Part 1 - Description of the works

Testing and commissioning

Testing and commissioning
General Overview
Each M&E contractor will be responsible for the testing and commissioning of the
ir standalone installations. In some instances one contractor's commencement will
be dependant upon another's completion or partial completion. For instance: All co
mmissioning is going to be dependant upon the provision of the LV electrical pow
er supplies. Temporary supplies can be provided to a certain
extent, which should be viewed as a last resort. The final commissioning of chil
lers and cooling towers is going to be dependant upon the chilled water flushing
. BMS commissioning is partially dependant upon the commissioning of the systems
with which it interfaces. Fire alarm commissioning is partially dependant upon
the commissioning of the systems with which it interfaces.
Incomplete building construction and finishes works can add to commissioning del
ays: Escape staircases cannot be pressure tested if there are walls and doors mi
ssing. Busbars cannot be energised whilst contractors are still using them as pa
rt of their scaffolding arrangements. Generator engines cannot be started up whi
lst bricklayers are making good around the flue discharges. Final decorations an
d finishes should be complete where final fix items have to be installed.
It is not the responsibility of the M&E contractors to point out the missing con
struction items that are likely to affect their commissioning. Due to their fail
ings particular M&E contractors may not be able to meet the programmed commissio
ning date. So they are hardly likely to present a list of construction items tha
t will delay the commencement of their commissioning in sufficient time for thos
e items to be cleared before a commencement date they know they cannot meet. It
is more than likely that they will drip-feed the reasons why they can't start as a
smoke screen for their own failings.
So it is important that meetings are held well in advance of the commissioning c
ommencement date to establish the following: -
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Testing and commissioning

The power on requirements associated with commissioning. The progress of design
matters, particularly regarding software writing. Are all of the control panels
available? Are all of the controls available? Are all of the interfaces clearly
established? Are the commissioning resources bought at the award stage still ava
ilable. Are all commissioning method statements in place. There are no misunders
tandings regarding responsibilities i.e. who provides the means of high level ac
cess. Any items of outstanding builderswork that could effect commissioning.
Throughout the commissioning period the majority of the work is going to have to
be demonstrated to the consultants and the local authority's satisfaction. This c
an lead to problems regarding attendance when one particular body cancels for so
me reason. It is important to ensure that this attendance time has been purchase
d from the contractors.
It is important to ensure that the commissioning periods of all individual M&E t
rades tie-in to the same dates. However, the overall commissioning period for th
e electrical
contractor will need to commence before the dates indicated in the other trades
contract programmes. This is because they need to commission their own MV and LV
supplies prior to the LV supplies being available for other trades commissionin
g. The commissioning power availability dates for each of the main areas need to
be separately identified on the contract programmes. It is important to show th
e commissioning periods as separate items. For instance Figure 1.7 clearly indic
ates that the Overall commissioning period is complete by the end of week 45, and
the Integrated System Testing commences on week 46.
Figure 1.7 Typical Contract Programme Commissioning Sequence
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Testing and commissioning
Don't wait until PC for the Operating Manuals (O&M'S), draft copies should be availa
ble well in advance.
Integrated System Testing (IST) When the contractors have completed their stand-
alone commissioning and the associated interfaces with other trades i.e. the fir
e alarm and in particular the BMS. They will all to some extent (perhaps only in
attendance) partake in the Integrated System Testing (IST). This is where all o
f the stand-alone commissioned systems work together to perform the functions as
defined in the specifications. This will include: Automatic sequential re-start
ing of systems by the generator following a power failure. Functionality of all
plant in conjunction with the BMS in fully automatic operation. Functionality of
all plant in conjunction with the fire alarm in fully automatic operation.
In order for this to work correctly all installation and commissioning works ass
ociated with the IST need to be complete before its commencement. It will be sai
d that the IST can be carried out in one-week, which in theory may be correct; i
n practice it is best to allow four-weeks.
