annex 13: T&C for PV System
Annex 14: T&C for Solar Heating System
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Introduction
The commissioning plan is the reference document that identifies the strategies, aspects and
responsibilities within the commissioning process for each phase of the project for all project team members.
This document outlines the overall process, schedule, organization, responsibilities and documentation
requirements of the commissioning process for all commissioning team members.
The commissioning plan is developed at the start of the commissioning process, and is updated during
the course of the project to reflect any changes in planning, schedule or other aspect.
The required commissioning plan components as per LEED reference guide for green building design and
construction are as follows:
Required commissioning plan components:
I Brief overview of the commissioning process.
II List of all systems and assemblies included in commissioning authority’s scope of work.
III Identification of commissioning team and its responsibilities.
IV Description of management, communication and reporting of commissioning process.
V Overview of commissioning process activities for pre‐design, design, construction,
occupancy and post‐occupancy phases.
VI List of expected work products.
VII List of commissioning process milestones.
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I‐ Overview of the commissioning process
Commissioning intent is to verify that the project’s energy related systems are installed, calibrated and
perform according to the owner’s project requirements, basis of design and construction documents and to
provide the owner with a high level of assurance that the mechanical and electrical systems have been
installed in the prescribed manner, and operate within the capabilities of the documented design and specified
equipment capacities.
In order to comply with the LEED requirements, the commissioning plan will be divided into two levels called
“Fundamental Commissioning” of building energy systems which is prerequisite for the system and
“Enhanced Commissioning” with its optional credits.
The prerequisite intent is to verify that the project’s energy related systems are installed, calibrated and
perform according to the owner’s project requirements, basis of design and construction documents.
The Commissioning authority will verify the installation and performance of the systems to be commissioned,
and will complete a summary commissioning report as part of the Fundamental commissioning process.
The commissioning authority will document all commissioning review process, submittals, system manual,
verify O&M training and review building operation after 10 month of final acceptance.
II‐ Systems and assemblies included in commissioning authority’s scope of work
The scope of services for the commissioning authority is based on the owner’s project requirements.
Thus, as requested by the owner, the mission will cover the following base building systems:
Ventilation systems(Supply air, Return air, Exhaust air)
HVAC and associated control systems
Chilled water
VRV system
Domestic water heating
Water distribution systems
Domestic water treatment
Electrical power generation and distribution systems
Building Management System
Sub‐meters and central electronic monitoring system
Lighting and lighting controls
Renewable energy systems
III‐ Commissioning team and its responsibilities
“Commissioning team” as defined in ASHRAE’s commissioning guide; it’s “Those people responsible for
working together in carrying out the commissioning process”.
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Commissioning, at every stage of a project, is a collaborative effort between all parties to the construction
project; it’s a team effort and requires communication, coordination and cooperation among all parties
involved with the project. The commissioning authority is the leader of the team.
By clearly establishing the Commissioning Team and individual responsibilities, the process execution
becomes easier, more effective and more accountable.
Below are the commissioning team members, along with their individual responsibilities in the commissioning
process during project phases.
A. Owner (The African development Bank)
1‐ Include a statement regarding commissioning responsibilities in request for design services.
2‐ Develop and commit to the Ownerʹs Program for the facility and its use.
3‐ Assign operations and maintenance personnel and schedule them to participate in the
various meetings, training sessions, and observations/inspections.
4‐ Review and approve any changes made to design intent.
5‐ Review and approve the construction documents.
6‐ Provide qualified personnel for videotaping and editing of training sessions.
7‐Videotape construction progress.
8‐ Review and comment on the commissioning authorityʹs verification report.
9‐ Review and accept the commissioning authorityʹs commissioning report.
B. Commissioning Authority (Apave)
1‐ Organize and lead the commissioning team.
2‐ Prepare a program‐phase Commissioning Plan that describes in general the extent of the
commissioning process to accomplish the Ownerʹs Program and the initial design intent.
3‐ Develop the design‐phase Commissioning Plan, which details the extent and activities of the
commissioning process including commissioning team organization, schedule, training, and
documentation requirements and all related testing, verification, and quality control
procedures.
4‐ Execute the commissioning process through attending meetings, tests, demonstrations,
training events, and performance verifications.
5‐ Review the plans and specifications with respect to their completeness in all areas relating to
commissioned systems. This includes ensuring that the design phase Commissioning Plan has
been followed and that there are adequate devices included in the design to ensure the ability to
properly test, verify, and adjust the systems. Any items required but not shown shall be
brought to the attention of the Owner.
6‐ Receive and review the operations and maintenance (O&M) manuals as submitted by the
contractor. Ensure that they follow the specified outline and format. Insert systems description
as provided by the design professional in the Systems Manual.
7‐ Witness equipment, subsystem, and system start‐up and testing. Ensure the results are
documented, including a summary of deficiencies, and incorporated in the O&M manuals.
8‐ Supervise the commissioning team members in the functional performance tests. The test
data will be part of the commissioning report.
9‐ Ensure that the O&M manuals and all other as‐built records have been updated to include all
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modifications made during the construction phase.
10‐ Prepare the final commissioning report and the systems manual.
11‐ Review operation after 10 month of completion.
C. Design / Technical Control Consultants
1‐ Provide system design parameters and revisions to the initial design intent document as
necessary, obtaining approval of the owner.
2‐ Prepare contract documents, including the commissioning specification and description of
the commissioned systems.
3‐ Attend construction‐phase coordination meeting.
4‐ Specify and verify adequate maintenance accessibility for each piece of equipment in shop
drawings and actual installation. Periodic inspections are part of the design professionalʹs
construction administration duties.
5‐ Develop an overview of system design and operation concepts for the Systems Manual.
6‐ Review and accept as‐built records as required by contract documents and turn them over to
the commissioning authority.
D. Contractor/Sub‐contractor/Supplier
1‐ Include costs for commissioning requirements in the contract price.
2‐ Include requirements for submittal data, O&M data and O&M training in each purchase
order or subcontract written.
3‐ Ensure cooperation and participation of specialty subcontractors and controls contractors.
4‐ Ensure coordination, installation, and operation of interfaces between commissioning team.
5‐ Ensure participation of major equipment manufacturers in appropriate training and testing
activities.
6‐ Attend construction‐phase coordination meeting scheduled by the commissioning authority.
7‐ Prepare necessary preliminary schedule for commissioned system orientation and
inspections, O&M manual submission, training sessions, equipment and systems’ testing, for
use by the commissioning authority. Update schedule as appropriate throughout the
construction period.
8‐ Attend initial training sessions, and conduct system orientation and inspection at the
equipment placement completion stage. Update drawings to record condition to date, and
review with the commissioning authority.
9‐ Gather O&M data on all equipment and assemble in binders as required by the
commissioning specification. Submit to commissioning authority prior to the completion of
construction.
10‐ Notify the commissioning authority when equipment and system start‐up and testing can be
witnessed.
11‐ Schedule equipment suppliers and contractors to participate in the O&M training sessions.
12‐ Conduct a system orientation and inspection with hands‐on training. Update drawings to
record condition to date, and review with the commissioning authority prior to the orientation.
13‐ Provide written notification to the construction manager and commissioning authority that
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the following work has been completed in accordance with the contract documents and that the
equipment, systems, and subsystems are functioning as required.
14‐ Demonstrate the operation of each piece of equipment to the commissioning authority.
Schedule subcontractors as may apply to demonstrate the operation of the equipment and
systems.
15‐ Provide services of an engineer to participate in verification tests.
16‐ Turn over a set of as‐built records to the commissioning authority. (Hard and soft copies)
17‐ Provide filled checklist data sheets to document verification tests for the commissioning
authority.
18‐ Submit detailed verification test procedures and data sheets for review by the design team.
19‐ Submit detailed list of test instrumentation with appropriate calibration records to be
utilized for verification. Record data as necessary.
20‐ Submit verification test data to the design team and the commissioning authority for review.
21‐ Conduct tests and verifications including opposite season tests, as required.
22‐ Retest if performance deficiencies are found and corrected and additional testing is
requested.
23‐ Repeat all required testing and verification procedures after 10 months of client’s
occupancy.
IV‐ Description of management, communication and reporting of commissioning process
Whole Building Commissioning is a process that relies upon high levels of communications and collaboration
between all parties to the construction process. By its nature, the levels of communication and cooperation
between the Commissioning Authority and all other parties to the construction process (Design team,
Engineers, Subcontractors, Vendors, third party testing agencies, etc.) is essential to the success of the
Commissioning effort. In the absence of these relationships, cooperation and support created by this
communication, the Commissioning Process will likely fail to achieve its ends.
With this fundamental conflict in mind, this section has been developed to recognize that, in the execution of
the Commissioning Process, the Commissioning Authority must develop effective methods to communicate
with every member of the construction team involved in delivering commissioned systems while
simultaneously respecting the exclusive contract authority of the Contracting Officer and his/her Designated
Representative.
The organizational process chart below shows lines of contractual authority in this project, yet
communications are encouraged between all commissioning team members, within the limit of their contracts.
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V‐ Commissioning Plan
The commissioning plan is implemented during the construction phase. Direct interaction between the
construction team and the commissioning authority and communication with the design team represents the
cornerstone of successful commissioning.
The commissioning authority provides leadership by communicating goals for the commissioning process,
including identification of roles and responsibilities of team members, and clearly defining and documenting
pass/fail criteria. Each commissioning team member shares a responsibility to support the commissioning
process and achieve a quality installation.
The sequence and timing of commissioning activities must be incorporated into the overall project schedule.
The commissioning authority identifies the required commissioning activities. Coordination requires input
from the owner, designer, and contractors. Cooperation among the parties facilitates integration of
commissioning into the total construction program.
At this stage, the commissioning authority obtains and reviews submittal data, and consults with the
designers and contractors regarding conformance with the design intent. The designer provides final approval
of all submittals.
The commissioning authority should work with the general contractor to schedule commissioning meetings in
conjunction with regular progress meetings, because many participants will attend both. The commissioning
authority keeps meeting minutes.
All commissioning team members are responsible for attending commissioning meetings and for completing
assigned action items by the agreed dates. Cooperation by all parties contributes to successful commissioning.
The contractor is responsible for preparing the O&M documentation and training program in accordance with
specification requirements.
Client
AfDB
Main contractor
To be defined
Subcontractors / Suppliers
To be defined
Project Manager
Design Consultants
Technical Control
Consultants
AIM
LEED Consultant
SEEDS
Commissioning authority
Apave
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The O&M training program should include:
Design intent.
System limitations.
Start‐up and shut‐down procedures.
Modes of control and operation sequences.
Detailed review of the information and organization of the O&M manual.
Complete listing of contractors and manufacturer contact information.
Complete listing of spare parts.
Detailed instructions on the control system.
Routine preventative maintenance procedures as specified by the designer or recommended by the
manufacturer.
Provisions for safety shutdowns, emergency conditions, and interfaces with building management
systems (BMS) and life‐safety systems (such as fire protection).
Video tapes of the training sessions to allow future use.
At the last phase of this stage, the commissioning authority will be responsible of preparing a summary
commissioning report.
This report uses the final commissioning plan as its template. The report includes all system verification and
start‐up checklists, and all functional performance test checklists, completed with all test observations,
problems encountered, corrective actions taken, and re‐test results dated and signed by those carrying out and
witnessing the tests.
Where the checklists make reference to other test reports, copies of those reports must be appended. The final
commissioning report should contain an executive summary addressing design intent conformance for all
commissioned equipment and systems. The report should include references to all relevant commissioned
system documentation, and should be organized and tabulated to facilitate access to specific information.
The commissioning authority will make a site review within 10 months after substantial completion, along
with the contractor and all concerned subcontractors.
Functional tests and verification will be repeated in order to get the required information.
Commissioning authority will then have to make another report concerning this site review.
VI‐ List of expected work products
Commissioning intent, as mentioned earlier in this report is to verify that the project’s energy related systems
are installed, calibrated and perform according to the owner’s project requirements, basis of design and
construction documents and to provide the owner with a high level of assurance that the mechanical and
electrical systems have been installed in the prescribed manner, and operate within the capabilities of the
documented design and specified equipment capacities.
Therefore our mission will be to provide the owner, in our final commissioning report and our site review
within 10 months of occupancy, with an objective point of view of the actual state of MEP equipment.
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VII‐ Testing equipment
It is be noted that all test equipment required for performing the specified tests shall be provided by
contractors. Any proprietary vendor specific test equipment shall be provided by that vendor or manufacturer.
Any portable or hand‐held setup / calibration devices required to initialize any control system shall be made
available by the control vendor (at no cost) to the commissioning authority.
The instrumentation shall meet the following requirements:
‐ Be of sufficient quality and accuracy to measure system performance within the tolerances required.
‐ Be calibrated with calibration tags permanently affixed to the instrument.
All items needed to undertake testing and verification as described in the attached annexes should be
provided by the contractor.
VIII‐ Commissioning process milestones, schedules
Commissioning milestones and schedules cannot be determined exactly for the time being, but will be
integrated to this report during future revisions once we receive the detailed construction planning.
The startup and testing of systems may proceed prior to final completion of systems. However, the
commissioning authority shall not perform checkout services that are the primary responsibility of the
contractor vendor in advance of their testing and checkout, whom in return are responsible to inform the
commissioning team once their systems are ready to be verified and tested.
Problems observed will be addressed immediately, responsible parties will be notified.
Contractor schedules and scheduling is the responsibility of the construction manager. The commissioning
authority shall provide commissioning scheduling information to the construction manager for review and
planning activities.
The commissioning process does not relieve any contractors from their obligations to complete all portions of
work in a satisfactory manner.
Throughout project construction, the following table including all systems to be commissioned will be
updated.
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Systems to be commissioned
System: Pre‐functional
checklists
Equipment
startup
Functional
testing
Sample
size Target date:
Supply air
Y/N Y/N Y/N % N/A
Return air
Y/N Y/N Y/N % N/A
Exhaust air
Y/N Y/N Y/N % N/A
Chilled water
Y/N Y/N Y/N % N/A
Hot water
Y/N Y/N Y/N % N/A
HVAC and control
Y/N Y/N Y/N % N/A
VRV Y/N Y/N Y/N % N/A
Domestic water heating
&distribution Y/N Y/N Y/N % N/A
Domestic water treatment
Y/N Y/N Y/N % N/A
Electric power generation
and distribution
Y/N Y/N Y/N % N/A
BMS Y/N Y/N Y/N % N/A
Sub‐metering & electronic
monitoring Y/N Y/N Y/N % N/A
Lighting and related controls Y/N Y/N Y/N % N/A
IX‐ Commissioning check‐lists and testing procedures
Commissioning check‐lists and systems’ testing and verification procedures shall be filled by the resident
consultant engineer and the concerned subcontractor.
The commissioning authority will direct and witness some verification operating tests and checks.
The testing contractor’s technician will inspect and verify the position of each device and interlock that is
identified on the checklist. Each item shall be signed off as acceptable or failed.
This test will be repeated for each operating cycle that applies to the system being tested.
Operating checks shall include all safety cutouts, alarms, and interlocks with smoke control and life safety
systems during all modes of operation of the system.
If, during a test, an operating deficiency is observed, appropriate comments shall be added to the checklist
data sheet.
The Interface of the monitoring and control system shall be verified.
The proper response of monitoring and control system controllers and sensors shall be verified.
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Final verification:
APAVE will direct and witness the field verification of the final testing report.
APAVE will select at random percentage of the report data for verification.
The contractor shall be given sufficient advance notice of the date of field verification. However, he shall not
be informed in advance of the data points to be verified. The test engineer must use the same instruments (by
model and serial number) that were used when the original data were determined.
Failure of an item is defined as the following :
‐ For all readings other than sound, a deviation of more than 10%.
‐ For sound pressure readings, a deviation of 3 decibels.
‐ A failure of more than 10% of the selected items shall result in the failure of acceptance of the final
testing report.
All these deviations are to be followed, unless otherwise referred to or specified.
Failure of the final testing and balancing report shall require contractor to complete the following work.
‐ Any system failing the verification procedure must be rechecked and corrected.
‐ New total system testing and verification reports must be provided.
‐ Field verification of the new testing and balancing report must be performed.
If deficiencies are identified during verification, the construction manager will be notified and action taken
to remedy the deficiency. Once verification is completed, the commissioning authority will provide a
verification report to the owner.
