Testing Commissioning

GUIDELINE

A Guide to Testing and Commissioning Guidelines

Testing and Commissioning Guidelines

LIST OF SECTION 1.0

INTRODUCTION

1

2.0

DEFINITIONS A ND INTERPRETA TION

1

3.0

PRE-COMMISSIONING

2

3.1

Gen er al

2

3.2

Ob j ec t i v es

4

3.3

Par t i es In v o l v ed

4

3.4

Ef f ec t o f Fai l u r e

4

3.5

Ef f ec t o f Su c c es s

4

3.6

Gen er al Req u i r em en t

6

3.6.1 Te T es t i n g Cer t i f i c at es an d Rec o r d

6

3.6.2 Tes t Eq u i p m en t

6

St ag es i n Pr e-Co m m i s s i o n i n g

6

3.7.1 St ag e On e

6

3.7.2 St ag e Tw o

6

3.7.3 3.7.3 Stage Three

6

3.7

4.0

COMISSIONING

7

4.1

Gen er al

7

4.2

Te Tes t s o n Co m p l et i o n

8

4.2.1 Ob j ec t i v es

8

4.2.2 Par t y In v o l v ed

8

4.2.3 Ty p i c al Pr o c ed u r es

10

St an d ar d Op er at i o n Pr o c ed u r es (SOPs )

20

4.3.1 4.3.1 SOP SOP Submi ssi on

20

4.3.2 Pr o c es s es Req u i r i n g SOPs

20

4.3.3 El em en t s o f SOPs

20

4.3

____________________________________ _____________________________________ ___________________ Testing and Commissioning Guidelines 1 Issue 01/ Revision 00 July 2007


LIST OF TABLE Figure 1: Flow chart of Testing and Commissioning

1

Figure 2: Flow chart of Pre-Commissioning

2

Figure 3: Preliminary Test Objectives

5

Figure 4: Final Test Objectives

9

Figure 5: Preliminary Issues

12

Figure 6: Flow chart of Commissioning

18

Figure 7: Flow chart of Final Test: Test on Completion

19

____________________________________ _____________________________________ ___________________ Testing and Commissioning Guidelines 2 Issue 01/ Revision 00 July 2007


1.0

INTRODUCTION

This guideline serves as a reference for both Pre-Commissioning and Commissioning of Sewerage Works for a development project. It ensures plant functionality and operation efficiency. Guidance is presented in general terms; site-specific requirements may be integrated as where and when necessary. The general flow charts on scheduling tasks of Pre-Commissioning and Commissioning with respective assigning responsibility are as attached. Again, they shall be replicated and modified at the time of application if deem necessary. Testing and commissioning can be divided into two main categories; (1) Pre-Commissioning and (2) Commissioning.

Testing and Commission ing Procedures

Pre - Commissi oning

Commissioning

Figure 1: Flow chart of Testing and Commissioning

2.0

DEFINITIONS AND INTERPRETATION

The following words and expressions shall have the meanings hereby assigned to them: (a) ‘Certifying Agency’ means any person appointed to be a certifying agent pursuant to Rule 7, Section 180 of the Water Services Industry Act 2006. (b) ‘Contractor’ means the person whose tender has been accepted by the Employer and the legal successors in title to the Contractor but not (except with the consent of the Employer) any assignee of the Contractor. (c) ‘Contract’ means the agreement between the Employer and the Contractor for the execution of the Works incorporating the Conditions, Specification, Drawings, Schedules, Tender, Letter of Acceptance and such further documents as may be expressly incorporated by Letter of Acceptance. (d) ‘Contract Price’ means the sum stated in the Letter of Acceptance as payable to the Contractor for the execution of the Works. (e) ‘Design’ means the detailed design, plans, calculation, drawings and the specification for material, equipment and workmanship.