Black Building Testing At sometime during the IST period the Black Building Test
s need to be carried out. These can be done either at the beginning or end of th
e IST period. The timing is usually determined by how well or not so well the IS
T is performing. The Black Building Tests basically relate to the operation of t
he electrical changeovers in respect of partial and total power failure scenario
s. It will be said that the Black Building Tests can be carried out in two-days,
which in theory may be correct; in practice it is best to allow two-weeks.
Individual services testing and commissioning Ventilation
The ventilation ductwork testing will be carried out and witnessed by the consul
tants during the natural progression of the installation works. The testing of d
uctwork involves air pressurisation for a given period of time. Following the su
ccessful testing particular aspects of the ductwork installations regarding supp
ly air require insulating; insulating is also referred to as lagging. The insulati
on of ductwork should not be carried out until the ductwork has been tested.
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There are occasions where parts of an installation may require sectional testing
before they are fully complete in order to allow for the commencement of a foll
owing trades work. For instance, sectional testing would be necessary for ductwo
rk that was going to be concealed within riser shafts, if it meant that the rise
r encasement was critical for another facet of the project's commencement. Section
al testing would also be necessary for all M&E services installed above a none-a
ccessible ceiling in a lobby or reception area, if the ceilings had to commence
before the M&E services were entirely complete.
The commissioning of a ventilation system should not commence until it has been
thoroughly inspected. The AHU's, ductwork, plenums and attenuators need to be clea
red of debris and dust. The commissioning of individual ventilation systems invo
lves: 1. Power on and live cable testing. 2. Ensuring that the fans and controls
operate correctly when turned on. 3. Ensuring that the BMS control is operation
al. 4. The total volumes of air movement are in accordance with the specificatio
n. 5. The balancing of the air around the system. 6. The fans and controls opera
te in smoke extract mode with the fire alarm.
Not all ventilation systems will have the full extent of the above six items ass
ociated with their commissioning. Some ventilation systems work in conjunction w
ith one-another and could be partially complete for a period of time. It is unli
kely that any of the ventilation systems would be commissioned with the BMS in au
tomatic prior to the IST.
Mechanical Mechanical pipework testing
The mechanical pipework testing will be carried out and witnessed by the consult
ants following sectional completions of the installation. The testing of pipewor
k involves water pressurisation for a given period of time. Following the succes
sful testing particular
aspects of the pipework installations require insulating. The insulation of pipe
work should not be carried out until the pipework has been tested. There are ins
tances where the pipework will have to be trace heated prior to being lagged. Si
milarly to the ventilation there are going to be instances where sectional testi
ng of pipework is required. The chilled water pipework cannot be tested until it
is filled with water, and it should not be filled with water until the entire p
ipework installation, or large sections of it have been completed. Once the chil
led water system pipework has been filled and is undergoing pressure testing, al
l of the leaking welds and flanged joints should reveal themselves.
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When the leaks have been discovered and rectified the system can be re-filled an
d retested. (The system may have to be fully drained in order to carry out the r
epairs). The capability of the mechanical contractor will determine how many tim
es they have to drain and re-fill the system to repair any leaks.
Chilled / condenser water pipework commissioning
The items described below refer also to the commissioning of the condenser water
pipework. The chilled water pipework system is fundamental to the final commiss
ioning of all ventilation systems that require cooling. Therefore any delays to
the chilled water
pipework installation and its subsequent commissioning will extend the IST perio
d and delay the project completion date.
With regard to its commissioning the chilled water pipework system as an entity
is probably one of the most difficult to accomplish. Because as stated within th
e Mechanical Description of Works The chilled water pipework extends throughout a
lmost every area of the building This will include the key areas of the project i
.e. basement level plant rooms, risers and levels 17 and 18 plant rooms.
Once the pipework has been fully tested to the approval of the consultants and t
he commissioning manager then the flushing process can commence.