Check‐lists and testing procedures are found in the annexes of this report.
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Testing & Commissioning Procedure
Electrical Installation
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Table of Contents 1 – Introduction: ........................................................................................................................................... 3
2 – Objective of the T & C: ............................................................................................................................ 3
3 – Scope of the T & C Works: ....................................................................................................................... 3
3.1 – Preliminary Steps for Testing and Commissioning: .......................................................................... 3
3.2 – Tests & Inspections during Construction: ........................................................................................ 4
3.3 – Functional Performance Tests: ........................................................................................................ 4
3.4 – Documentation and Deliverables: ................................................................................................... 4
4 – Testing and Commissioning (T & C) Procedure: ...................................................................................... 5
4.1 Tests and Inspections during Construction ......................................................................................... 5
4.2 Inspection and Test for Low Voltage Installations .............................................................................. 5
4.2.1 Inspection before Test ................................................................................................................. 5
4.2.2 Sequence of Tests ........................................................................................................................ 5
4.2.3 Conductor Continuity ................................................................................................................... 6
4.2.4 Earth Electrode Resistance .......................................................................................................... 6
4.2.5 Earth Fault Loop Resistance ......................................................................................................... 6
4.4 Functional Test of System/Equipment ................................................................................................ 7
4.4.1 Circuitry Check ............................................................................................................................. 7
4.4.2 Lighting Installation ...................................................................................................................... 7
4.4.3 Digital Multifunction Power Meter .............................................................................................. 8
4.4.4 Equipment and Appliances .......................................................................................................... 9
4.5 Assessment of Any Characteristics of Equipment Likely to have Harmful Effects .............................. 9
Appendix A .................................................................................................................................................. 10
Part1. Items Inspected and Tested ......................................................................................................... 11
1.1. StatutoryInspectionandTestforLowVoltage(L.V.)Installation .................................... 11
1.2. FunctionalTestofSystem/Equipment ............................................................................... 22
Part 2: Test Record attached to the Test Certificate .............................................................................. 25
2.1 TestforLowVoltage(L.V)Installation ................................................................................ 25
2.2 FunctionalTestofSystem/Equipment’ .............................................................................. 25
2.3 TestingEquipment ................................................................................................................ 25
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1 – Introduction:
The procedures stated in this document cover the activities in preliminary tests and
inspections, functional performance tests and the commissioning of newly completed electrical
installations.
The Contractor shall carry out the T & C works for LEED as detailed in this document.
2 – Objective of the T & C:
The objectives of the T & C works are:
To verify proper functioning of the equipment/system after installation.
To verify that the performance of the installed equipment/systems meet with the
specified design intent through a series of tests and adjustments.
To capture and record performance data of the whole installation as the baseline for
future operation and maintenance.
3 – Scope of the T & C Works:
3.1 – Preliminary Steps for Testing and Commissioning: Before carrying out T&C, the Contractor shall take the following steps:
a. Review approved shop drawings and equipment schedules; b. Check manufacturer’s operating instructions and statutory requirements; c. Physically inspect the installation and equipment to determine variations from designs
and/or specifications. d. Check individual components, e.g. key switches, control equipment, circuit breaker
status, etc. for proper position and settings for completeness of installation. e. Check inclusion of manufacturer’s typical equipment testing data or factors before T&C
of particular equipment.
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3.2 – Tests & Inspections during Construction:
The purpose of these tests is to ensure that all components and systems are in a satisfactory
and safe condition before start up. Preliminary adjustment and setting of equipment at this
stage also be carried out at the same time to pave way for the functional performance tests.
Before carrying out any test, The Contractor shall ensure that the installation complies with all
relevant statutory requirements and regulations. The T & C works shall also comply with all site
safety regulatory requirements including but not limited to:
(i) IEC 60364 “ Electrical Installations of Buildings”
(ii) Electricity supply rules of the relevant power supply companies
Or other approved codes and standards.
3.3 – Functional Performance Tests:
The purpose of functional performance tests is to demonstrate that the equipment/installation
can meet the functional and performance requirements as specified in the General/Particular
specifications. Functional performance test should proceed from the testing of individual
components to the testing of different systems in the installation.
Any performance deficiencies revealed during the functional performance tests must be
evaluated to determine the cause and whether they are part of the contractual obligations.
After completion of the necessary corrective measures, the Contractor shall repeat the tests.
If any test cannot be completed because of circumstances that are beyond the control of the
Contractor, it shall be properly documented. The contractor shall resume his testing work
immediately upon the attainment of a suitable testing environment.
3.4 – Documentation and Deliverables:
All inspection and T & C results shall be recorded in the data record forms.
A functional performance test report covering all measured data, data sheets, and a comprehensive summary describing the operation of the system at the time of the functional performance tests shall be prepared and submitted. Deviations in performance from the General/Particular Specifications or the design intent should be recorded, with a description and analysis included.
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4 – Testing and Commissioning (T & C) Procedure:
4.1 Tests and Inspections during Construction
For those tests to be carried out on different systems of the installation during construction to ensure their suitability for operating at the design conditions, certificates of such tests shall be issued together with certificates of any work tests. The tests and inspection shall include, but not limited to, the followings: (a) Visual inspection; (b) Earth electrode resistance; and (c) Continuity of protective conductor. (d) Voltage measurements. (e) Lux measurements.
Details of these tests shall be in accordance with relevant sections of this procedure.
4.2 Inspection and Test for Low Voltage Installations
4.2.1 Inspection before Test
A visual inspection shall be made to verify that the electrical installation /equipment as installed is correctly selected and erected and that there is no apparent damage. The visual inspection shall include a check on the following items, where appropriate: a. Adequacy of working space, access, and maintenance facilities; b. Connections of conductors; c. Identification of conductors; d. Adequacy of the sizes of conductor in relation to current carrying capacity and voltage
drop; e. Correct connections of all equipment with special attention to socket outlets, lamp
holders, isolators, switches, and protective conductors, f. Presence of appropriate devices for isolation and switching; g. Presence of diagrams, instructions and other similar information;
4.2.2 Sequence of Tests
The following items, where relevant, are to be tested preferably in the sequence indicated below:
a. Continuity of protective conductors, including main and supplementary equipotential bonding,
b. Earth electrode resistance,
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c. Earth fault loop impedance, In the event of any test indicating failure to comply, that test and those preceding, the results of which may have been influenced by the fault indicated, shall be repeated after the fault has been rectified.
4.2.3 Conductor Continuity
Continuity of Protective Conductors Every protective conductor, including all conductors and any extraneous conductive parts used for equipotential bonding should be tested for continuity. The test should be made by connecting together the neutral and protective conductors at the mains position and checking between earth and neutral at every outlet by a continuity tester, which should show a reading near zero.
4.2.4 Earth Electrode Resistance
A proper earth electrode resistance tester should be used to measure earth electrode resistance. An alternating current at 50 Hz of a steady value is passed between the earth electrode T and an auxiliary earth electrode T1 placed at a separation distance recommended by the manufacturer of the tester but in any case should not be less than 20 metres away. A second auxiliary earth electrode T2, which may be a metal spike driven into the ground, is then inserted half‐way between T and T1, and the voltage drop between T and T2, divided by the current flowing between T and T1, gives a measured earth electrode resistance of earth electrode T. For an electrical installation having four or more earth electrodes which are installed more or less in line, following a general direction not exceeding 15� deviation and with separation between adjacent electrodes not less than the recommended distance by the manufacturer of the tester but in any case not less than 20 meters, these electrodes can be used in turn as the auxiliary electrodes for the purpose of measuring the earth electrode resistances. The following alternative method for measuring the earth electrode resistance may be used if the electricity supply is connected. A loop impedance tester should be connected between the phase conductor at the origin of the installation and the earth electrode with the test link open, and a test performed. This impedance reading could be treated as the electrode resistance.
4.2.5 Earth Fault Loop Resistance
The earth fault loop impedance should be measured by a phase‐earth loop tester with a scale calibrated in ohms.
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The earth fault loop impedance should not exceed the requirements of applicable code. Before the test begins, it is essential to establish, by inspection, that the earthing conductor and all relevant earth connections are in place, and that the bonding connection to electricity supplier’s earthing facilities is disconnected. Measures should be taken, during the impedance tests especially when the earth leakage protective devices are effectively removed for the duration of the tests, to ensure that the installation is not being used other than by person(s) carrying out the tests.
4.4 Functional Test of System/Equipment
4.4.1 Circuitry Check
All circuits shall be verified through switching operation to ensure that the circuits are installed in accordance with the designated circuit. The tests shall include but not be limited to the following:
a. On/off switching of the lighting circuit to ensure that the lighting circuit is installed corresponding to the lighting switch, protective device and labeling;
b. Switching of the general power circuit to ensure that the circuit corresponds to the protective device such as RCD, RCBO and MCB, and that the protective device performs in accordance with the designated duty;
c. Switching of the main switch / isolator to ensure the corresponding circuit is properly controlled by the main switch / isolator;
d. Switching of all sub‐main and main distribution circuits, e.g. bus ducts, cable feeders, underground cables, etc. to ensure the correct isolation of the connected circuit;
e. Switching of all changeover switches to ensure the changing over sequence corresponds to the design criteria;
f. Ensuring all the protective devices perform properly against the designated circuit.
4.4.2 Lighting Installation
Lighting installation shall be tested in terms of its light quality and control as following: a. Before carrying out the lighting measurement and test, all luminaries shall be checked
against the specified color temperature, beaming angle of spot lamp and aiming angle for exterior floodlights.
b. The aiming angle of external lighting or planter lighting shall be commissioned so as not to create glare or any obstructive light to external environment.
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c. Before commissioning and /or setting of lighting control devices which including but not limited to timer switch, occupancy sensor, photocell and infra‐red sensor, the Contractor shall submit commissioning /setting proposal for approval.
d. Illumination level of lighting installation for individual areas/rooms shall be measured to verify the light output. The Contractor shall submit the proposed locations and height levels for carrying out the measurement of illuminance level for approval before commencement of measurement. Presentation of the measurement result shall be in the form of marked up layout plan for the particular area.
e. Base on the measured illuminance results for individual areas/rooms, the lighting uniformity of the respective areas /rooms shall be evaluated in terms of minimum to average illuminance ratio.
f. All grouping of luminaries shall be tested by hand operation of the corresponding switches or timers.
g. For lighting installation with interface connection to building management system (BMS), or central control and monitoring system (CCMS) or similar central computer control system, the Contractor shall co‐ordinate with other contractors responsible for such computer control system, if required, to demonstrate proper control function of the lighting installation.
4.4.3 Digital Multifunction Power Meter
The digital multifunction power meter shall be tested to verify the measurement, recording and interfacing functions as required in the General Specification. Prior to the test for every digital multifunction power meter, the Contractor shall provide manufacturer’s calibration certificate for each meter for checking on the accuracy. The Contractor shall provide testing kit to verify the reading accuracy of the digital multifunction power meter. For installation of digital multifunction power meter with connection to building management system (BMS), or central control and monitoring system (CCMS) or similar central computer monitoring system, the Contractor shall co‐ordinate with other contractor responsible for such computer monitoring system, if required, to demonstrate proper functioning and interfacing of the meter. For installation of digital multifunction power meter without external connection to building management system or CCMS, the interface functions including digital and analogue output shall be tested by means of plugging in communication module provided by the Contractor. The replacement mechanism of the meter shall be tested. The test shall demonstrate that the replacement of the meter does not require the switching off of the respective switchgear.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 32
Current transformers shorting block to prevent open circuiting the current transformers shall also be tested.
4.4.4 Equipment and Appliances
Testing on electrical equipment and appliances supplied within the electrical installation, e.g. meters, fans, etc. shall be carried out in accordance with the relevant sections of other Building Services Branch Testing and Commissioning Procedures for other building services installations and manufacturer’s recommended testing procedures.
4.5 Assessment of Any Characteristics of Equipment Likely to have Harmful Effects
Before carrying out the T&C, the Contractor shall conduct assessment for any characteristics of equipment likely to have harmful effects upon other electrical equipment or other services, or impair the supply. Those characteristics include the following:
a. Overvoltages; b. Undervoltages; c. Fluctuating loads; d. Unbalanced loads; e. Power factor; f. Starting currents; g. Harmonic currents; h. Direct current (d.c.) feedback; i. High frequency oscillations; and j. Necessity for additional connection to earth.
The Contractor shall, after conduct the assessment, submit an assessment report for consideration.
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AppendixA
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Item tested / checked by: Contractor
Item witnesses by:
Part1. Items Inspected and Tested
1.1. StatutoryInspectionandTestforLowVoltage(L.V.)Installation
1.1.1. Visual Inspection
1.1.1.1 Working Space and Facilities a. Adequacy working space and safe access provided for switch room and /or
electrical facilities.
Yes/No/N.A. Yes/No/N.A.
b. Entrance /exit to switch room and/or electrical facilities are free of obstruction
Yes/No/N.A. Yes/No/N.A.
c. Suitable locking facilities provided for switch room and /or electrical facilities.
Yes/No/N.A. Yes/No/N.A.
d. Suitable lighting provision provided for switch room and /or electrical
facilities.
Yes/No/N.A. Yes/No/N.A.
e. Suitable ventilation provision provided for switch room and /or electrical facilities.
Yes/No/N.A. Yes/No/N.A.
f. Suitable tools for withdrawal of fuses at fuse board provided.
Yes/No/N.A. Yes/No/N.A.
g. A warning notice ‘DANGER—SUBSTATION, UNAUTHORISED ENTRY PROHIBITED’ provided at every entrance of switch room.
Yes/No/N.A. Yes/No/N.A.
h. Fire barriers and other measures for protection against thermal effects are properly installed.
Yes/No/N.A. Yes/No/N.A.
i. Danger notices, warning notices, schematic diagrams, instructions and similar information are correctly and adequately provided.
Yes/No/N.A. Yes/No/N.A.
j. Warning notices for substations and switchrooms provided
Yes/No/N.A. Yes/No/N.A.
k. Warning notices for earthing and main bonding connections provided
Yes/No/N.A. Yes/No/N.A.
l. All switchgears, distribution boards and electrical equipment properly labelled.
Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
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Item tested /
checked by: Contractor
Item witnesses by:
1.1.1.2 Switchboard, Main Switch and Circuit Breaker
a. An up-to-date notice of periodic inspection and testing provided at point of supply (i.e. a switchboard, a circuit breaker or a distribution board) of the installation.
Yes/No/N.A. Yes/No/N.A.
b. Circuits, fuses, switches, terminals, etc. are provided with a legible and durable identification label.
Yes/No/N.A. Yes/No/N.A.
c. No visible damage to impair safety.
Yes/No/N.A. Yes/No/N.A.
d. Work done properly recorded in logbook.
Yes/No/N.A. Yes/No/N.A.
e. An up-to-date schematic diagram displayed.
Yes/No/N.A. Yes/No/N.A.
f. All accessible live parts screened with insulating plate or earthed metal.
Yes/No/N.A. Yes/No/N.A.
g. All exposed conductive parts effectively earthed.
Yes/No/N.A. Yes/No/N.A.
h. Earthing system effectively connected.
Yes/No/N.A. Yes/No/N.A.
i. Warning notice displayed at main bonding connections
Yes/No/N.A. Yes/No/N.A.
j. All protective devices are functioned properly and correctly set.
Yes/No/N.A. Yes/No/N.A.
k. Suitable interlock scheme provided to prevent parallel operation of two or more sources of supply and 4-pole incoming and interconnecting circuit breakers provided for supply to be taken from more than one source and is interconnected.
Yes/No/N.A. Yes/No/N.A.
l. Electrically and mechanically interlocked 4-pole changeover device(s) where standby generator set(s) is installed.
Yes/No/N.A. Yes/No/N.A.
m. The breaking capacities of all circuit breakers / interconnection devices are able to withstand the prospective fault current.
Yes/No/N.A. Yes/No/N.A.
n. Protective relays have been correctly set and overcurrent protective devices suitably set for all circuits.
Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 13 / 32
Item tested /
checked by: Contractor
Item witnesses by:
o. Protective type current transformers are used for protective relays.
Yes/No/N.A. Yes/No/N.A.
p. A means of isolation provided for every circuit.