Testing and Commissioning Guidelines Issue 01/ Revision 00 July 2007

1


(f) ‘Engineer’ means the person appointed by the Employer to act as Engineer for the purposes of the Contract. (g) ‘Individual Service Licensee’ refers to the individual Service Licensee responsible for the relevant areas. (h) ‘Qualified Person’ means professional Engineers, Architect or Town Planner; (i) ‘Section’ means a part of the Works specifically identified as such in the Contract. (j) ‘Sub-Contractor’ means any person (other than Contractor) named in the Contract for any part of the Works or any person to whom any part of the Contract has been sub-contracted. (k) ‘Sewerage Works’ means –  

Sewage Treatment Plant, Pump Station; Sludge Facilities and Sewer Network.

(l) ‘Specification’ means the specification of the Works included in the Contract and any modifications thereof made. (m) ‘Test on Completion’ means the tests specified in the Contract or otherwise agreed by the Qualified Person, Certifying Agency, etc. and the Contractor to be performed upon completion of erection and/or installation. (n) ‘Works’ means all Plant to be provided and work to be done by the Contractor under the Contract.

3.0

PRE-COMMISSIONING

3.1

General

Pre-Commissioning is carried out prior to the Commissioning of the plant. This is to ensure that all activities while plant erections have been done accordingly to specification and proper works method. Three (3) stages of Pre-Commissioning have been identified for the purpose mentioned namely; stage one: Acceptance of Equipment, stage two: Installation of Equipment and stage three: Trial Dry Test. Flow chart on Pre-Commissioning procedure is as illustrated in Figure 2. These will involve various tests and procedures undertaken by the Contractor on his own prior to the notification and/or application to the Qualified Person for the final tests to be carried out; hence the use of the label ‘Pre-Commissioning’.


2


Figure 2: Flow chart of Pre-Commissioning Stages

Description

Stage One

Factory Test, As-Delivered/Pre-Installation Testing and Inspection for Acc eptance.

Ac cept ance o f Eq ui pm ent

Documents to be submitted for this stage : Endorsed Construction & Shop Drawing Endorsed As -Built Drawing Electrical Control / Single Line Drawing Product & Material Specifications Operation & Maintenance Manual Quality Assurance Certificate Performance Test Certificate Certificate of Origin Letter of Appointment for Exclusive Agent  

NO

 

Complete & Approve

    

YES

Stage Two Checking of M&E Equipment Installation .

Installation of Equipment



NO



Complete & Approve

Check installation of equipment and accessories against Construction Drawings , Supplier 's Shop Drawings and Technical Literatures etc . through check list Involve checking that the installation are in accordance to supplier 's Procedures and Method Statement for Installation

YES

Stage Three Trial Dry Test Functional & Operational Test for Individual M &E Equipment. 

Refer to Equipment Check List





NO



Functional tests are performed These trial dry tests involve checking the equipment functionality according to the specification The equipment are also checked for vibration and noise etc These tests are carried out jointly with all responsible parties

Complete & Approve

YES

To Commissioning


3


3.2

Objectives

Since the Pre-Commissioning tests are prelude to the Commissioning tests, the Contractor must ensure that the following primary objectives are fulfilled. ( Figure 2) •

That all the complete systems, individual components, etc. are thoroughly adjusted, regulated, balanced, etc. to ensure that these function as intended; That the relevant performance criteria or specifications and/or contract requirements can be satisfactorily met;

•

That any material/structural deficiencies and/or non-conformances could be properly identified and addressed in time before the final tests; and

•

That the Contractor is satisfied and confident that the works are sufficiently ready to undergo the final test without any reasonable possibility of failure.

•

3.3

Parti es Invol ved

The above test shall be carried out by the Contractor in the present of Qualified Person and the Certifying Agency, the other active participants include: •

Individual Service Licensee;

•

Nominated Sub-Contractors;

•

Other Specialist Sub-Contractors; and

•

Third parties, e.g. Independent testers, etc.

3.4

Effect of Failu re

The Contractor must attend to the causes and reasons for any failure experienced and repeat the necessary tests until the purposes listed above are reasonably fulfilled. The Contractor must note that until he has successfully undertaken the tests on his own, any attempt to proceed to the next stage, i.e. final testing may be gamble or an exercise in futility. It may not only further delay his works but may in addition compromise his integrity should the final tests eventually prove unsuccessful.

3.5

Effect of Success

Once the Pre-Commissioning tests have been successfully carried out, the Contractor shall proceed with the application or request for the commissioning tests to be formally undertaken.