Flushing involves the pumping of chemically treated water around the pipework. I
n doing so this treatment removes all of the burrs and debris within the pipewor
k that were created during the welding process. The flushing process will be rep
eated until the entire residue has been removed from the pipework to the satisfa
ction of the commissioning manager. A complete description of the chilled water
commissioning process is detailed in template TP01 Chilled Water Plant Room. The
pipework installation is the only part of the chilled water system that gets fl
ushed. The plant items i.e. chillers, AHU's, pumps & fan coil units remain isolate
d from the system and by-pass valves and spades are inserted ensure that the wat
er flow is maintained throughout the pipework. This means that the residue does
not enter into and clog up the small bore pipework that makes up the internal co
oling coils of the plant. Once all of the debris has been flushed out of the pip
ework the by-pass valves are closed and clean treated water is allowed to flow t
hrough all of the coils within the plant.
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The above describes the correct method of carrying out the work. Of course in th
e real world all manner of shortcuts are utilised to meet the commissioning date
. These usually involve the blanking off of pipes in risers that should serve ar
eas where the pipework has not been installed (for whatever reason) prior to the
commissioning commencement date. But being eager not to delay the programmed fl
ushing
commencement, mechanical contractors have been known to commence the flushing on
a partly completed pipework installation. Then following its installation the m
issing pipework is back-flushed using the clean treated water that is flowing ar
ound the system. The effects of this can be quite catastrophic, depending upon h
ow much of the systems pipework has been back-flushed, and how much of the resid
ue is blocking the coils of the plant. Unfortunately this may not be known until
particular plant items fail to accomplish their specified criteria. Then it bec
omes a case of stripping down each particular plant item and manually cleaning o
ut the coils. It has been known for a manufacturer to spend six-weeks cleaning o
ut their chiller coils as a result of back-flushing incomplete pipework.
Other items to be aware of during the chilled water commissioning process are: F
aulty main valves blowing causing flooding to the project Pumps undersized by th
e consultants and requiring replacement Main flow and return pipework connection
s crossed
There is a lot of work to be accomplished regarding the installation of the chil
led water pipework system before the commissioning stage is reached. Also, the p
rogrammed installation has to fit within the parameters of the Key Dates and Dur
ations Schedule.
Chillers and cooling towers
Both of the above can be commissioned to a certain extent before they require co
nnection to a fully commissioned condenser water pipework system. The condenser
water pipework will be commissioned in the same manner as the chilled water pipe
work. The chillers and cooling towers then need to be fully commissioned in orde
r to provide cooling to the ventilation plant via the chilled water system.
Public health Rainwater and foul drainage
The rainwater and foul drainage pipework testing will be carried out and witness
ed by the consultants following sectional completions of the installation. The l
ocal authority will also
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want to witness these tests once they are fully complete. The rainwater and foul
drainage pipework testing involves water pressurisation for a given period of t
ime. The only commissioning involves the foul drainage sump pumps that are locat
ed in the basement level B3 slab.
Instances will arise where bathroom pod wastes are connected to foul drainage ri
ser stacks. Both the pod supplier and the riser installer will be responsible fo
r the testing of their own works. Once the pod has been connected to the riser i
t will have to be re-tested through the connection and into the riser. This is f
ine so long as the test holds up. If the test fails then problems will arise bec
ause neither the pod supplier nor the riser installer will initially assume resp
onsibility for the leak. This could amount to both companies re-testing their wo
rks, and if an innocent party is discovered then they will want compensating for
their additional work. A project that consisted of a series of high-rise apartm
ent blocks that collectively contained over 500 bathroom pods would warrant a re
gime that ensured the testing was co-ordinated between all parties. Otherwise th
ere could be serious delays to that project's completion as well extension of time
claims.
