T&CM Services Scope
The following is a technical direction statement extracted from a recent bid document
Testing and Commissioning Management
Testing and Commissioning (T&C) Management is a highly developed and technically complex process. Working with the construction teams and programme of work (PoW), all testing and commissioning work needs to be correctly scheduled, tracked, recorded and accurately executed.
T&C Management provides the tools for achieving a fully commissioned development which is essential for correct and efficient operation, maintenance, repair and in time, refurbishment.
The starting point for T&C Management is to establish the programme for the T&C works. This is developed from the project PoW and is a work in progress for the duration of the commissioning works as it is constantly adapting to changes in the project schedule.
The level of detail in the T&C programme also develops over time from an initial outline to sufficient detail to direct the works on site and ensure critical T&C activities are not missed.
An initial / indicative programme of works has been prepared and is shown in Appendix B below. This programme has been prepared using the information provided with the RFP as the basis for the proposal. On appointment this will form the starting point for developing the T&C programme based on the PoW.
Meetings are required on a regular basis to coordinate T&C work, monitor progress, identify and correct any errors that are occurring and manage the administrative tasks of T&C including tracking submissions / approvals.
While many meetings can and will be arrange through tele / video conferencing, key face to face meetings will be held at the war room.
3. Method Statements
Forsspac will provide reference T&C Method Statements and help the Contractors and Suppliers with developing their procedures and processes for carrying out their T&C works including sectional testing, equipment testing and system commissioning.
Forsspac will develop the Integrated Systems Testing (IST) (cause and effect testing) methodology for all of the fire and life safety and related systems. Forsspac will work with TPM, LIPAD, the construction management team and contractors for scheduling of this work which can be complex, time consuming and require a large resource for validation.
This work will integrate MEP services, ELV services and the Special Airport Systems (SAS).
4. Compliance management
One of the greatest challenges is ensuring that all Contractors and Suppliers comply with the requirements for Testing and Commissioning. The level of non-compliance can vary and is not always easy to uncover. There are 3 key approaches which can help to create a high degree of compliance:
5. Team Building
The first and arguably the most important approach to gaining compliance is team building.
Forsspac work with the staff of the Contractors and Suppliers to develop a strong team spirit amongst all parties to the T&C process.
With many years of leading the execution of T&C works, our team is well known to most contractors. We are trusted and known in the industry for our passion for ensuring that the T&C works are correctly carried out.
With this, there is no misunderstanding about the direction and the requirement to execute the T&C works correctly. Knowing where they stand, there is a high level of compliance from the staff of the Contractors and Suppliers from the start.
6. Work references
Establishing the baseline for the correct execution of the works ensures that there is no confusion over the application of method statements or the requirements for record keeping. To this end, testing and commissioning work references are required to be established for all activities. Whether it be for pressure testing of a particular type of pipe, leak or light testing a duct, testing of fans or pumps, a work reference is established.
What this means in practice is that the method statement and process having been established, a sample of the testing work is carried out. For example for pipe testing, this will include checking the calibration of pressure gauge/s used and the qualifications of the technicians doing the work. The test is then executed in accordance with the method statement while being fully witnessed and the test data recorded. Once the test data and records are validated as complying with the method statement this then becomes the work reference for this type of test.
For each Work Reference, the option is available to retest, should an argument arise over say the procedure used or the acceptance criteria.
With the baseline established, the Contractors / Suppliers know what is required which reduces the opportunity for misunderstandings / arguments to arise.
Enforcement ultimately falls back on the contract formed with the Contractor or Supplier.
It is likely that by the time a formal contractual dispute has arisen, there is significant potential for poor workmanship and incorrect testing and commissioning to be in place, which may be hard to undo. To avoid failures in T&C. leading to formal contractual proceedings any discrepancies need to be identified as they occur and appropriate notices served.
Strict enforcement of a Non-Compliance Notice system is therefore necessary to ensure that issues with T&C workmanship / results are recorded and the Contractor or Supplier put on notice that the work will need to be corrected before it is accepted. In practice we have found that there is generally a limited need for NCN’s in T&C work.
8. Progress tracking and Reporting
Progress against programme will be monitored closely. This will cover tracking of method statements, test packs, inspections and tests through the various stages of testing and commissioning, preparation and compilation of Operation and Maintenance Manuals and Training.
Progress will be reported weekly using S curves and spreadsheets as necessary to visualise progress and any delays that are occurring for corrective action to be taken.
A monthly report will be issued identifying progress, issues and concerns. Other reports will be prepared as directed / as needed
9. Commissionability Study
The RFP requires a Commissionability study of the design to be carried out. This is a very important part of the commissioning process leading as it does to resolution of design issues at an early stage. Note that this differs from a design peer review in that the focus is on ensuring the systems as designed can be commissioned effectively.