Yes/No/N.A. Yes/No/N.A.
q. Operation of circuit breakers and main switches checked.
Yes/No/N.A. Yes/No/N.A.
r. Control, indication and alarm functions checked.
Yes/No/N.A. Yes/No/N.A.
s. No undersized conductor used between the main busbar and fuse/MCB.
Yes/No/N.A. Yes/No/N.A.
t. Fuses/MCB’s matching the lowest rated conductor in the circuit.
Yes/No/N.A. Yes/No/N.A.
u. Suitable cable terminations provided.
Yes/No/N.A. Yes/No/N.A.
v. Cable conductors of correct phases connected.
Yes/No/N.A. Yes/No/N.A.
w. Single-pole devices for protection or switching connected in phase conductors only.
Yes/No/N.A. Yes/No/N.A.
1.1.1.3 Distribution Board
a. A warning notice ‘DANGER’ provided on the front panel of every distribution board.
Yes/No/N.A. Yes/No/N.A.
b. A notice of periodic testing provided at or near the main distribution board incorporating a residual current device.
Yes/No/N.A. Yes/No/N.A.
c. Distribution boards securely mounted on suitable supports.
Yes/No/N.A. Yes/No/N.A.
d. A suitable switch provided to control each distribution board.
Yes/No/N.A. Yes/No/N.A.
e. Phase barriers for 3-phase distribution board provided.
Yes/No/N.A. Yes/No/N.A.
f. The breaking capacity of MCB is correct according to calculation
Yes/No/N.A. Yes/No/N.A.
g. Suitable tools for withdrawal of fuses at a fuse board provided, where necessary.
Yes/No/N.A. Yes/No/N.A.
h. Circuits connected to MCB or fuse in accordance with the schematic diagram.
Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : Signature
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Item tested / checked by: Contractor
Item witnesses by:
1.1.1.4 Conductors, Cables and wirings
a. No visible damage to impair safety.
Yes/No/N.A. Yes/No/N.A.
b. All live conductors and their methods of insulation, in relation to design currents of circuits and to the operating currents of the protective devices, are properly selected and erected.
Yes/No/N.A. Yes/No/N.A.
c. All cables, flexible cords, switches, plugs and socket outlets, accessories and equipment are found to be in good working conditions.
Yes/No/N.A. Yes/No/N.A.
d. All conductors are correctly and securely connected and identified.
Yes/No/N.A. Yes/No/N.A.
e. Armoured cables properly terminated to metal casing or trunking by proper cable glands.
Yes/No/N.A. Yes/No/N.A.
f. Cables passing through smoke lobby protected by enclosures of adequate fire rating.
Yes/No/N.A. Yes/No/N.A.
g. Non-sheathed cables protected by conduit, trunking or ducting.
Yes/No/N.A. Yes/No/N.A.
h. Cables and ductings adequately supported.
Yes/No/N.A. Yes/No/N.A.
i. Cables at distribution board or busbar terminated with cable lugs.
Yes/No/N.A. Yes/No/N.A.
j. Main cables connected up with correct polarity
Yes/No/N.A. Yes/No/N.A.
k. Cables protected against mechanical damage and suitably supported.
Yes/No/N.A. Yes/No/N.A.
l. All exposed metal parts including the armour effectively earthed. Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 15 / 32
Item tested / checked by: Contractor
Item witnesses by:
1.1.1.5 Busbar trunking system including rising mains
a. The rising mains, lateral mains and meter boards positioned at places accessible from public area.
Yes/No/N.A. Yes/No/N.A.
b. Fire barriers provided where the busbar trunking system passes through floor slabs or walls designated as fire barriers.
Yes/No/N.A. Yes/No/N.A.
c. Cables passing through smoke lobby protected by enclosures of adequate fire rating.
Yes/No/N.A. Yes/No/N.A.
d. Non-sheathed cables protected by conduit, trunking or ducting.
Yes/No/N.A. Yes/No/N.A.
e. Busbar trunking systems, cables and ductings adequately supported.
Yes/No/N.A. Yes/No/N.A.
f. The bolts, nuts, screws, etc. for busbar supports, busbar connections have been checked for correct tightness in accordance with manufacturers’ recommendations.
Yes/No/N.A. Yes/No/N.A.
g. The busbar trunking system is properly and correctly installed and aligned.
Yes/No/N.A. Yes/No/N.A.
h. No dust, foreign particles and deleterious substances are accumulated on the busbar trunking system.
Yes/No/N.A. Yes/No/N.A.
i. The busbar trunking system is free from condensation.
Yes/No/N.A. Yes/No/N.A.
j. Armoured cables properly terminated to metal casing or trunking by proper cable glands.
Yes/No/N.A. Yes/No/N.A.
k. Suitable cable lugs used for terminating cables.
Yes/No/N.A. Yes/No/N.A.
l. Precaution against corrosion taking on aluminium conductor joined to copper conductor.
Yes/No/N.A. Yes/No/N.A.
m. Cutout fuses for tapping off supply fitted with insulated carriers. Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 16 / 32
Item tested / checked by: Contractor
Item witnesses by:
1.1.1.6 Final circuits
a. All fuses and single pole switches connected to the phase conductors only with correct polarity.
Yes/No/N.A. Yes/No/N.A.
b. Wiring for emergency lightings and fire services installation segregated from other wirings.
Yes/No/N.A. Yes/No/N.A.
c. Low voltage circuits segregated from extra low voltage circuits.
Yes/No/N.A. Yes/No/N.A.
d. Cables of all phases and neutral of the circuit bunched and contained in the same conduit.
Yes/No/N.A. Yes/No/N.A.
e. Exposed insulated non-sheathed cables protected.
Yes/No/N.A. Yes/No/N.A.
f. Wiring inside false ceiling protected by conduit/trunking or metallic sheath.
Yes/No/N.A. Yes/No/N.A.
g. Socket outlets installed below 1.5m from floor being shuttered type complying with the prescribed requirements.
Yes/No/N.A. Yes/No/N.A.
h. No socket outlet installed close to water tap, gas tap or cooker so as to avoid danger.
Yes/No/N.A. Yes/No/N.A.
i. Floor socket outlets protected with suitable cover.
Yes/No/N.A. Yes/No/N.A.
j. No 2-pin sockets installed. All socket outlets connected with protective conductors and live conductors terminated at correct terminals.
Yes/No/N.A. Yes/No/N.A.
k. Radial final circuits using socket outlets.
Yes/No/N.A. Yes/No/N.A.
l. Final circuits using socket outlets.
Yes/No/N.A. Yes/No/N.A.
m. Final circuits using industrial socket outlets.
Yes/No/N.A. Yes/No/N.A.
n. Circuit protective conductor is formed by the enclosure and a separate protective conductor between the earthing terminal of socket outlet and its associated metal box provided.
Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 17 / 32
Item Tested/
checked by: Contractor
Witnessed by:
o. Circuit protective conductor is not formed by the enclosure and a separate protective conductor to the earthing terminal of socket outlet provided.
Yes/No/N.A. Yes/No/N.A.
a. Residual current device having a rated residual operating current not exceeding 30mA provided for all socket outlets.
Yes/No/N.A. Yes/No/N.A.
b. Minimum sizes of protective conductors are provided for limitation of protective conductor impedance.
Yes/No/N.A. Yes/No/N.A.
c. Means of isolation provided for every fixed appliance.
Yes/No/N.A. Yes/No/N.A.
d. All chokes, starters and capacitors of discharge lamps enclosed in earthed metal box(es) and suitably ventilated.
Yes/No/N.A. Yes/No/N.A.
e. Phase conductors connected to the centre contact of the Edison-type screw
lamp holders.
Yes/No/N.A.
Yes/No/N.A.
f. No switches other than a switch fed from a safety source or operated by an insulation cord or rod or a push-button type of switch having an insulated button of a large surface area provided in bathrooms.
Yes/No/N.A. Yes/No/N.A.
g. Shaver supply unit complying with EN 60742 or equivalent.
Yes/No/N.A. Yes/No/N.A.
h. Socket outlet in bathroom installed in zone 3 (i.e. 0.6m away from shower basin or bathtub); and protected by a 30mA residual current device or protected by an isolating transformer to EN 60742.
Yes/No/N.A. Yes/No/N.A.
i. No fixed luminaire nor fixed heater having unguarded heating elements installed within reach of a person using the bath or shower.
Yes/No/N.A. Yes/No/N.A.
j. Appliances exposed to weather being splash-proof type.
Yes/No/N.A. Yes/No/N.A.
k. Luminaires, switches, sockets and plugs, cable couplers installed outdoor, being splashproof type.
Yes/No/N.A. Yes/No/N.A.
l. General/site lighting readily accessible to the public supplied from a safety source.
Yes/No/N.A. Yes/No/N.A.
m. General/site lighting not readily accessible to the public and not supplied from a safety source, protected by RCD having a rated residual operating current not exceeding 30mA.
Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 18 / 32
Item tested /
checked by: Contractor
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1.1.1.7 Earthing and Bonding
a. Earth rod electrode(s) having a diameter as shown on the drawing
Yes/No/N.A. Yes/No/N.A.
b. Copper tape earth electrode having a cross section of not less than 25 mm x 3 mm.
Yes/No/N.A. Yes/No/N.A.
c. Copper plate earth electrode not less than 3mm in thickness and having a maximum dimension of 1200mm x 1200mm
Yes/No/N.A. Yes/No/N.A.
d. No gas/water pipe used as earth electrodes..
Yes/No/N.A. Yes/No/N.A.
e. A test link provided at the main earthing terminal.
Yes/No/N.A. Yes/No/N.A.
f. Minimum size of protective conductor used
Yes/No/N.A. Yes/No/N.A.
g. Protective conductor up to and including 6mm2 with green and yellow insulation sheath used throughout its length.
Yes/No/N.A. Yes/No/N.A.
h. Proper bonding conductors copper or equivalent used for connection to the earthing terminal of the electricity supplier’s transformer(s) or underground cable(s).
Yes/No/N.A. Yes/No/N.A.
i. Copper links provided at joints of metallic trunking which forms part of a protective conductor.
Yes/No/N.A. Yes/No/N.A.
j. Separate protective conductors provided for all flexible conduits.
Yes/No/N.A. Yes/No/N.A.
k. A warning notice ‘SAFETY ELECTRICAL CONNECTION—DO NOT REMOVE provided at all main earthing and bonding connections.
Yes/No/N.A. Yes/No/N.A.
l. Main equipotential bonding conductors effectively connected to main water pipes, main gas pipes, other services pipes/ducting and exposed metallic parts of structural framework.
Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 19 / 32
Item Tested/ checked by: Contractor
Witnessed by:
m. Supplementary equipotential bonding effectively provided between exposed conductive parts and extraneous conductive parts.
Yes/No/N.A. Yes/No/N.A.
n. Exposed conductive parts of fixed equipment installed outside equipotential zone effectively earthed for 0.4 sec. disconnection.
Yes/No/N.A. Yes/No/N.A.
o. Exposed conductive parts of fixed equipment installed within equipotential zone effectively earthed for 5 sec. disconnection.
Yes/No/N.A. Yes/No/N.A.
p. Effectiveness of the main equipotential bonding connection to the main earthing terminal and lightning protection system.
Yes/No/N.A. Yes/No/N.A.
q. Earthing conductors of adequate size. Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 20 / 32
Item Tested/
checked by: Contractor
Witnessed by:
1.1.1.9 Motors /Transformers
a. No visible damage to impair safety
Yes/No/N.A. Yes/No/N.A.
b. A local switch was provided to control every motor
Yes/No/N.A. Yes/No/N.A.
c. Means provided to prevent unexpected restarting of motors where such restarting might cause danger
Yes/No/N.A. Yes/No/N.A.
d. Flexible conduits terminated with suitable brass bushes
Yes/No/N.A. Yes/No/N.A.
e. Separate supply to motor heaters having its terminals screened, with warning notice provided.
Yes/No/N.A. Yes/No/N.A.
f. All accessible live parts screened with insulating plate or g. earthed metal
Yes/No/N.A. Yes/No/N.A.
h. Proper ventilation provided to avoid excessive temperature rise Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 21 / 32
Item Tested/ checked by: Contractor
Witnessed by:
1.1.2 Conductor Continuity
1. All protective conductors including all conductors and any extraneous conductive parts used for equipotential bonding have been tested for continuity.
Yes/No/N.A. Yes/No/N.A.
2. All final ring circuit conductors including the protective conductors have been tested for continuity
Yes/No/N.A. Yes/No/N.A.
3. Conductor continuity test results recorded in Annex I.
Yes/No/N.A. Yes/No/N.A.
1.1.3 Earth Electrode Resistance 1. The resistance to earth has been measured at the position of every earth
electrode and of the main earth terminal. The results are satisfactory.
Yes/No/N.A. Yes/No/N.A.
2. Details of earth electrode and resistance test results recorded in Annex I
Yes/No/N.A. Yes/No/N.A.
1.1.4 Earth Fault Loop Impedance 1. The earth fault loop impedance of all circuits has been found satisfactory
for operation of the protective devices for earth fault protection.
Yes/No/N.A. Yes/No/N.A.
2. Earth fault loop impedance measurement results recorded on Annex I
Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 22 / 32
Item tested / checked by: Contractor
Item witnesses by:
1.2. FunctionalTestofSystem/Equipment
1.3.1. Lightning Protection System
a. The continuity between air terminations and earthing terminations is tested.
Yes/No/N.A. Yes/No/N.A.
b. Measured earth termination network resistance to earth not more than 10 Ohm when the connection to main earthing terminal disconnected.
Yes/No/N.A. Yes/No/N.A.
c. Test results recorded in Annex I Yes/No/N.A. Yes/No/N.A.
1.3.2. Circuitry Check
a. All circuits including lighting and power circuits have been verified through switching operation that they are installed in accordance with the designated circuits.
Yes/No/N.A. Yes/No/N.A.
1.3.3. Charger and Battery Set
a. The original factory test certificates of the charger and battery have been checked and found satisfactory.
Yes/No/N.A. Yes/No/N.A.
b. The charger is connected to the mains supply through a suitable rated fuse.
Yes/No/N.A. Yes/No/N.A.
c. Batteries connections have been done properly.
Yes/No/N.A. Yes/No/N.A.
d. Instruments, indicating lamps, fuses, relays and labels on battery charger are provided and installed properly.
Yes/No/N.A. Yes/No/N.A.
e. The capacity of the charger is capable of recharging the batteries from fully discharged to fully charged within the specified duration.
Yes/No/N.A. Yes/No/N.A.
f. The charger output on load with batteries disconnected is satisfactory.
Yes/No/N.A. Yes/No/N.A.
g. The charger current on load with batteries disconnected is satisfactory. Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 23 / 32
h. The capacity of batteries has been checked and tested by interrupting the mains input to the charger and actuation / operation of the connected devices and the results are satisfactory.
Yes/No/N.A. Yes/No/N.A.
i. The functions and indications of charger fail / main fail / battery disconnected / boost charge / trickle charge, mains and battery have been checked and tested and the results are satisfactory.
Yes/No/N.A. Yes/No/N.A.
1.3.4 Lighting Installation
1.3.4.1 Switchboard and Circuit Breakers
a. Colour temperature of light fittings was checked and as specified.
Yes/No/N.A. Yes/No/N.A.
b. All lamps are the correct wattage and voltage ratings Yes/No/N.A. Yes/No/N.A.
c. Beam angle of spot lamp is commissioned. Yes/No/N.A. Yes/No/N.A.
d. Aiming angle of external lighting or planter lighting is commissioned so as not to create glare or any obstructive light to external environment.
Yes/No/N.A. Yes/No/N.A.
e. Exterior floodlights have been aimed according to requirements
Yes/No/N.A. Yes/No/N.A.
f. Fluorescent lamps have the correct phosphor.
Yes/No/N.A. Yes/No/N.A.
1.3.4.2 Lighting Control (On/Off and Dimming)
a. Groups of luminaries are assigned to the correct position in grid switch or grid single circuit dimmer and tested by hand operation.
Yes/No/N.A. Yes/No/N.A.
b. Lighting control system (e.g. timer switch, occupancy sensor, photocell and infra-red sensor, etc.) are correctly commissioned and set.
Yes/No/N.A. Yes/No/N.A.
c. Timer switch operated lighting control system can properly operate as commissioned.