Domestic water supplies
The domestic water supply pipework testing will be carried out and witnessed by
the consultants following sectional completions of the installation. The domesti
c water supply pipework testing involves water pressurisation for a given period
of time. Following the successful testing the domestic water supply pipework in
stallations require insulating. This should not be carried out until the pipewor
k has been tested. There are instances where the pipework will have to be trace
heated prior to being lagged. Domestic water tanks will have to be tested for le
akage, booster sets and pumps will have to be commissioned. In toilets, water he
aters need commissioning along with
mixing valves and tap pressure and temperature settings. Flood tests need to be
carried out and finally the system will have to be chlorinated.
Fire protection Wet risers and sprinklers
The fire protection wet riser and sprinkler pipework testing will be carried out
and witnessed by the consultants following sectional completions of the install
ation. The testing of pipework involves water pressurisation for a given period
of time. Following the successful testing particular aspects of the fire protect
ion pipework installations require insulating. The insulation of pipework should
not be carried out until the pipework has been tested.
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Wet riser and sprinkler water tanks will have to be tested for leakage, pumps an
d controls will have to be commissioned along with fire alarm and BMS interfaces
. Flow rates and pump pressures and drain tests have to be carried out. All of w
hich will have to be demonstrated to the local authority.
Electrical
The termination and testing of an MV cable is a specialist operation that usuall
y occurs at the same time. MV cables are generally energised within 24 hours of
termination and testing. Failure to do so means that the testing should be repea
ted before the cables are energised. The switching on and off of MV supplies is
also a specialist operation. An MV supply has to be energised in order to create
a LV supply. It is possible that the MV supply to a transformer could be energi
sed for a long period of time before the supply is switched through to its LV pa
nel. LV cable terminations are not necessarily a specialist operation, but compa
nies tend to sub-out the termination work along with the pulling-in of the LV (&MV
) cables. Before MV / LV supplies are energised the following items need to be c
ompleted or in place: Lockable door to the switch room Main ea
ncoming utility services. Emergency power off buttons installed and working. Met
ering (if remote from LV panel). Test LV panel with remote power source (flash t
est) Pressure test (for MV). Earth cable readings. Phase rotation (supply connec
tions must not be crossed). Written power on method statement. Signage on 11,000
Volt cables. Advise others of power on date. Provide warning signs and notices.
Provide electric shock notice. Provide framed schematic drawing. Provide rubber
mats in front of electrical switchgear and switchpanels. Lock off all switches
on MV and LV switchgear and switchpanels.
Electrical commissioning will not be carried out until the majority of a distrib
ution boards sub-circuits or an LV cable installation has been fully terminated.
Electrical
commissioning involves testing the cables before they are energised to ensure th
at there
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are no short-circuits or earth faults. Then following energisation testing to ma
ke sure that the circuit will trip in the event of a fault occurring.
Typical electrical commissioning problems
A power-on regime needs to be established by the commissioning manager in order
to focus the electrical contractor and prevent power on delays to critical items
.
Single phase 230 Volt supplies for dampers or BMS outstations fed from a local d
istribution board can give rise to commissioning problems. There could be a situ
ation where power is required to these items but the distribution board has not
been commissioned. Worse still, it has hundreds of cables hanging out of it that
are awaiting connection. To prevent situations like this arising the commission
ing manager needs to establish what items are likely to present commissioning pr
oblems and address them accordingly.
Emergency power supplies
Each individual aspect of the emergency power supplies has to be commissioned se
parately before the generators can be fully commissioned. The ventilation, cooli
ng and fuel oil commissioning will be as explained in the previous ventilation a
nd mechanical paragraphs. So by the time the generators are ready to be fully co
mmissioned they should have: Ventilated plant room Cooling system Completed exha
ust Automatic fuel supply Complete and partially tested electrical mains and con
trols
The generators will be run-up and commissioned separately before being synchroni
sed and set to work as a group. They will each undergo a load-test for which a s
eparate loadbank will have to be brought in. The controls and remote starting of
the generators will have to be tested along with the functionality testing of t
he whole electrical systems; culminating with the Black Building Testing. Each o
f these steps will have interfaces with the BMS. The most complicated interface
with the BMS is going to be the load management of the building. This is the
determination and control of the sequential re-switching of the emergency power
supplies to the building following a total power failure.