4


d n a e r n d o e a i n s t g c i k r n s o f u e w o d s l l t a a l e n t b o a a i t h t d c n e u r n a f u s d t o n t e e e e l o l b T p a m o c

y l e l b b t a a c n c o i a s l r a t p e p e n r a c o e c n e a / b t s h t m n n e t r i o a m a o t c f h s t r a t c e i e f n r p i e u c m s e e n p r e s i u o q T e r

: N O I T E L P S E M S O O C P N R O U P T L S E A T P I Y C R N A I R N I P M I L E R P l a s i n i r f f o t o e c t h t n a r n o t e t u i t n d i o e o f l C n g p n m e o c i h t d y r o c t n r a a a n c h t d y o s e l e l t r i s f u e u s f t s i s n t s a e s e c o T c u s


S . K n h o i t g n c i u S r t s s n n a o b C r a d H n . a r I g , n t i r n e e e m n e i g g n a E n a m M o s r t f c e a c r r t u n o o S C

s e v i t c e j b O t s e T y r a n i m i l e r P : 3 e r u g i F

e e m l b i a t i r n n e a i t a c d s m n e o s s y i e n s r s d a i t m d a o a h t / s d e e n r i c a u s n d n i e e e c i f i o i f t T e n e d d i

5


3.6

General Requirement

3.6.1 Testi ng Certi fic ates and Record Certificates of tests shall be completed when the tests were carried out and the Contractor shall provide the specified number of certificates. The test certificates are compulsory for all tests and shall have detailed record of all necessary information. The Qualified Person shall endorse all test certificates and data records.

3.6.2 Test Equipment The Contractor shall satisfy the Certifying Agency, Individual Services Licensee, etc. of the accuracy of the equipment. The recent calibration test shall be produced or otherwise have them calibrated.

3.7

Stages in Pre-Commi ssi oning

Pre-Commissioning involves the following stages.

3.7.1 Stage One - Acceptance of Equipment / Constr uction Material This involves off-site factory witness testing and pre-installation on site physical inspection and checking of all Mechanical & Electrical (M&E) equipment and accessories as well as construction materials. This is to ensure conformance to the requirements, performance specification, Contractor’s proposal, construction drawings/shop drawings, supplier’s technical literature, source of equipment etc. before approval is given for installation.

3.7.2 Stage Two - Installation of Equipment / Construct ion of Structural Elements This checks installation of equipment and accessories as well as construction of structural elements against construction drawings, supplier’s shop drawing and technical literature etc. It also involves checking that the installations and constructions are in accordance to supplier’s procedure and method statement for installation.

3.7.3 Stage Three - Trial Dry Test At this stage, functional tests for M&E equipment are performed. These trial tests involve checking that the equipments are functioning according to specification. The Contractor carries out various tests and inspection on equipment. These tests will be repeated during commissioning stage. The Pre-Commissioning of this stage is done to avoid major hiccup during the formal commissioning stage.


6


4.0

COMISSIONING

4.1

General

The objective of Commissioning is to ensure that the Sewerage Works is operating as planned and where necessary; establishing training programs and Standard Operating Procedures to ensure continued facility operation. It is vital to note that a Sewerage Works must be operated in accordance with the project design requirements. Hence, the requirements for both Pre-Commissioning and Commissioning a Sewerage Works should also take into consideration the verification of system operation to the component level. All testing procedures, related equipment and materials required and other related items for approval shall be prepared by the Contractor. All documentation relating to the factory tests shall be submitted with the description of the testing procedures. Test certificates shall contain sufficient information for ready identification of equipment and material to which the certificate refers. Performance Commissioning consists of 2 major categories namely; (a) Test on Completion; (b) Standard Operation Procedures. The Contractor shall make available the necessary certified instruments, gauges or any other equipment necessary for checking the installation. During the course of inspection, the Certifying Agency, Individual Services Licensee, etc. shall have the full access for inspecting the progress of works and checking the accuracy as may be required. On completion of erection before commencement, the Contractor shall satisfy himself that the works are entirely suitable for operational services and ready for Commissioning. The Qualified Person responsible for the Sewerage Works shall supervise the commissioning of the Sewerage System. A record of the commissioning of the Sewerage Works shall be prepared and signed by Qualified Person. Such a record shall be made available to the Certifying Agency. All individual component test results during Pre-Commissioning should meet the compliance standard and to be compiled and made available to the Certifying Agency, Individual Services Licensee, etc. The documents shall be jointly analysed and interpreted between responsible parties.