Yes/No/N.A. Yes/No/N.A.
d. Photocell operated lighting control system can properly operate as commissioned.
Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 24 / 32
Item Tested/ checked by: Contractor
Witnessed by:
e. Infra-red sensor operated lighting control system can properly operate as
commissioned.
Yes/No/N.A. Yes/No/N.A.
f. Occupancy sensor operated lighting control system can properly operate as commissioned.
Yes/No/N.A. Yes/No/N.A.
g. FM radio switches have been configured to the relevant receivers
Yes/No/N.A. Yes/No/N.A.
h. Lighting control by CCMS or BMS is tested and properly functioned.
Yes/No/N.A. Yes/No/N.A.
1.3.4.3 Lighting Measurement
a. Illuminance level of lighting installation for individual areas /rooms is measured under its design condition.
Yes/No/N.A. Yes/No/N.A.
b. Measurement results recorded. Yes/No/N.A. Yes/No/N.A.
1.3.5 Digital Multifunction Power Meter
a. Manufacturer’s calibration certificate for each meter is provided. Yes/No/N.A. Yes/No/N.A.
b. The readings of electrical parameters by the meter and by test kit are recorded in Annex I
Yes/No/N.A. Yes/No/N.A.
c. Remote monitoring functions by CCMS or BMS are tested and found satisfactory..
Yes/No/N.A. Yes/No/N.A.
d. Interfacing functions for self-contained meter are tested by using plug-in communication module and found satisfactory.
Yes/No/N.A. Yes/No/N.A.
e. Replacement mechanism of meter is tested and found satisfactory.
Yes/No/N.A. Yes/No/N.A.
f. Current transformer (C.T.) shorting block to prevent open circuiting the C.T. is provided and tested.
Yes/No/N.A. Yes/No/N.A.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 25 / 32
Test record attached
Part 2: Test Record attached to the Test Certificate
2.1 TestforLowVoltage(L.V)Installation
2.1.1. Conductor continuity Measurement Yes/No/N.A.
2.1.2. Earth Electrode Resistance Measurement
Yes/No/N.A.
2.1.3. Earth Fault Loop Impedance Measurement
Yes/No/N.A.
2.2 FunctionalTestofSystem/Equipment’
2.2.1. Earth Electrode Resistance Measurement for Lightning Protection System
Yes/No/N.A.
2.2.2. Test of Digital Multifunction Power Meter /Power Analyzer
Yes/No/N.A.
2.3 TestingEquipment
.
2.3.1. List of Testing equipment
Yes/No/N.A.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 26 / 32
2.1.1. Conductor continuity Measurement
Circuit No. or Detailed
Equipment
Continuity of protective Conductors
Measured Resistance (Ohm) at outlet
Continuity of Ring Final Circuit
Measured Resistance (Ohm) for
Remarks
Phase Conductor
Neutral Conductor
Protective Conductor
Note: The test method for ring final circuit is only applicable when the circuit has been inspected throughout, prior to the test, to ascertain that no interconnection (multi-loops) exists on the ring circuit. Otherwise, the testing methods stipulated in the previous Part of the Guidance Note 3 to BS7671, should be adopted instead.
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 27 / 32
2.1.2. Earth Electrode Resistance Measurement
Earth Electrode Designation
Types, Materials and Sizes/Dimensions of Earth
Electrode
Resistance to Earth at Position of main
Electrode (Ohm)
Resistance to Earth at Position of main Earth Terminal
(Ohm)
Remarks
Rod / Tape / Plate / Others: ( ) Copper / Stainless Steel / Galvanised Steel/ Others: ( ) Size /dimension /diameter: __________
Separation of Earth Electrodes (for installation having multiple rod electrodes): _________________ (m) Description of Bonding Connections to the Point of Supply: __________________________________________________________________________________________________________________________________________________________________________
_____________________________________________________________________________________________
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 28 / 32
2.1.3. Earth fault Loop Impedance Measurement
Circuit No. or Detailed Equipment
Earth Fault Loop Impedance (Ohm)
Remarks
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 29 / 32
2.2.2. Test of Digital Multifunction Power Meter /Power Analyzer
A. Equipment Details
Circuit Designation : _______________________ Brand and Model Number : _______________________ Current Transformer Ratio : _______________________ Voltage Transformer Ratio : _______________________
B. Reading Accuracy Test
Parameters Meter reading Test Kit reading % error
R.M.S Voltage (V)
L1-N L2-N L3-N L1-L2 L2-L3 L3-L1
R.M.S Current (A)
L1 L2 L3 N
3 phase average
Active Power (kW)
L1 L2 L3
3 phase total
Reactive Power (kVAr)
L1 L2 L3
3 phase total
Apparent Power (kVA)
L1 L2 L3
3 phase total
Active Energy (kWh)
Instantaneous Cumulated
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 30 / 32
2.2.2. Test of Digital Multifunction Power Meter /Power Analyzer
B. Reading Accuracy Test (continued)
Parameters Meter reading Test Kit reading % error
Frequency
Power Factor
L1 L2 L3
Demand Current (A)
L1 L2 L3
Demand Active Power (kW)
3 phase total
Demand Apparent Power (kVA)
3 phase total
THD (%)
Voltage Current
Voltage THD of Order (%)
3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 31 / 32
2.2.2. Test of Digital Multifunction Power Meter /Power Analyzer
B. Reading Accuracy Test (continued)
Parameters Meter reading Test Kit reading % error
Current THD of Order (%)
3 5 7 9 11 13 15 17 19 21 23 25 27 29 31
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 32 / 32
2.3.1. List of Testing Equipment
Type Model Serial No. Of Instrument
Date of Calibration
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 19
Testing & Commissioning Procedure
Emergency Generator Installation
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 19
1 – Introduction:
The Procedures stated in this document cover the activities in preliminary tests and
inspections, functional performance tests and the commissioning of newly completed
installations and existing ones after major alteration.
The contractor shall carry out the T & C works as detailed in this document.
2 – Objective of the T & C:
The objectives of the T & C works are:
To verify proper functioning of the equipment/system after installation.
To verify that the performance of the installed equipment/systems meet with the
specified design intent through a series of tests and adjustments.
To capture and record performance data of the whole installation as the baseline for
future operation and maintenance.
3 – Scope of the T & C Works:
3.1 – Tests & Inspections during Construction:
The purpose of these tests is to ensure that all components and systems are in a satisfactory
and safe condition before start up. Preliminary adjustment and setting of equipment at this
stage also be carried out at the same time to pave way for the functional performance tests.
Before carrying out any test, The Contractor shall ensure that the installation complies with all
relevant statutory requirements and regulations. The T & c works shall also comply with all site
safety regulatory requirements.
3.2 – Functional Performance Tests:
The purpose of functional performance tests is to demonstrate that the equipment/installation
can meet the functional and performance requirements as specified in the General/Particular
specifications. Functional performance test should proceed from the testing of individual
components to the testing of different systems in the installation.
Any performance deficiencies revealed during the functional performance tests must be
evaluated to determine the cause and whether they are part of the contractual obligations.
After completion of the necessary corrective measures, the Contractor shall repeat the tests.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 19
If any test cannot be completed because of circumstances that are beyond the control of the
Contractor, it shall be properly documented. The contractor shall resume his testing work
immediately upon the attainment of a suitable testing environment.
3.3 – Commissioning and Statutory Inspection:
Commissioning is the advancement of an installation from the stage static completion to full working conditions and to meet the performance requirements as specified in the General/Particular Specification. This will include setting into operation and regulation of the installation. It is expected that fine‐tuning of the commissioned system shall be done by the Contractor to match system performance to the actual needs of the building occupier more closely.
3.4 – Documentation and Deliverables:
All inspection and T & C results shall be recorded in the data record forms.
A functional performance test report covering all measured data, data sheets, and a comprehensive summary describing the operation of the system at the time of the functional performance tests shall be prepared and submitted. Deviations in performance from the General/Particular Specifications or the design intent should be recorded, with a description and analysis included.
4 – T & C Procedure:
4.1 Tests and Inspections during Construction
Certain tests will be carried out on different systems of the installation during construction to ensure their suitability for operating at the design conditions. Certificates of such tests have to be issued together with certificates of any work tests. N.B: The following tests should be conducted in accordance with the procedures as specified by the manufacturers.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 19
4.1.1 Emergency Generator
a. Visual inspection on engine, alternator, radiator, and various systems of the generating set
b. Full operating test c. Control function test d. Circuit & engine protection tests e. Fuel consumption test f. Step load acceptance test
4.1.2 Control Cubicle
a. Visual inspection on control panel b. Performance tests on individual components c. Temperature rise test
4.1.3 Underground/ Daily Services Fuel Tank
a. Visual inspection on welding surfaces and primer coating b. Hydraulic test
4.2 Functional Performance Tests
4.2.1 Emergency Generator
a. Pre‐commissioning inspection on various components / systems b. Control function test c. Dummy load test d. Battery charger output test e. Step load acceptance test
4.2.2 Control Cubicle
a. Pre‐commissioning inspection on various components / systems b. Performance tests of individual components such as voltmeter, ammeter, frequency
meter, wattmeter, indicating lamps, buttons and switches c. Circuit protection & load transfer tests
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 5 / 19
4.2.3 Main/Daily Services Fuel Tank
a. Pre‐commissioning inspection on the construction, welding, painting and components of tank & pipe work
b. Hydraulic test
4.3 Commissioning and Statutory Inspections
In Addition to tests performed in the previous sections.
4.3.1EmergencyGeneratora. Insulation test b. Earthing protection test c. Noise level measurement
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 6 / 19
AppendixA
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 7 / 19
TestingandCommissioningForms
ForEmergencyGeneratorInstallation
Part1:DetailofProject1.1 Project title (with location):
1.2 Contractor/Sub –contractor:
Part2:ItemsInspectedandTested
Item tested/ checked by Contractor
Items witnesses by
2.1 Main tank The welding has been examined and the effectiveness of the welding and standard of workmanship is satisfactory.
Yes / No Yes / No
The metal surface has been properly prepared in accordance with the specification.
Yes / No Yes / No
The manufacturer’s application procedure for the primer has been followed and the type of primer, the numbers of coatings are in accordance with the specification.
Yes / No Yes / No
The Main tank has been subjected to hydraulic test to a pressure as specified and the results are satisfactory.
Yes / No Yes / No
2.2 Daily service fuel tank
The daily service fuel tank has been fabricated and welded in accordance with the specifications and drawings.
Yes / No Yes / No
The pipe work & socket connections (for filling, overflow, drainage, return and vent) have been properly installed at the fuel tank in accordance with the specifications and drawings.
Yes / No Yes / No
One quick closing valve has been installed properly with all necessary linkage for operation from outside the building.
Yes / No Yes / No
The fuel tank has been fitted with an approved content gauge unit and level sensing equipment.
Yes / No Yes / No
The fuel tank has been subjected to hydraulic test to a pressure as specified and the results are satisfactory.
Yes / No Yes / No
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 8 / 19
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
2.3 Visual inspection
The Generating Set has been properly fixed on a common steel section base frame.
Yes / No Yes / No
Protection screen has been provided on all moving parts. Yes / No Yes / No
Protection guard has been provided on hot exhaust. Yes / No Yes / No
The fresh‐water‐cooled radiator has been properly fixed and there is no water leakage.
Yes / No Yes / No
The radiator cooling fins and water tank are in good condition and properly fixed.
Yes / No Yes / No
The water circulation pump with thermostatically controlled temperature regulator has been properly fixed.
Yes / No Yes / No
The engine mounted instrument panel has been fixed properly and c/w lubrication oil temp. and cooling temp. gauges, tachometer and hour meter.
Yes / No Yes / No
The lubrication oil system with replaceable element type’s filter has been properly fixed.
Yes / No Yes / No
The fuel oil system c/w filter, fuel transfer pumps has been properly installed.
Yes / No Yes / No
The fuel control solenoid c/w emergency shut off valve has been provided and properly installed.
Yes / No Yes / No
The tubular exhaust silencer has been properly installed. Yes / No Yes / No
For remote radiator, if applicable, c/w break tank booster pump, heat exchanger etc. has been properly installed.
Yes / No Yes / No
The enclosure to the alternator satisfy IP21 or as specified Yes / No Yes / No
Anti‐condensate heater for the alternator has been provided and proper fixed.
Yes / No Yes / No
Where specified, facilities for generation at 380/220V have been provided.
Yes / No Yes / No
Starting batteries have been provided and properly installed. Yes / No Yes / No
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 19
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
Item tested/ checked by
Contractor
Items witnesses by
2.4 Pre‐commissioning inspection Fuel engine Radiator water is at right level. Yes / No Yes / No Lubrication oil is at right level and with replaceable filter. Yes / No Yes / No The engine exhaust has been properly fixed and covered with asbestos‐fee insulation.
Yes / No Yes / No
The engine anti‐vibration mounting is effective. Yes / No Yes / No Proper replaceable air filter has been installed. Yes / No Yes / No Effective and adequate earth bonding have been provided for the engine and alternator.
Yes / No Yes / No
Alternator Batteries electrolyte is at right level. Yes / No Yes / No Batteries output voltage is as specified. Yes / No Yes / No The alternator output terminal is at correct phase sequence. Yes / No Yes / No
Control cubicle Permanent engraved labels have been provided for all accessories, fixed with machined brass screws.