There are a number of elements in carrying out the Commissionability Study which generally happen in parallel to speed up the process. The process is intended to identify any issues from concerns with the design meeting the Employers Requirements, to specific issues with calculations, equipment schedules and plan / detail design provisions
9.2 Scheme Validation
The starting point is to understand the designs schemes through a review of the Schematic and Single Line Diagrams. This establishes an overall understanding of the services and systems and leads to general questioning of the design intent and design assumptions.
Design schemes are reviewed against the Employers Requirements (ER) to verify that the systems as designed meet the ER.
Any issues found during the Commissionability study will be addressed with the PM team and the designers. A log of issues will be generated and back checks carried out to close issues.
9.3 Calculation validation
The calculations for each trade are reviewed for approach, completeness and correctness
Rule of Thumb calculations provide an insight into the correctness of the outcomes, while a review of the design calculation inputs, settings and outputs provide validation. Spot manual check calculations are also carried out.
9.4 Plan validation
The plans will be reviewed in general for compliance between schemes and plans and between plans and calculations. By doing this, any potential issues with plant / equipment capacity or reticulation routing / sizing will be identified for resolution.
The plans will also be reviewed for compliance with the requirements for commissionability and maintainability. Mark ups will be generated to guide the placement of any additional commissioning devices required and to identify any changes needed in reticulation to enable testing / correct operation of systems and plant.
9.5 Specification Review
A review of the specifications will be carried out to look for any omissions and / or discrepancies between the specs and the ER, the scheme requirements, the equipment schedules and the environmental constraints.
9.6 RFP Compliance
The above provide the approach to the Commissionability Study carried out by Forsspac, at all times ensuring that the specific requirements of the RFP are met.
The key to effective execution of the Pre-Commissioning testing and test witnessing is putting in place the method statements early on, establishing the work references (see above) and randomising the witnessing.
Forsspac have Method Statements for all types of reticulation testing and will use these as the basis for establishing the project method statement with the contractors.
With the overall construction schedule in place and being monitored, our technicians will be on site monitoring the work and observing the installation. This will be recorded on soft copy files of the schematics and single line diagrams and the plans as needed. This allows the technicians to select when they will formally witness a test without pre-scheduling the witnessing activity.
During online or face to face meetings, these files will be used to monitor progress against the plan and to identify any discrepancies for corrective action.
11. Overall System Commissioning
There are several steps leading from static completion of the installation to commissioned systems
Prior to start-up of any plant or equipment, an initial inspection is carried out to establish if start-up can be carried out. A complete punch list will be prepared at this time. Any significant issues with the installation that would impact start-up and operation will be noted and only on rectification / completion will start-up be permitted.
Start up and initial testing follows. This will establish the initial performance of the plant / equipment and enable the carrying out of Testing, Adjusting and Balancing works (TAB works)
TAB works are now carried out and where necessary, adjustments are made to plant / equipment to meet the required system performance.
Pre-acceptance testing is carried out once TAB works are complete, to validate that the system under testing meets the design performance within specified tolerances.
On completion of the pre-acceptance testing and sign off, the system may be offered to the Client for acceptance testing. On completion of the acceptance testing, the system is turned over to the Client operations team.
Acceptance testing for some plant / equipment will be dependent on completion of the Integrated Systems Testing.
During the stages of testing and commissioning, punchlist items will be back checked and signed off once cleared. Any remaining noncritical punchlist items will be retained in the acceptance punchlist which will be included in the acceptance test packs for clearance during the defects liability period.
12. Integrated Systems Testing
Integrated Systems Testing (IST), also known as Cause and Effect testing, is an essential step in the acceptance and turnover of a development to the Client. It is particularly important in an airport development. The potential for a high number of passengers who are unfamiliar with the airport building to be involved in evacuation during an emergency, the issues with airside and landside segregation and the presence of flammable fuel near the building, all contribute the extreme risk that an emergency poses in this environment.
The purpose of IST is to ensure that ALL active systems operate correctly in an emergency. The primary purpose is to ensure correct operation in a fire emergency and this is the most complex emergency to simulate during IST. A major seismic event is also an emergency which will require IST validation.
The initial planning of the IST is to establish the cause and effect matrix. This will identify the number of integrated system tests to be carried out, simulating all identified causes which result in different effects.
The systems involved in IST include:
Fire Detection and Alarm System (FDAS)
Emergency Evacuation Announcement and Public Address System/s
Mechanical Ventilation Systems
Building Management System (BMS)
Fire Protection systems
Fuel Oil Systems
Power Generation System/s
Special Airport Systems
From the cause and effect matrix, the IST schedule is prepared and coordinated with all parties to allocate the resources for conducting the IST.
Prior to IST execution, all individual systems must have completed pre-acceptance testing with no significant punchlist items remaining, such that the correct operation of each system is already proven, including its interaction with command and control through the BMS and FDAS.
As the IST is carried out, the interaction of all systems during the simulated emergencies validate that the command and control systems are working correctly and that all connected systems respond correctly.