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BMS
In terms of commissioning everything regarding the BMS is critical. But some thi
ngs are more critical than others. The most critical items are: Power failure /
re-start load management Chilled & condenser water Ventilation
The BMS has input into the majority of the items that make up the IST / Black Bu
ilding Testing. All of these interfaces have to be proved and demonstrated indiv
idually and then globally prior to the IST / Black Building Testing commencement
.
In terms of commissioning the BMS has to demonstrate all of the controls / alarm
s and graphics as identified in the specification, for all associated plant and
switchgear to the consultant's satisfaction.
It is only when the BMS is ready for commissioning that the real problems are ab
out to begin. A typical selection of BMS commissioning problems for a single pla
nt item are listed below. (They usually arrive in this sequence and they commenc
e with the appropriate emotion): -
1. Confusion - with the M&E and fire alarm contractors over who connects to what
with regard to interfaced plant connections. 2. More confusion - with the M&E a
nd fire alarm contractors over who provides what with regard to interfaced plant
connections. 3. Further confusion - regarding exactly what requires power-on fo
r the BMS controls commissioning of a single item of plant. 4. Amazement /slight
anger - when it discovered that the criteria finally determined for item 3 was
actually incorrect. 5. Shock / anger - when it is discovered that there are some
critical points that have not been wired. 6. Debate / rage - to determine the bla
me for item 5. 7. Astonishment - at the discovery that there are not enough point
connections in the local outstation therefore a further outstation is required. 8. M
ajor debate / fighting-talk - to determine the blame for item 7. 9. Joy / surpri
se - the BMS controls did work. 10. Astonishment / fury - following the discover
y that the interfaces with the M&E and fire alarm contractors didn't work, usually
due to the wrong relays being fitted and generally resulting in a small explosi
on.
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11. Bewilderment / time off sick when the software design does not work in relat
ion to the plant and the graphics are displaying something totally different as
well. 12. Satisfaction When it is eventually working correctly. That wasn't too ba
d! So what if there were a few snags lets move on to the next item, only another
109 to go.
There they are, the 12 things needed to know about BMS commissioning. Oh! there
is another. The BMS contractor will not assume responsibility for any of them.
Fire alarm
The commissioning of the fire alarm will revolve around the functionality of its
Cause and Effect Schedule. This relates to all scenarios involving evacuation w
hen fire has been detected with various parts of the building. Like the BMS the
fire alarm interfaces with other systems. All of which have to be proved and dem
onstrated individually and then globally prior to the IST / Black Building Testi
ng commencement.
The final software for the annunciator panel cannot be completely written until
the last detection loop has been completed. This is because the order in which t
he loops are wired will determine the way the software is written, and it cannot
be commissioned until the software writing is complete.
The fire alarm commissioning involves the activation of each individual detector
and a visual inspection of the annunciator panel display to ensure that they ar
e compatible. The ventilation plant interfaces need to be tested including the s
moke extract and staircase pressurisation. All of the ventilation plant should s
hut down, with the exception of the staircase pressurisation fans, which should
start up. There are switches on the annunciator panel that will operate the smok
e extract fans at the discretion of the fire marshal or the fire brigade. Other
items that have to be demonstrated include:
Beam detection Fire telephones Voice alarm sound levels Testing on battery suppl
y only All other plant interfaces Interfaces with the security system Interfaces
with lifts
All of this has to be demonstrated to the consultants and local authority's satisf
action.
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Security
The security commissioning involves the setting up and operational testing of al
l the devices that it consists of. Including the programming of access devices (
cards etc.), which enable various modes of restrictive access. The system should
fail safe (depending upon the area) in the event of power failure or fire detec
tion.
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