Yes / No Yes / No
All control wirings are fitted with ferrules. Yes / No Yes / No The following devices are provided in the control cubicle: a) Voltmeter & selector switch Yes / No Yes / No b) Ammeter & selector switch Yes / No Yes / No c) Frequency meter Yes / No Yes / No d) Wattmeter Yes / No Yes / No e) Auto/off/manual selector switch Yes / No Yes / No f) Emergency stop Yes / No Yes / No g) Engine starting Yes / No Yes / No h) Engine stopping Yes / No Yes / No i) Lamp test Yes / No Yes / No Indicating lamp & reset button for: a) Engine fault Yes / No Yes / No b) Alarm sounder Yes / No Yes / No
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 10 / 19
Item tested/ checked by Contractor
Items witnesses by
Indication lamp for: Emergency stop operated (Red) Yes / No Yes / No System failure (Amber) Yes / No Yes / No No voltage (Amber) Yes / No Yes / No Low DC voltage (Amber) Yes / No Yes / No High DC voltage (Amber) Yes / No Yes / No Fail to sync (Amber) Yes / No Yes / No Overcurrent alarm (Amber) Yes / No Yes / No High oil temperature (Amber) Yes / No Yes / No Breaker failure (ON/OFF) (Red) Yes / No Yes / No Breaker tripped (Red) Yes / No Yes / No Overcurrent (Red) Yes / No Yes / No Short circuit (Red) Yes / No Yes / No Reverse power (Red) Yes / No Yes / No Overcrank (Red) Yes / No Yes / No Under frequency (Red) Yes / No Yes / No Over frequency (Red) Yes / No Yes / No Under voltage (Red) Yes / No Yes / No Over voltage (Red) Yes / No Yes / No Phase rotation (Red) Yes / No Yes / No Generator running (Green) Yes / No Yes / No Breaker open (Green) Yes / No Yes / No Breaker closed (Green) Yes / No Yes / No Water temperature failure Yes / No Yes / No Oil pressure failure Yes / No Yes / No Over speed Yes / No Yes / No
No starting Yes / No Yes / No
Daily fuel tank low level Yes / No Yes / No
Daily fuel tank high level Yes / No Yes / No
Test lamp switch is provided Yes / No Yes / No The following tests has been done and delivered to the Commissioning authority:
Insulation test Yes / No Yes / No Control functions test Yes / No Yes / No Dummy load test Yes / No Yes / No Earthing protection test Yes / No Yes / No Battery charger output test Yes / No Yes / No Step‐load acceptance test Yes / No Yes / No
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 11 / 19
Alternator overload protection test Yes / No Yes / No Alternator output protection test Yes / No Yes / No Reverse power protection test Yes / No Yes / No Metering equipments test for accuracy Yes / No Yes / No Synchronizing and load sharing test Yes / No Yes / No Totalizing panelboard: Yes / No Yes / No System status panel Yes / No Yes / No Alarm silence push button Yes / No Yes / No Alarm horn Yes / No Yes / No Lamp test Yes / No Yes / No LED indication lamps Yes / No Yes / No
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 12 / 19
Part3:TestRecordattachedtotheTestForms3.1 EmergencyGeneratorInstallation
3.1.1 Equipment Details (i) Generating Set
1. Manufacturer 2. Model 3. Net prime rating (MCR) (kW)
(ii) Fuel Engine 1. Make 2. Model 3. Serial No. 4. Rated power (kW) 5. Speed (rpm) 6. Governor 7. Turbocharger (type/model)
(iii) Alternator 1. Make 2. Model 3. Serial No. 4. Rated kVA 5. Voltage (V) / Full load current (A) 6. Phase / Rated p.f. 7. Insulation class
(iv) Starting Battery 1. Manufacturer 2. Make/Model No. 3. No. of battery / Voltage (V) 4. Ampere hour 5. Starting time (sec)
(v) Lifting Hoist 1. Manufacturer 2. Make / Model No. 3. Safe working load (kg) 4. Lifting height (m) 5. Test Certificate *Yes/No (vi) Other Accessories
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 13 / 19
3.1.2 Type of Control
Starting *Automatic/Manual Loading Transfer to Generating Set *Automatic/Manual Stopping *Automatic/Manual Load Transfer to Mains *Automatic/Manual
3.1.3 Insulation Resistance Test (Temporarily open alternator star point)
1. Brown phase (L1) to earth Megaohm‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 2. Black phase (L2) to earth Megaohm‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 3. Grey phase (L3) to earth Megaohm‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 4. Brown phase (L1) to Black phase (L2) Megaohm‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 5. Black phase (L2) to Grey phase (L3) Megaohm‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ 6. Grey phase (L3) to Brown phase (L1) Megaohm‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 14 / 19
3.1.4
Control Function Test Tested Results Remarks
1. Starting Manual
Simulate Mains Failure
Test 1
Test 2
Delay Start Timer
Delay Repeat Start
2. Stopping Manual
Resumption of Mains
Delay Stop Timer
3. Engine Protection
Overload Trip (MCCB)
Engine Overspeed HL
LL
Low Lub‐oil Pressure (kPa)
HL
LL
High Water Temp.0(C)
HL
LL
Under Voltage Trip
Overvoltage Trip
Under Frequency (Hz)
4. Others Response Time from Mains Failure to Changeover (Sec)
Battery 3 Attempt Start Quick closing Mechanism Governor Function Voltage Regulator (346V - 380V) Auto-starting of Vent. Fan Manual Override Facilities Phase Sequence of Alternator Output Frequency Setting
TDH (% should be less than 5%)
Presence of multiples of the 3rd harmonic (shouldn’t be)
Each harmonic should be less than 3 %
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 15 / 19
3.1.5. Dummy Load Test (Parameters to be recorded at 15 min interval during the whole dummy load test period)
Time from start
Duration (HR)
1/2 1/2 1 1 1 ½
Duration (HR)(actual)
Frequency (Hz)
Current (Amp)
L1
L2
L3
Voltage (Volts)
L1‐L2/ L1‐N
L2‐L3/ L2‐N
L3‐L1/ L3‐N
Dummy Load
KW
% Full Load 0% 25% 50% 100% 100% `110% Engine Speed (RPM) Cooling Water Temp. Engine Oil Temp. (oC) Engine Oil Pressure (kPa) Fuel Consumption (L) Engine Room Temp. (OC) System operation has been tested according to the specification, and results were delivered to the CxA:
Remarks:
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 16 / 19
3.1.6. Earthing Protection Test
Measured Earthing Resistance
Earthing Relay Make ____________ Model ____________ Serial No ____________ Rated Current ____________
Current Setting
Time Setting
Function Test
3.1.7. Noise Level Measurements Values should be less than 65 dbA at 1 m outside the room all around (As per specifications)
Location Mean Sound Level (dBA)
Background Inside Generator Room (1m from Generator Set)
Outside Generator Room (1m from Radiator Exhaust)
Outside Generator Room (1m from Door)
Outside Generator Room (1m from Louvre)
Outside Generator Room (1m from flue discharge if possible)
Outside Generator Room (at the nearest Noise Sensitive Receiver)
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 17 / 19
This section is dedicated to the efficiency of the generators:
Tested / Checked by : (Name of Contractor’s Representative)
Signature:
Witnessed by : (Name(s))
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 18 / 19
AppendixB
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 19 / 19
ListofCalibratedInstrumentNecessary
FortheT&CWorks
Performance Specification Accuracy Maximum period between calibrations
Tachometer 30‐5000 rpm
Multi‐tester AVO) 0‐1000V 0‐10A 0‐W
Clamp on ammeter 0-1000A Insulation tester 500V-1000V
Pressure Gauge 0‐100kPa 0‐1000kPa
Sound meter 0-120 dbA Other necessary testing equipment
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 11
Testing & Commissioning Procedure
Split Unit System
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 11
TableofContents1 – General: ................................................................................................................................................... 3
1.1 – Purpose of the Testing & Commissioning Procedures ..................................................................... 3
1.2 – Reference to Other Controlling Documents .................................................................................... 3
1.3 – Responsibility ................................................................................................................................... 3
2 – Tests & Inspections to be Carried Out : .................................................................................................. 3
3 – Testing Equipment : ................................................................................................................................ 3
Appendix A .................................................................................................................................................... 4
Appendix B .................................................................................................................................................... 6
Split Unit Checklist Inspection (1) ............................................................................................................. 7
Split Unit Checklist Inspection(2) .............................................................................................................. 8
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 11
1–General:
1.1–PurposeoftheTesting&CommissioningProceduresHaving already been inspected as material in their reserved location, the purpose of this
document is to ensure that all split units are in a good condition and operating properly.
1.2–ReferencetoOtherControllingDocuments 1.2.1 –ReferenceDocuments
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1.2.2 –ReferenceDrawings
Refer to Appendix A
1.3–ResponsibilityThe main contractor will carry out the testing and commissioning with association of this
subcontractor and the related supplier.
2–Tests&InspectionstobeCarriedOut:Visual inspection and performance test of split unit will be carried out and recorded on the
relative forms.
3–TestingEquipment:The following instruments are to be provided before proceeding in the testing and
commissioning of the split unit system.
a. Clamp‐multimeter
b. Ballometer
c. Temperature and humidity meter
The testing equipment should be approved by the Engineer.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 11
AppendixA
List of References Drawings
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 5 / 11
Building Drawing No. Rev Drawing Name
Status Date Comments
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 6 / 11
AppendixB
Testing & Commissioning Forms
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 7 / 11
SplitUnitChecklistInspection(1)Building: __________ Date:________
Floor:__________ Related Drawings:_________
Room No:_________
Item Description Complying Not
Complying
Comments
1 Indoor unit installation
2 Indoor unit fixation
3 Outdoor unit installation
4 Outdoor unit fixation
5 Condensate drain pipe installation
6 Refrigerant pipes installation
7 Pipes insulation
8 Filters condition
9 Thermostat Condition
10 Electrical connection & disconnect
switch
11 Grounding is installed
12 Physical condition
13 Tagging & Labeling
14 Cleanliness
Comments:
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 8 / 11
SplitUnitChecklistInspection(2)Building: _________ Date:_________
Location: _________ Related Drawings:_________ Room: ________
Number of filters: _______
Refrigerant type: ________
Indoor Unit Outdoor Unit
Manufacturer Motor data
Model Number Manufacturer
Serial Number Model Number
Type Serial Number
Power
Motor data FLC
Manufacturer Power factor
Model Number
Serial Number Compressor
Power Manufacturer
FLC Model Number
Power factor Serial Number
Power
Low pressure cut‐off
High pressure cut‐off
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 11
Fan Fan
No. of fan No. of fan
Fan type Fan type
Fan CFM Fan CFM
Performance test Design Actual Performance test Design Actual
Current Suction pressure
Voltage Discharge pressure
Total air flow Voltage
Ent. Air DB/WB Compressor Amps
Lvg. Air DB/WB Fan Motor Amps
Comments:
____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 10 / 11
This section is dedicated to the power efficiency test for each split unit:
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 11 / 11
This section is dedicated to the test of noise level:
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 20
Testing & Commissioning Procedure
AHU & VAV
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 20
TableofContents1 – General : .................................................................................................................................................. 3
1.1 – Purpose of the Testing & Commissioning Procedures ..................................................................... 3
1.2 – Reference to Other Controlling Documents .................................................................................... 3
1.3 – Responsibility ................................................................................................................................... 3
2 – Tests & Inspections to be Carried Out : .................................................................................................. 3
2.1 – Visual Inspection: ............................................................................................................................. 3
2.2 – Operational Tests: ............................................................................................................................ 3
2.5 – Tolerance .......................................................................................................................................... 4
3 – Testing Equipment : ................................................................................................................................ 5
4 – Safety: ..................................................................................................................................................... 5
Appendix A .................................................................................................................................................... 6
Appendix B .................................................................................................................................................... 8
FCU’s Checklist & Start‐up Inspection ....................................................................................................... 9
VAV’s visual Inspection Checklist ............................................................................................................ 11
AHU Fan Performance Test Sheet ........................................................................................................... 12
Duct Traverse Readings ........................................................................................................................... 14
Terminal Air Distribution Readings ......................................................................................................... 16
Coil Performance Test Sheet ................................................................................................................... 17
Variable Air Volume Boxes ...................................................................................................................... 18
AHU Schematic ........................................................................................................................................ 19
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 20
1–General:
1.1–PurposeoftheTesting&CommissioningProceduresHaving already been inspected as materials and installed in their reserved location the purpose
of this document is to ensure that:
‐ The AHU(s) are in a good condition and operating properly.
‐ Airflows in relevant ducts & air terminals are as per design drawings.
1.2–ReferencetoOtherControllingDocuments 1.2.1 –ReferenceDocuments
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1.2.2 –ReferenceDrawings
Refer to Appendix A
1.3–ResponsibilityThe main contractor will carry out the testing and commissioning with the related supplier.
2–Tests&InspectionstobeCarriedOut:The following tests and inspections will be carried out and recorded on the relative forms.
2.1–VisualInspection:Before Fan operation, Visual Inspection shall be carried out to ensure that the material has no
defects and installation is proper. Refer to visual inspection checklist for fans.
2.2–OperationalTests:Before running the fan, make sure that all fire dampers, duct volume dampers, splitters
dampers and outlets dampers, splitters dampers and outlets dampers are fully opened. Run the
fan and check if it is giving the required design flow. Then proceed airflow‐balancing starting
with the terminals with least resistance & work towards the terminals with greater resistance.
The terminal with the greatest resistance might be the most remote one it the one that have a
lot of duct direction changes.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 20
Using the Airflow Meter (Hood for ceiling diffusers and rotating vane for side grilles), airflow
rate can be measured at each terminal. Duct volume dampers & splitter dampers shall be
adjusted to distribute the required flow in the various branches. Airflow velocity in duct (Duct
Traverse reading) shall be measured by a Pitot Traverse; several velocities should be taken to
get the average velocity. Volumetric airflow rate can then be calculated by multiplying the final
average velocity by the duct area. Fan static pressure (inlet, outlet, total) shall be measured by
Micro‐Manometer. Fan & Motor speed, electric Current, Voltage etc…. Shall be measured as
well.
For AHU’s serving VAV’s units, system shall be balanced at maximum design data, and then
remeasured at simulated partial load conditions. Each VAV box will be considered as a small
independent system by itself.
All measurements and readings shall be recorded in the relevant performance sheets.
For AHU’s coils water balancing refer to (Secondary chilled and hot water systems).
2.5–ToleranceFor air system, the tolerances on terminals and fans are as follows:
1. Supply, return and exhaust fans shall not be less than 95%.
2. For any space the flow should be within – 5% and – 10%.
‐ Space with one outlet, the tolerance is as above.
‐ Space with two outlets, the tolerance is + or – 10%.
‐ Space with 3 outlets or more, the tolerances is + or – 10%.
3. Return and exhaust inlets, the tolerance is + or – 10%.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 5 / 20
3–TestingEquipment:The following instruments are to be provided before proceeding in the testing and
commissioning of the system:
a. Tachometer
b. Clamp‐multimeter
c. Ballometer
d. Micro Manemeter / Pitot tube
e. Anemometer
f. Temperature & Pressure gauges
The testing equipment should be approved by the Engineer.
4–Safety: Skilled Technicians should do all tests operation under the supervision of Senior
Mechanical Engineer.
The Operator should be fully equipped with safety equipment as per the Safety
Manual Applied in the project
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 6 / 20
AppendixA
List of References Drawings
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 7 / 20
Building Drawing No. Rev Drawing Name
Status Date Comments
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 8 / 20
AppendixB
Testing & Commissioning Forms
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 20
AHU’sChecklist&Start‐upInspectionBuilding: __________ Date:________
Floor:__________ Related Drawings:_________ Room No:_________
Item Description Complying Not
Complying
Comments
1 AHU located as per drawings
2 AHU is clean and undamaged
3 Anti‐vibration system installed properly
4 AHU is totally isolated from support base
5 Joints in between sections properly made and airtight
6 Access doors & sealing gaskets properly fitted
7 Locking handles are working properly
8 Heating and cooling coils connections
9 Valves, motorized valves and accessories
10 Filters are clean, accessible and undamaged
11 Condensate drain pipe and pan connections
12 Fan and fan motor anti‐vibration system
13 Fan drive (pulleys, belts, alignment & tension)
14 Supply, return and fresh air duct connections
15 Fire & volume dampers are totally open
16 Outlets dampers are totally open
17 Electrical connections, disconnect switch are made properly
18 Grounding
19 Frequency modulator installed properly (VAV – AHU)
20 Economizing fan is inter‐lock with
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 10 / 20
AHU (Eco. AHU) 21 Ventilation Duct is connected
properly (Eco. AHU)
22 Motorized Volume Damper is connected properly
23 Lubrication
24 Tagging & Labeling
AHU Start‐Up 25 Provisions are made for TAB
measurements
26 Star delta timer setting correctly
27 Motor current reaching design value
28 Fan rotation is correct
29 Motor and fan free from vibration
30 No seepage of lubricant from the housing
Comments:
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 11 / 20
VAV’svisualInspectionChecklistBuilding: _________ Date: _________
Location: _________ Related Drawings: _________
Room: ________ Serving Room: _________
Item Description Complying Not
Complying
Comments
1 VAV installation
2 Accessibility
3 VAV support
4 Duct connections
5 VAV Damper is totally opened
6 Thermostat condition
7 Electrical Connection
8 Grounding
9 Tagging & labeling
10 Cleanliness
11
12
Comments:
____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 12 / 20
Representative Name Signature Date
AHUFanPerformanceTestSheetBuilding: _________ Date: _________
Location: _________ Related Drawings: _________
Room: ________
Filter: _________ Type: _________ Size: ________
Electric heater capacity: ________ Kw
AHU No. AHU Manufacturer AHU Model No.
Fan
Manufacturer: Type:
Serial Number: Size:
Model Number: Pitch Angle:
Motor
Manufacturer: Frame No.
Serial Number: Power:
Type: FLC:
Drive
Manufacturer: Fan Pulley Dia: Type: Fan Shaft Dia: Belt Size: Motor Pulley Dia: No. of Belts: Motor Shaft Dia
Starter
Manufacturer: O/L Range Type: Timer setting: O/L setting: Fuse Rating:
Performance
Fan
Design Actual
Discharge airflow L/s L/s %
Outlet airflow L/s L/s %
Return airflow L/s L/s %
Fresh airflow L/s L/s %
Coils section pressure drop Pa Pa
Filters section pressure drop Pa Pa
Discharge static pressure Pa Pa
Inlet static pressure Pa Pa
Velocity pressure Pa Pa
Total pressure Pa Pa
RPM RPM RPM
Motor
Voltage: Volt Volt
Current: Amps L1 L2 L3 Amps
Speed: RPM RPM
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 13 / 20
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 14 / 20
DuctTraverseReadingsBuilding: _________ Date: _________
Location: _________ Related Drawings: _________
Room: ________
Vel. Read Section
1st 2nd 3rd 4th 5th 6th 7th 8th Average Velocity
A
B
C
D
E
F
G
H
Final Average Velocity (m/s)
Comments:
____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
Design Flow Duct Size Duct Area Design Velocity
X Average Velocity Actual Flow % design Static Pressure
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 15 / 20
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 16 / 20
TerminalAirDistributionReadingsBuilding: _________ Date:_________
Location: _________ Related Drawings:_________ Room: ________
Terminal Ref.
Terminal Maximum Actual
Type Size Free Area
Factor
Design
ips
Actual
Ips %
Design
Design
ips
Actual
Ips %
Design
Total Airflow (L/S)
Comments:
____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 17 / 20
CoilPerformanceTestSheetBuilding: _________ Date:_________
Location: _________ Related Drawings:_________
Coil Data Cooling coil
Heating Coil
Comments
Manufacturer
Model number
Coil type
Face area (m2)
Number of rows
Number of fins
Coil material
Air Side
Test Data Design Actual Design Actual
Air Flow
Air velocity
Pressure drop
Out. Air DB/WB
Ret. Air DB/WB
Ent. Air DB/WB
Lvg. Air DB/WB
Coil Air T (C)
Water Side
Water flow (lps)
Pressure drop (Pa)
Ent. Water temp (C)
Lvg. Water temp (C)
Coil water T (C)
Comments:
_____________________________________________________________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 18 / 20
VariableAirVolumeBoxesBuilding: _________ Date:_________
Location: _________ Related Drawings:_________
PRE-START-UP INSPECTION
Check the following equipment for:
local valving and piping local ductwork mounting support and seismic system maintenance access valve operation damper operation sensor location and operation Control system - point to point checks complete Building cleanliness
START-UP
Start air handling system (see separate checklist) Local air leakage acceptable
Unit ID
Room Reheat Ducting Valving
& Piping
Mounting Support Seismic
Maint. access
Valve operation
Damper operation
Airflow Sensor
Temp. Sensor
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 19 / 20
AHUSchematic
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 20 / 20
This section is dedicated to the efficiency of AHUs and VAVs:
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 11
Testing & Commissioning Procedure
Chillers and Accessories
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 11
TableofContents1 – General : .................................................................................................................................................. 3
1.1 – Purpose of the Testing & Commissioning Procedures ..................................................................... 3
1.2 – Reference to Other Controlling Documents .................................................................................... 3
1.3 – Responsibility ................................................................................................................................... 3
2 – Tests & Inspections to be Carried Out : .................................................................................................. 3
2.1 – Visual Inspection .............................................................................................................................. 3
2.2 – Tests To Be Carried Out (Before or During Chiller operation) ......................................................... 3
2.4 – Operational Tests ............................................................................................................................. 4
3 – Testing Equipment: ................................................................................................................................. 4
4 – Safety: ..................................................................................................................................................... 4
Appendix A .................................................................................................................................................... 5
Appendix B .................................................................................................................................................... 7
Checklist & Start‐up Inspection ................................................................................................................. 8
Chillers ....................................................................................................................................................... 8
Primary Pump Performance Test Sheet .................................................................................................... 9
System Verification/Start up Check List .................................................................................................. 10
Chillers ..................................................................................................................................................... 10
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 11
1–General:
1.1–PurposeoftheTesting&CommissioningProcedures
Having already been inspected as materials and installed in their reserved locations, the purpose of this document is to ensure that the Chillers and their components are installed as required, are in a good condition, and operating properly.
1.2–ReferencetoOtherControllingDocuments 1.2.1 –ReferenceDocuments
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1.2.2 –ReferenceDrawings
Refer to Appendix A
1.3–ResponsibilityThe main contractor will carry out the testing and commissioning with the association of his
subcontractor and the related supplier.
2–Tests&InspectionstobeCarriedOut:
2.1–VisualInspection
When the installation of the Chillers is complete, a visual inspection should be carried out to ensure that the workmanship is satisfactory, and that the system complies with the approved design and project specifications. Checklists that should be used with visual inspection for the system are included in this document.
2.2–TestsToBeCarriedOut(BeforeorDuringChilleroperation)Some tests should be carried out before or during chiller operation as follows:
1- Primary chilled water system. 2- Expansion tanks system. 3- Water treatment systems. 4- Chilled water system. 5- Fan Coil Units. 6- Air Handling Units.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 11
2.4–OperationalTestsThis test should be held on a summer day (hot and humid weather) as follows:
1. Provide required cooling load in building. 2. Operate the primary and secondary pumps. 3. Test shall be done on chillers one by one. 4. Wait for several hours till the system is stabilized. The actual performance for chillers
components as evaporator, condenser, compressor, motor, and others shall be checked by recording readings and measurements as per the performance test sheets included in this document.
5. Verify that all controls are operational.
3–TestingEquipment:The following instruments will be used in the testing and commissioning of the Domestic Water
System.
a. Multi‐meter. b. Halogen detector. c. Electronic leak detector. d. Manometer (mercury type). e. Noise level meter f. Pressure gauges & thermometers
The testing equipment should have been approved by the Engineer.
4–Safety: Skilled technicians should do all tests operation under the supervision of a Senior
Mechanical Engineer.
The Operator should be fully equipped with all safety equipment as per the Safety
Manual applied in the project.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 5 / 11
AppendixA
List of References Drawings
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 6 / 11
Building Drawing No. Rev Drawing Name
Status Date Comments
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 7 / 11
AppendixB
Testing & Commissioning Forms
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 8 / 11
Checklist&Start‐upInspection
ChillersBuilding: __________ Date: ________
Location: __________ Related Drawings: _________ chillers No: _________
Item Description Complying Not
Complying
Comments
1 All snags are removed
2 Chillers installation
3 Anti-vibration installation
4 Pipes connections to evaporator side
5 Valves installation
6 Modulating valve installation & operational
7 Chillers insulation conditions
8 Differential pressure installation & operation
9 Connection to expansion tanks is as per approved detail
10 Expansion tanks operation and setting
11 Starter installation and calibration
12 Connection to power supply
13 Tightness of electrical connections
14 Grounding is installed and tested
15 Tagging and labeling
16 Name plate
17 Control panel
Comments:
___________________________________________________________________
___________________________________________________________________
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 11
PrimaryPumpPerformanceTestSheetBuilding: _________ Date:_________
Location:_________ Related Drawings:_________
Pump
Manufacturer: Size:
Serial Number: Stages:
Model Number: Seal Type:
Type: Base:
Motor
Manufacturer: Type:
Serial Number: Output(HP):
Model Number: FLC:
Performance
Pump
Design Actual
Flow Rate: I/s I/s
Pump Head: Bar ‐ ‐ Bar
Shut off Head: Bar ‐ ‐ ΔP: Bar
Speed: RPM ΔP: RPM
NSPH: Bar
Motor
Voltage: Volts Volts
Current: Amps L1 L2 L3 Amps
Speed: RPM RPM
Power:
Comments:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 10 / 11
SystemVerification/StartupCheckList
ChillersBuilding: __________ Date: ________
Location: __________ Related Drawings: _________ chillers No: _________
ITEM COMMENTS
PRE-START-UP INSPECTION
Commissioning lock-out procedures reviewed Operation and maintenance information Mounting/support system Seismic restraints Maintenance clearance Local valves/piping correct (including expansion tanks, make-up water and identification).
Pressurization and leak tests Supplier pre-start (including charging the system) (report attached)
Chemical cleaning and treatment (report attached) Insulation/lagging Refrigerant relief valve Temperature and pressure gauges Flow switches - safety interlocks Temperature sensors - safety interlocks UL and ASME approvals Control/diagnostic/programmable module Electrical wiring Overload protection (sized correctly) Disconnect switch (tested) Control system - point to point checks complete
START-UP
Start chilled cooling system to create load
Chiller startup by supplier
Modulation through specified range
Safety interlocks
Supplier certificate or log provided for start-up and all specified and regulatory tests
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 11 / 11
This section is dedicated to the electrical efficiency:
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 13
Testing & Commissioning Procedure
Cooling Pumps, Piping, & Accessories
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 13
TableofContents1 – General : .................................................................................................................................................. 3
1.1 – Purpose of the Testing & Commissioning Procedures ..................................................................... 3
1.2 – Reference to Other Controlling Documents .................................................................................... 3
1.3 – Responsibility ................................................................................................................................... 3
2 – Tests & Inspections to be Carried Out : .................................................................................................. 3
2.1 – Visual Inspection .............................................................................................................................. 3
2.2 – Pipe Pressure Leak Test .................................................................................................................... 3
2.3 – Pipe Flushing Process ....................................................................................................................... 3
2.4 – Operational Tests ............................................................................................................................. 4
2.5 – Tolerance .......................................................................................................................................... 5
3 – Testing Equipment : ................................................................................................................................ 5
4 – Safety: ..................................................................................................................................................... 5
Appendix A .................................................................................................................................................... 6
Appendix B .................................................................................................................................................... 8
Checklist & Start‐up Inspection ................................................................................................................. 9
Chilled Water Systems .............................................................................................................................. 9
Pump Performance Test Sheet ............................................................................................................... 11
Water Flow Balancing Sheet ................................................................................................................... 12
Chilled Water System .............................................................................................................................. 12
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 13
1–General:
1.1–PurposeoftheTesting&CommissioningProceduresHaving already been inspected as materials in their reserved locations, the purpose of this
document is to ensure that all Pumps, Piping, & Accessories are in a good condition and
operating properly.
1.2–ReferencetoOtherControllingDocuments 1.2.1 –ReferenceDocuments
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1.2.2 –ReferenceDrawings
Refer to Appendix A
1.3–ResponsibilityThe main contractor will carry out the testing and commissioning with the association of his
subcontractor and the related supplier.
2–Tests&InspectionstobeCarriedOut:
2.1–VisualInspectionWhen the installation of the Water Pumps, Piping, & Accessories is complete, a visual
inspection should be carried out to ensure that the workmanship is satisfactory, and that the
system complies with the approved design and project specifications. Checklists that should be
used with visual inspection for the system are included in this document.
2.2–PipePressureLeakTestWater Pipes lines shall all undergo hydraulic pressure leak test at 1.5 working pressure for 24
hours.
2.3–PipeFlushingProcessPipes should be cleaned and flushed in accordance with the method statement for flushing by
the specialist.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 13
2.4–OperationalTestsAfter the flushing process of cooling water Pipes is complete, the system will be filled with clean treated water and air is scavenged out through automatic air vents and air relief valves. Cooling pumps are then operated to verify the operational performance by checking the actual measured performance against the design data via the following steps:
1. With the pump operating, assure that piping system. AHU's. FCU's are vented properly. 2. Connect a suitable differential pressure gauge across the suction and discharge pressure
test points of pumps. 3. Take measurements for voltage, current. & speed for pump motor. 4. Check the operation of variable frequency drive by closing partially the main valve. 5. With the pump running, close the discharge valve slowly for several minutes. 6. Determine the "Shut‐off" head and check against manufacturer's data for zero flow. 7. If the test shut‐off head does not coincide with the manufacturer's figure, draw a
corrected curve parallel to the manufacturer's curve starting from the measured shut‐off head.
8. Open discharge valve slowly to fully open position. 9. Record the total head with the D.P Gauge at full flow rate & read the actual flow from
the manufacturer's data, or from the corrected graph curve. If the flow is more than 5% above the design flow then regulate by closing slightly the globe valve.
10. If performance is inadequate refer to installation Contractor & Designer. 11. Record all readings & measurements in the pump performance test sheet attached in
this document.
After verifying the required pump flow, water balancing shall proceed as follows:
12. Check the operation of two/three ways valves. 13. Verify that the farthest FCU or AHU from the pump is receiving the correct design water
flow or more (by using the flow meter at the DRV of this unit) 14. Adjust the FCU's and AHU's flow rates by regulating the DRV's starting with the units of
least resistance and work towards the units with the greater resistance. 15. On cooling system and where three‐way motorized valves are used, balance the globe
valves at the bypass line to restrict the by‐ passed flow to 90% of the maximum value at the relevant coil.
16. Make a final check of pressures and flows of the pumps and terminal units. 17. Record all flow measurements corresponding to each FCU, AHU. HWST & HEX in the
flow balancing sheets attached in this document which are classified as per type of system control as chilled water system.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 5 / 13
2.5–ToleranceThe tolerance on the performance of pumps and coils are as per specification the following:
Pumps: ‐0%, + 5%.
Coils: plus/minus 5%.
3–TestingEquipment:The following instruments will be used in the testing and commissioning of the Domestic Water
System.
a. Tachometer
b. Liquid Manometer
c. Clamp‐multimeter
d. Pressure gauges
The testing equipment should be approved by the Engineer.
4–Safety:
Skilled technicians should do all tests operation under the supervision of a Senior
Mechanical Engineer.
The Operator should be fully equipped with all safety equipment as per the Safety
Manual applied in the project.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 6 / 13
AppendixA
List of References Drawings
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 7 / 13
Building Drawing No. Rev Drawing Name
Status Date Comments
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 8 / 13
AppendixB
Testing & Commissioning Forms
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 13
Checklist&Start‐upInspection
ChilledWaterSystemsBuilding: __________ Date:________
Location:__________ Related Drawings:_________
Pumps No:_________
Item Description Complying Not
Complying
Comments
1 Pump located as per drawings
2 Piping and insulation
3 Pipes flushing
4 Pump base & supporting system
5 Valves are open or set
6 Strainers are clean
7 Two way valve operational
8 Bypass modulation valve operational
9 VFD installation & operational
10 Difference pressure transducer operational
11 Gauges & thermometer
12 Flexible connections
13 Shaft alignment
14 Guard in place
15 Completeness of components
16 Grounding is installed and tested
17 Tightness of electrical connections
18 Labeling and tagging
19 Lubricant
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 10 / 13
Pump Start‐up
20 All normally open valves are fully open
21 All bypass valves are closed
22 Starter is setting correctly
23 Motor current reaching design value
24 Impeller rotation direction
25 Provisions are made for TAB measurments
Comments:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 11 / 13
PumpPerformanceTestSheetBuilding: _________ Date:_________
Location:_________ Related Drawings:_________
Pump
Manufacturer: Size:
Serial Number: Stages:
Model Number: Seal Type:
Type: Base:
Motor
Manufacturer: Type:
Serial Number: Output(HP):
Model Number: FLC:
Performance
Pump
Design Actual
Flow Rate: I/s I/s
Pump Head: Bar ‐ ‐ Bar
Shut off Head: Bar ‐ ‐ ΔP: Bar
Speed: RPM ΔP: RPM
NSPH: Bar
Motor
Voltage: Volts Volts
Current: Amps L1 L2 L3 Amps
Speed: RPM RPM
Power:
Comments:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 12 / 13
WaterFlowBalancingSheetChilledWaterSystemBuilding: _________ Date:_________
Pump No:_________ Related Drawings:_________
Item FCU/AHU DRV Design Actual DRV Setting
Remarks
Size Model LPS ΔP Kpa ΔP Kpa LPS %
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Comments:
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 13 / 13
This section is dedicated for the electrical efficiency of the components:
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 11
Testing & Commissioning Procedure
Domestic Water System
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 11
TableofContents1 – General : .................................................................................................................................................. 3
1.1 – Purpose of the Testing & Commissioning Procedures ..................................................................... 3
1.2 – Reference to Other Controlling Documents .................................................................................... 3
1.3 – Responsibility ................................................................................................................................... 3
2 – Tests & Inspections to be Carried Out : .................................................................................................. 3
2.1 – Visual Inspection .............................................................................................................................. 3
2.2 – Pipe Pressure Leak Test .................................................................................................................... 3
2.3 – Pipe Flushing Process ....................................................................................................................... 3
2.4 – Operational Tests ............................................................................................................................. 4
2.5 – Tolerance .......................................................................................................................................... 5
3 – Testing Equipment : ................................................................................................................................ 5
4 – Safety : .................................................................................................................................................... 5
Appendix A .................................................................................................................................................... 6
Appendix B .................................................................................................................................................... 8
Checklist & Start‐up Inspection ................................................................................................................. 9
Domestic Water Systems .......................................................................................................................... 9
Pump Performance Test Sheet ............................................................................................................... 11
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 11
1–General:
1.1–PurposeoftheTesting&CommissioningProceduresHaving already been inspected as materials in their reserved locations, the purpose of this
document is to ensure that all Pumps, Piping, & Accessories are in a good condition and
operating properly.
1.2–ReferencetoOtherControllingDocuments 1.2.1 –ReferenceDocuments
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1.2.2 –ReferenceDrawings
Refer to Appendix A
1.3–ResponsibilityThe main contractor will carry out the testing and commissioning with the association of his
subcontractor and the related supplier.
2–Tests&InspectionstobeCarriedOut:
2.1–VisualInspectionWhen the installation of the Water Pumps, Piping, & Accessories is complete, a visual
inspection should be carried out to ensure that the workmanship is satisfactory, and that the
system complies with the approved design and project specifications. Checklists that should be
used with visual inspection for the system are included in this document.
2.2–PipePressureLeakTestWater Pipes lines shall all undergo hydraulic pressure leak test at 1.5 working pressure for 24
hours.
2.3–PipeFlushingProcessPipes should be cleaned and flushed in accordance with the method statement for flushing by
the specialist.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 11
2.4–OperationalTestsAfter the flushing process for water line is complete, the system will be filled clean water and
air is scavenged out through automatic air vents and air relief valves. The Pumps are then
operated to verify the operational performance by checking the actual measured performance
against the design data via the following steps:
1. Connect a suitable differential pressure gauge across the suction and discharge
pressure test points of pumps.
2. With the pump running, close the discharge valve slowly for several minutes. (Do not
close any valves in the discharge piping of a positive displacement pump).
3. Determine the “Shut‐off” head and check against manufacturer’s data for zero flow.
4. If measured shut‐off head does not coincide with the manufacturer’s figure. Draw a
corrected curve parallel to the manufacturer’s curve starting from the measured shut‐
off head.
5. Open discharge valve slowly to fully open position.
6. Record the total head with the D.P. Gauge at full flow rate & read the actual flow from
the manufacturer’s data, or from the corrected graph curve.
7. If total head of pump is higher than design data, the water flow will be lower than
designed. Solution will be prepared and submitted to the Engineer for approval.
8. If the total head of pump is less than design data, the water flow will be higher than
designed. Closing of the globe valve at the pump discharge will increase the pressure
drop of system and reduce the flow until reach 110% of the design flow. Motor current
shall be checked and be kept within the nameplate indication.
9. Take measurements for voltage, current, & speed for pump motor.
10. Record all readings & measurements in the pump performance test sheet attached in
this document.
Once pumps are tested, overall domestic water system will be operated tested as per
procedure described in the test sheet enclosed to this document.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 5 / 11
2.5–ToleranceThe tolerance on the performance of pumps is as per specification plus/minus 5%.
3–TestingEquipment:The following instruments will be used in the testing and commissioning of the Domestic Water
System.
a. Tachometer
b. Clamp‐multimeter
c. Pressure gauges
The testing equipment should be approved by the Engineer.
4–Safety: ‐ Skilled technicians should do all tests operation under the supervision of a Senior
Mechanical Engineer.
‐ The Operator should be fully equipped with all safety equipment as per the Safety
Manual applied in the project.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 6 / 11
AppendixA
List of References Drawings
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 7 / 11
Building Drawing No. Rev Drawing Name
Status Date Comments
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 8 / 11
AppendixB
Testing & Commissioning Forms
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 11
Checklist&Start‐upInspection
DomesticWaterSystemsBuilding: __________ Date:________
Location:__________ Related Drawings:_________ Pumps No:_________
Item Description Complying Not Complying Comments
1 Pump location
2 Pipe layout
3 Pipes flushing
4 System is vented properly
5 Pump base & supporting system
6 Flexible connections
7 Suction and discharge connections
8 Strainers are clean
9 Shaft alignment
10 Guards in place
11 Float valve installation
12 Pump location
13 Pipe layout
14 Pipes flushing
15 System is vented properly
16 Pump base & supporting system
17 Flexible connections
18 Suction and discharge connections
19 Strainers are clean
20 Shaft alignment
21 Guards in place
22 Float valve installation
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 10 / 11
Comments:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 11 / 11
PumpPerformanceTestSheetBuilding: _________ Date:_________
Location:_________ Related Drawings:_________
Pump
Manufacturer: Size:
Serial Number: Stages:
Model Number: Seal Type:
Type: Base:
Motor
Manufacturer: Type:
Serial Number: Output(HP):
Model Number: FLC:
Performance
Pump
Design Actual
Flow Rate: I/s I/s
Pump Head: Bar ‐ ‐ Bar
Shut off Head: Bar ‐ ‐ ΔP: Bar
Speed: RPM ΔP: RPM
NSPH: Bar
Motor
Voltage: Volts Volts
Current: Amps L1 L2 L3 Amps
Speed: RPM RPM
Power:
Comments:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 11
Testing & Commissioning Procedure
Fan Coil Units
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 11
TableofContents1 – General : .................................................................................................................................................. 3
1.1 – Purpose of the Testing & Commissioning Procedures ..................................................................... 3
1.2 – Reference to Other Controlling Documents .................................................................................... 3
1.3 – Responsibility ................................................................................................................................... 3
2 – Tests & Inspections to be Carried Out : .................................................................................................. 3
2.1 – Visual Inspection: ............................................................................................................................. 3
2.2 – Operational Tests: ............................................................................................................................ 3
2.5 – Tolerance .......................................................................................................................................... 4
3 – Testing Equipment : ................................................................................................................................ 4
4 – Safety: ..................................................................................................................................................... 4
Appendix A .................................................................................................................................................... 5
Appendix B .................................................................................................................................................... 7
FCU’s Checklist & Start‐up Inspection ....................................................................................................... 8
FCU Performance Test Sheet .................................................................................................................. 10
Terminal Air Distribution Readings ......................................................................................................... 11
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 11
1–General:
1.1–PurposeoftheTesting&CommissioningProceduresHaving already been inspected as materials and installed in their reserved location, the purpose
of this document is to ensure that all FCU’s are in a good conditions and operating properly
1.2–ReferencetoOtherControllingDocuments 1.2.1 –ReferenceDocuments
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1.2.2 –ReferenceDrawings
Refer to Appendix A
1.3–ResponsibilityThe main contractor will carry out the testing and commissioning with association of this
subcontractor and the related supplier.
2–Tests&InspectionstobeCarriedOut:The following tests and inspections will be carried out and recorded on the relative form.
2.1–VisualInspection:Before FCU Operation, visual inspection shall be carried out to ensure that the material has no
defects & the installation is proper. Refer to visual inspection checklist for FCU (s).
2.2–OperationalTests:Operate the FCU from the thermostat at medium speed at the required preset temperature.
Get the air flow rates at grilles or diffusers by using the Airflow Meter (Hood for Ceiling
diffusers and rotating vane for side grilles). Measure the voltage, current & speed, record them
in performance test sheet.
Three speeds flow rate shall be tested for each size of FCU on a selected percentage of 10 to
15% of all units since these units are mass produced and factory tested
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 11
2.5–ToleranceFor air system, the tolerances on terminals and fans are as follows:
1. Supply and return of fan‐coil units shall not be less than 95%.
2. For any space the flow should be within – 5 %and 10 + 10%.
‐ Space with one outlet, the tolerance is as above.
‐ Space with two outlets, the tolerance is – or – 10%.
‐ Space with 3 outlets or more, the tolerances are – or – 10%.
3–TestingEquipment:The following instruments are to be provided before proceeding in the testing and
commissioning of the system:
a. Tachometer
b. Clamp‐multimeter
c. Ballometer
d. Anemometer
The testing equipment should be approved by the Engineer.
4–Safety: Skilled Technicians should do all tests operation under the supervision of Senior
Electrical Engineer.
The Operator should be fully equipped with safety equipment as per the Safety
Manual Applied in the project.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 5 / 11
AppendixA
List of References Drawings
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 6 / 11
Building Drawing No. Rev Drawing Name
Status Date Comments
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 7 / 11
AppendixB
Testing & Commissioning Forms
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 8 / 11
FCU’sChecklist&Start‐upInspectionBuilding: __________ Date:________
Floor:__________ Related Drawings:_________
Room No:_________
Item Description Complying Not
Complying
Comments
1 FCU installation
2 Supporting system
3 Anti‐vibration system
4 Fan shaft alignment
5 Filters condition
6 Condensate drain pan and pipes
7 Connections to HVAC pipes
8 Pipes and valves are properly insulated
9 Valves, 3 way valve and accessories
10 Strainers are clean
11 FCU duct connection
12 Duct are clean
13 Thermostat condition
14 Electrical connection & disconnect
switch
15 Physical condition
16 Tagging & Labeling
17 Cleanliness
FCU Start‐Up
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 11
Item Description Complying Not
Complying
Comments
18 Motor current reaching design value
19 Fan rotation
20 Motor & Fan free from vibration
21 No. Seepage of lubricant from the
housing
22 Related F/A fan operated and tested
23 Related exhaust fan operated and
tested
Comments:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 10 / 11
FCUPerformanceTestSheetBuilding: _________ Date:_________
Location: _________ Related Drawings:_________ Room: ________
Fan Coil Tag
Fan Coil Manufacturer
Fan Coil Model No.
Fan
Manufacturer:
Serial Number: Type:
Model Number: Size:
Motor
Manufacturer:
Serial Number: Power:
Model Number: FLC:
Performance
Fan
Design Actual
Fan airflow high speed L/s L/s %
Outlet airflow high speed L/s L/s %
Fan airflow medium speed L/s L/s %
Outlet airflow medium
speed
L/s L/s %
Fan airflow low speed L/s L/s %
Outlet airflow low speed L/s L/s %
Static pressure (for ducted fan‐coil)
Pa
Motor
Voltage: Volt Volt
Current: Amps Amps
Speed: RPM RPM
Power:
Comments:
____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 11 / 11
TerminalAirDistributionReadingsBuilding: _________ Date:_________
Location: _________ Related Drawings:_________ Room: ________
Terminal Ref.
Location
Terminal Design Actual
Type Size Free Area Factor
lps m/s High Medium Low
% Design m/s lps m/s lps m/s lps
Total Airflow (LS)
Comments:
____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 14
Testing & Commissioning Procedure
Fans
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 14
TableofContents1 – General : .................................................................................................................................................. 3
1.1 – Purpose of the Testing & Commissioning Procedures ..................................................................... 3
1.2 – Reference to Other Controlling Documents .................................................................................... 3
1.3 – Responsibility ................................................................................................................................... 3
2 – Tests & Inspections to be Carried Out : .................................................................................................. 3
2.1 – Visual Inspection: ............................................................................................................................. 3
2.2 – Operational Tests: ............................................................................................................................ 3
2.5 – Tolerance .......................................................................................................................................... 4
2.4 – Acceptable Duct Air leackage ........................................................................................................... 4
3 – Testing Equipment : ................................................................................................................................ 5
4 – Safety: ..................................................................................................................................................... 5
Appendix A .................................................................................................................................................... 6
Appendix B .................................................................................................................................................... 8
Fan’s Checklist & Start‐up Inspection ....................................................................................................... 9
Fan Performance Test Sheet ................................................................................................................... 11
Duct Traverse Readings ........................................................................................................................... 12
Terminal Air Distribution Readings ......................................................................................................... 13
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 14
1–General:
1.1–PurposeoftheTesting&CommissioningProceduresHaving already been inspected as materials and installed in their reserved location the purpose
of this document is to ensure that:
‐ The Fans are in a good condition and operating properly.
‐ Airflows in relevant ducts & air terminals are as per design drawings.
1.2–ReferencetoOtherControllingDocuments 1.2.1 –ReferenceDocuments
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1.2.2 –ReferenceDrawings
Refer to Appendix A
1.3–ResponsibilityThe main contractor will carry out the testing and commissioning with the related supplier.
2–Tests&InspectionstobeCarriedOut:The following tests and inspections will be carried out and recorded on the relative forms.
2.1–VisualInspection:Before Fan operation, Visual Inspection shall be carried out to ensure that the material has no
defects and installation is proper. Refer to visual inspection checklist for fans.
2.2–OperationalTests:Before running the fan, make sure that all fire dampers, duct volume dampers, splitters
dampers and outlets dampers, splitters dampers and outlets dampers are fully opened. Run the
fan and check if it is giving the required design flow. Then proceed airflow‐balancing starting
with the terminals with least resistance & work towards the terminals with greater resistance.
The terminal with the greatest resistance might be the most remote one or the one that have a
lot of duct direction changes.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 14
Using the Airflow Meter (Hood for ceiling diffusers and rotating vane for side grilles), airflow
rate can be measured at each terminal. Duct volume dampers & splitter dampers shall be
adjusted to distribute the required flow in the various branches. Airflow velocity in duct (Duct
Traverse reading) shall be measured by a Pitot Traverse; several velocities should be taken to
get the average velocity. Volumetric airflow rate can then be calculated by multiplying the final
average velocity by the duct area. Fan static pressure (inlet, outlet, total) shall be measured by
Micro‐Manometer. Fan & Motor speed, electric Current, Voltage etc…. Shall be measured as
well.
2.5–ToleranceFor air system, the tolerances on terminals and fans are as follows:
1. Supply, return and exhaust fans shall not be less than 95%.
2. For any space the flow should be within – 5% and – 10%.
‐ Space with one outlet, the tolerance is as above.
‐ Space with two outlets, the tolerance is + or – 10%.
‐ Space with 3 outlets or more, the tolerances is + or – 10%.
3. Return and exhaust inlets, the tolerance is + or – 10%.
2.4–AcceptableDuctAirleackageAs per specification, duct static pressure and seal classes are defined as below:
Low pressure: 0 to 5 mm w.g., seal class C.
Medium pressure: 50 to 75 mm w.g., seal class B.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 5 / 14
3–TestingEquipment:The following instruments are to be provided before proceeding in the testing and
commissioning of the system:
a. Tachometer
b. Clamp‐multimeter
c. Ballometer
d. Micro Manometer / Pitot tube
e. Anemometer
f.dB meter
The testing equipment should be approved by the Engineer.
4–Safety: Skilled Technicians should do all tests operation under the supervision of Senior
Mechanical Engineer.
The Operator should be fully equipped with safety equipment as per the Safety
Manual Applied in the project
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 6 / 14
AppendixA
List of References Drawings
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 7 / 14
Building Drawing No. Rev Drawing Name
Status Date Comments
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 8 / 14
AppendixB
Testing & Commissioning Forms
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 14
Fan’sChecklist&Start‐upInspectionBuilding: __________ Date:________
Floor:__________ Related Drawings:_________ Room No:_________
Item Description Complying Not
Complying
Comments
1 Fan installation
2 Fan base and support
3 Alignment of Pulleys and belts
4 Belts Tension
5 Filters condition
6 Electrical Connection
7 Disconnect switch installation
8 Duct are connections
9 Duct are clean
10 Dampers & outlets are totally
opened
11 Access Doors are in correct location
12 Vibration isolators installation
13 Grounding
14 Tagging & labeling
15 Cleanliness
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 10 / 14
Fan Start‐Up Item Description Complying Not
Complying
Comments
16 All Dampers are fully open
17 Outside air louvers are clean
18 Star delta timer setting correctly
19 Motor current reaching design value
20 Fan rotation
21 Motor & Fan free from vibration
22 No. Seepage of lubricant from the
housing
23 Doors and windows are closed
Comments:
___________________________________________________________________
___________________________________________________________________
___________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 11 / 14
FanPerformanceTestSheetBuilding: _________ Date: _________
Location: _________ Related Drawings: _________
Room: ________
Filter: _________ Type: _________ Size: ________
Electric heater capacity: ________ Kw
Fan
Manufacturer: Type:
Serial Number: Size:
Model Number: Pitch Angle:
Motor
Manufacturer: Frame No.
Serial Number: Power:
Type: FLC:
Drive
Manufacturer: Fan Pulley Dia: Type: Fan Shaft Dia: Belt Size: Motor Pulley Dia: No. of Belts: Motor Shaft Dia
Starter
Manufacturer: O/L Range Type: Timer setting: O/L setting: Fuse Rating:
Performance
Fan
Design Actual
Discharge airflow L/s L/s %
Outlet airflow L/s L/s %
Discharge static pressure Pa Pa
Inlet static pressure Pa Pa
Total pressure Pa Pa
RPM RPM RPM
Motor
Voltage: Volt Volt
Current: Amps L1 L2 L3 Amps
Speed: RPM RPM
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 12 / 14
DuctTraverseReadingsBuilding: _________ Date: _________
Location: _________ Related Drawings: _________
Room: ________
Vel. Read Section
1st 2nd 3rd 4th 5th 6th 7th 8th Average Velocity
A
B
C
D
E
F
G
H
Final Average Velocity (m/s)
Comments:
____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
Design Flow: Duct Size: Duct Area: Design Velocity:
Average Velocity: Actual Flow: % design: Static Pressure:
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 13 / 14
TerminalAirDistributionReadingsBuilding: _________ Date:_________
Location: _________ Related Drawings:_________ Room: ________
Terminal Ref.
Terminal Maximum Actual
Type Size Free Area
Factor
Design
lps
Actual
Ips %
Design
Design
lps
Actual
Ips %
Design
Total Airflow (L/S)
Comments:
____________________________________________________________________________________________________________________
_____________________________________________________________________________________________________________________
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 14 / 14
Fan Schematic
Building: _________ Date:_________
Location: _________ Related Drawings:_________
Fan: ________
This section is dedicated to the efficiency of the fans:
Sub‐Contractor Representative
Name
Signature
Date
Main Contractor Representative
Name
Signature
Date
Engineer Representative
Name
Signature
Date
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 3
Testing & Commissioning Procedure
BMS
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 3
This section will be discussing the BMS system testing and commissioning according to the specifications
and design drawings:
Tested by: Contractor:
Witnessed by:
Management and control Yes /No / N.A. Yes /No / N.A.
Monitoring and control of controllers
Yes /No / N.A. Yes /No / N.A.
Programmable logic controllers including sensors, actuators, environmental delivery systems
Yes /No / N.A. Yes /No / N.A.
Operator interface Yes /No / N.A. Yes /No / N.A.
Video display integration Yes /No / N.A. Yes /No / N.A.
Data collection and filing Yes /No / N.A. Yes /No / N.A.
Alarm management Yes /No / N.A. Yes /No / N.A.
Trending Yes /No / N.A. Yes /No / N.A.
Report generation Yes /No / N.A. Yes /No / N.A.
Networl integration Yes /No / N.A. Yes /No / N.A.
Data exchange and integration with a diverse range of other computing and facilities system
Yes /No / N.A. Yes /No / N.A.
Energy monitoring Yes /No / N.A. Yes /No / N.A.
Efficiency monitoring Yes /No / N.A. Yes /No / N.A.
Accessible data in each room:
Space temperature Yes /No / N.A. Yes /No / N.A.
Space temperature set point Yes /No / N.A. Yes /No / N.A.
Occupancy status Yes /No / N.A. Yes /No / N.A.
Operating mode Yes /No / N.A. Yes /No / N.A.
Window status Yes /No / N.A. Yes /No / N.A.
Valve position Yes /No / N.A. Yes /No / N.A.
Air volume flow Yes /No / N.A. Yes /No / N.A.
Percent terminal load Yes /No / N.A. Yes /No / N.A.
Time schedules Yes /No / N.A. Yes /No / N.A.
Zero energy bands Yes /No / N.A. Yes /No / N.A.
Room name Yes /No / N.A. Yes /No / N.A.
Terminal type (e.g. fan coil) Yes /No / N.A. Yes /No / N.A.
Systems connected to the BMS are properly checked, and all feature required by the specification and the drawings are fulfilled:
Yes /No / N.A.
Yes /No / N.A.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 3
Tested by:
Signature
Witnessed by:
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 2
Testing & Commissioning Procedure
Metering Systems
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 2
Test of the meter:
A. Equipment Details
Designation : _______________________ Brand and Model Number : _______________________
B. Reading Accuracy Test
Parameters (All parameters shall be
tested as per specifications and
drawings)
Meter reading Test Kit reading % error
Tested by:
Whitnessed by:
Connection and wiring of the meter:
Proper installation:
Connection to the BMS:
Tested by:
Signature
Witnessed by:
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 10
Testing & Commissioning Procedure
VRVs
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 10
TableofContents1 – General : .................................................................................................................................................. 3
1.1 – Purpose of the Testing & Commissioning Procedures ..................................................................... 3
1.2 – Reference to Other Controlling Documents .................................................................................... 3
1.3 – Responsibility ................................................................................................................................... 3
2 – Tests & Inspections to be Carried Out : .................................................................................................. 3
2.1 – Visual Inspection: ............................................................................................................................. 3
2.2 – Operational Tests: ............................................................................................................................ 3
2.5 – Tolerance ........................................................................................... Error! Bookmark not defined.
3 – Testing Equipment : ................................................................................................................................ 4
4 – Safety: ..................................................................................................................................................... 4
Appendix A .................................................................................................................................................... 5
Appendix B .................................................................................................................................................... 7
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 10
1–General:
1.1 –PurposeoftheTesting&CommissioningProceduresHaving already been inspected as materials and installed in their reserved location the purpose
of this document is to ensure that:
‐ The VRV(s) are in a good condition and operating properly.
‐ Airflows in relevant ducts & air terminals are as per design drawings.
1.2–ReferencetoOtherControllingDocuments 1.2.1 –ReferenceDocuments
‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
1.2.2 –ReferenceDrawings
Refer to Appendix A
1.3–ResponsibilityThe main contractor will carry out the testing and commissioning with the related supplier.
2–Tests&Inspectionstobecarriedout:The following tests and inspections will be carried out and recorded on the relative forms.
2.1–VisualInspection:Before Fan operation, Visual Inspection shall be carried out to ensure that the material has no
defects and installation is proper. Refer to visual inspection checklist for fans.
2.2–OperationalTests:Before running the fan, make sure that all fire dampers, duct volume dampers, splitters
dampers and outlets dampers, splitters dampers and outlets dampers are fully opened. Run the
fan and check if it is giving the required design flow.
All measurements and readings shall be recorded in the relevant performance sheets.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 10
3–TestingEquipment:The following instruments are to be provided before proceeding in the testing and
commissioning of the system:
a. Tachometer
b. Clamp‐multimeter
c. Balometer
d. Micro Manometer / Pitot tube
e. Anemometer
f. Temperature & Pressure gauges
The testing equipment should be approved by the Engineer.
4–Safety:
Skilled Technicians should do all tests operation under the supervision of Senior
Mechanical Engineer.
The Operator should be fully equipped with safety equipment as per the Safety
Manual Applied in the project
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 5 / 10
AppendixA
List of References Drawings
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 6 / 10
Building Drawing No. Rev Drawing Name
Status Date Comments
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 7 / 10
AppendixB
Testing & Commissioning Forms
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 8 / 10
VRV’sChecklist&Start‐upInspection
Building: __________ Date: ________
Floor: __________ Related Drawings: _________ Room No: _________
Manufacturer: Location:
Air Distribution System:
Pressure testing of pipe servicing system or any section
of a completed system, shall be completed prior to the
application of any thermal insulation to the cleaned pipe
surfaces. The pressure test for this system is
recommended by the Manufacturer’s.
Yes/No/N.A Yes/No/N.A
The system is required to vacuum by a vacuum pump. Yes/No/N.A Yes/No/N.A
Add the refrigerant to the indoor unit through the
refrigerant pipe. Yes/No/N.A Yes/No/N.A
The refrigerant is extracted by the new vacuum pump. Yes/No/N.A Yes/No/N.A
Refrigerant High Side Test Pressure, kPa Low Side Test Pressure, kPa
General
Specification
Requirement
Test Result General
Specification
Requirement
Test Result
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 9 / 10
Evacuation Test ‐ (Remark: The evacuation shall be pulled down to between 170 Pa absolute and 340 Pa absolute)
1st Duration of Test 4 hours
2nd Duration of Test 3 hours
3rd Duration of Test 2 hours
Refrigerant Type
Variable Refrigerant Volume System (VRV) (Cont’d)
Design
Data
Test Result Remark
Operating Voltage (V)
Capacity (kW)
Compressor Operating
Current (A)
Evaporator Operating
Current (A)
Discharge Pressure (kPa)
Suction Pressure (kPa)
Discharge Gas Temperature
(°C)
Heat Exchanger Liquid Pipe
Temperature (°C)
Emergency Stop Operation
High Pressure Cut‐out (kPa)
Low Pressure Cut‐out (kPa)
Frequency Inverter (Hz)
Outdoor Fan Step
Outdoor Unit Expansion
Valve Opening
Indoor Unit (Unit No.)
Expansion Valve Opening
Heat Exchanger Liquid Pipe
Temperature (°C)
Discharge Gas Temperature
(°C)
Intake Air Temperature (°C)
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 10 / 10
Outlet Air Temperature (°C)
Capacity (kW)
Return Air Temperature (°C)
Supply Air Temperature (°C)
Room Air Temperature (°C)
Air Flow Rate (l/s)
Tested / Checked
by:
Signature:
Witnessed by:
Signature:
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 4
Testing & Commissioning Procedure
PV System
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 4
This section will be discussing the PV system testing and commissioning according to the
specifications and design drawings:
Building: __________ Date: ________
Floor: __________ Related Drawings: _________ Room No: _________
Tested by:
Contractor:
Witnessed
by:
Notes:
PV Modules and Array
Utility has given permission to interconnect the PV
system‐if applicable.
Yes /No /
N.A.
Yes /No /
N.A.
As‐built electrical drawings received Yes /No /
N.A.
Yes /No /
N.A.
PV system plans and drawings received (showing
array layout, balance‐of‐system (BOS) locations,
components, disconnects, wiring, and conduit
specifications)
Yes /No /
N.A.
Yes /No /
N.A.
PV module specifications Yes /No /
N.A.
Yes /No /
N.A.
PV module mounting details (tilt, orientation) Yes /No /
N.A.
Yes /No /
N.A.
Inverter specifications Yes /No /
N.A.
Yes /No /
N.A.
Combiner‐box specifications Yes /No /
N.A.
Yes /No /
N.A.
Solar resource is documented from location where
array shading will be most significant
Yes /No /
N.A.
Yes /No /
N.A.
Total Solar Resource Fraction (TSRF) is 75% or greater
at all points on the collector(s)
Yes /No /
N.A.
Yes /No /
N.A.
PV modules are physically installed per plans
(number and layout), and have been fastened to the
roof to support weight and wind loads.
Yes /No /
N.A.
Yes /No /
N.A.
Trees and plants will not grow tall enough to shade
array
Yes /No /
N.A.
Yes /No /
N.A.
Array installation is neat and permanent Yes /No /
N.A.
Yes /No /
N.A.
String fuses or circuit breakers are DC‐rated and no Yes /No / Yes /No /
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 4
larger than module fuse rating N.A. N.A.
PV modules are in good condition (no broken glass or
cells, no discoloration, frames not damaged)
Yes /No /
N.A.
Yes /No /
N.A.
Wire and conduit sizes installed per plans Yes /No /
N.A.
Yes /No /
N.A.
Module connectors tight and secure Yes /No /
N.A.
Yes /No /
N.A.
Proper grounding of all other metallic surfaces that
might possibly become energized (conduit, combiner
boxes, disconnect enclosures, etc.)
Yes /No /
N.A.
Yes /No /
N.A.
Inverter, batteries and Electrical
Confirm inverter model number, and batteries model
and number matches plans
Yes /No /
N.A.
Yes /No /
N.A.
Wire and conduit sizes installed per plans Yes /No /
N.A.
Yes /No /
N.A.
Inverter and batteries is easily accessible, and securely
mounted
Yes /No /
N.A.
Yes /No /
N.A.
Electrical room is properly ventilated. Ventilation is
activated.
Yes /No /
N.A.
Yes /No /
N.A.
DC disconnect is DC‐rated and permanently installed
and readily accessible
Yes /No /
N.A.
Yes /No /
N.A.
AC disconnect is permanently installed and accessible Yes /No /
N.A.
Yes /No /
N.A.
Utility power connected Yes /No /
N.A.
Yes /No /
N.A.
Check the Meter data:
Manufacturer
Model
Serial Number
Meter Register Read kWh
Yes /No /
N.A.
Yes /No /
N.A.
System Labeling
All equipment and parts are labeled as required
(check polarity labels…)
Yes /No /
N.A.
Yes /No /
N.A.
Label identifies PV power source attributes at DC
disconnect
Yes /No /
N.A.
Yes /No /
N.A.
Label identifies AC point of connection Yes /No /
N.A.
Yes /No /
N.A.
Outdoor labels designed to withstand the elements Yes /No /
N.A.
Yes /No /
N.A.
Performance Testing
Solar irradiance level: Yes /No /
N.A.
Yes /No /
N.A.
Ambient temperature: Yes /No /
N.A.
Yes /No /
N.A.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 4 / 4
Array temperature: Yes /No /
N.A.
Yes /No /
N.A.
Measure and record open‐circuit voltage (Voc) and
polarity of each string (verify all strings have the same
number of modules)
Yes /No /
N.A.
Yes /No /
N.A.
Measure and record short‐circuit current (Isc) of each
string
Yes /No /
N.A.
Yes /No /
N.A.
Inverter startup sequence – follow manufacturer’s
instructions for initial startup
Yes /No /
N.A.
Yes /No /
N.A.
Confirm inverter’s power reading using independent
meters. (Afterwards, inverter power readings may be
used for subsequent reporting.)
Yes /No /
N.A.
Yes /No /
N.A.
Tested by:
Signature
Witnessed by:
Signature
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 1 / 3
Testing & Commissioning Procedure
Solar Heating System
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 2 / 3
This section will be discussing the solar thermal testing and commissioning according to the
specifications and design drawings:
Building: __________ Date: ________
Floor: __________ Related Drawings: _________ Room No: _________
Tested by:
Contractor:
Witnessed by: Notes:
Installation of Collectors
Collectors have been fastened to the roof to support
collector weight and wind load
Yes /No / N.A. Yes /No / N.A.
Collectors are properly oriented Yes /No / N.A. Yes /No / N.A.
Potential for shading of collectors (trees, buildings,
etc ) is limited
Yes /No / N.A. Yes /No / N.A.
Waterproofing and air sealing of collectors to roof
connection and pipe penetrations
Yes /No / N.A. Yes /No / N.A.
Solar Loop
Solar loop pipe work is watertight/airtight under
pressure
Yes /No / N.A. Yes /No / N.A.
Pipe work in the solar loop has been insulated
thoroughly(no significant gaps in slits or clips or
joints)
Yes /No / N.A. Yes /No / N.A.
Solar loop external pipe and fittings insulated with
UV resistant insulation
Yes /No / N.A. Yes /No / N.A.
Pipes securely fixed but allowing for thermal
movement
Yes /No / N.A. Yes /No / N.A.
Expansion and pressure release valve sized and
installed correctly
Yes /No / N.A. Yes /No / N.A.
Connection of solar loop to storage tank heat
exchanger is correct
Yes /No / N.A. Yes /No / N.A.
Indicate pressure temperature and flow rate in the
solar loop
Yes /No / N.A. Yes /No / N.A.
Check valves are correctly installed Yes /No / N.A. Yes /No / N.A.
Air bleeding of the loop: no audible or visible gases
left
Yes /No / N.A. Yes /No / N.A.
Controller and electrical work
Sensors correctly placed and sensor wire correctly
fastened
Yes /No / N.A. Yes /No / N.A.
Electrical installation is properly secured and Yes /No / N.A. Yes /No / N.A.
PI12.154 AfDB Field office in Abuja Commissioning Plan ‐ April 2013 ‐ 3 / 3
mounted
Circulation indicator for the solar loop is present Yes /No / N.A. Yes /No / N.A.
Temperature readings and controller settings
correct
Yes /No / N.A. Yes /No / N.A.
Domestic hot water installation
Anti‐water boiling controls are in place Yes /No / N.A. Yes /No / N.A.
Pressure relief valve operating correctly Yes /No / N.A. Yes /No / N.A.
Overflow safety valve sent to the drainage Yes /No / N.A. Yes /No / N.A.
Hot water tank and pipes properly insulated Yes /No / N.A. Yes /No / N.A.
Temperature interlock present between solar heated
storage and auxiliary heating
Yes /No / N.A. Yes /No / N.A.
Auxiliary heating set up to allow rising water
temperature above 60 C regularly to avoid
legionella risk
Yes /No / N.A. Yes /No / N.A.
Tested by:
Signature
Witnessed by:
Signature