7


4.2

Tests on Completion

4.2.1 Objectives The objectives of Tests on Completion are; (a) To show compliance with the performance requirements and/or contract requirements; (b) To meet the applicable statutory requirements, e.g. MS 1228: Code of Practice for Sewerage Systems, Factories and Machinery Act 1967 (rev 1974), etc.; (c) As a pre-condition to the issuance of the completion certificate, etc.; (d) As a pre-condition to certification by independent third party specialist.

4.2.2 Party Invol ved The party specifically entrusted with the task of carrying out the Tests on Completion varies with the particular form of condition of contract involved. These include: •

The Contractor;

•

Qualified Person;

•

Certifying Agency;

•

Individual Service Licensee;

•

Nominated Sub-Contractors;

•

Other Specialist Sub-Contractors; and

•

Third parties, e.g. independent testers, etc.


8


y r o t u t a t s t e n l e b m a e c r i l i p u p q a e t r e e m o T

h t t i w c a r e t c e n t s n c o n a c i l n a / e p m s n m o e m r r i o t i o f u c r a c q e i e w p f r o i c h e s p s o T

: N O I T E L S P E S M O O C P R N U O P S N T I S A E M T L A N I F

y t r a p d r i e h t t a t i c n f i e t d r n e e c p e e d u s n i s i e o l t b a n e o T


S . S n K . o i h K t g c n h n i o u g i r t S t n i c s s S n u r n t o a s s n C b n r a d o a b n C r a H . a d r H g n I . n a , r i r t I n , e g t n e e i n n r m e i e e g e g m n n i n e E g a g a n m M n E o s a r t f m M c e o a s r c r t f t r n c u e o a o c r t r S C n u o o S C

s e v i t c e j b O t s e T l a n i F : 4 e r u g i F

e b o t n o i t e d l e p i f i m t o r c e t i c m r e p o T

9


4.2.3 Typical Procedur es 4.2.3.1

Prelimi naries Issues

Prior to the commencement of any official tests, the Contractor shall carry out all the ‘Preliminary Tests’ accordingly and both parties should agree upon the principal issues pertaining to the contract, namely: i. The parts of the works to be tested, e.g. components or systems or sections or complete works, etc.; ii. The types of tests to be carried out and the number of tests on an individual and cumulative basis; iii. The anticipated duration of each tests; iv. The programming and sequencing of the tests; v. The facilities required for the tests, e.g. Consumables – water, power, etc.; • •

Labour – number, type and level of skills of personnel, etc.;

•

Testing apparatus/equipment – Type, accuracy, etc.;

•

Party responsible for procuring, paying, etc.

vi. The details of each tests, e.g. Type of readings; • •

Number of readings;

•

Format for recording;

•

Accuracy and tolerance permitted;

•

Other relevant details.

vii. The applicable codes of practice, standard, etc.; viii. The rules on the interpretation of the results inclusive of the criteria of acceptability; ix. The method of resolving disagreements as to interpretation of results, acceptability, etc., unless this is expressly prescribed in the contract; x.

The identities and particular of: The testers

•

•

The recorder of the results/readings

•

Other relevant personnel

•

The interpretators of the results/readings


10


xi. Any other relevant matter or detail.

It is to be noted failure to resolve the above listed matters is the primary cause of either the tests not being successful or failing to meet the eventual certification criteria. Prudent Contractors and Qualified Person must either build most, if not all such requirements into the contract as schedules to the specifications or pre-agree to this way before the works even reach a stage fit for preliminary testing.


11


Figure 5: Preliminary Issues

Extent of Testing

Types of Tests to be Carried Out

Number of Tests

Programme & Sequencing of Tests

Facilities Required for Tests

TEST ON COMPLETION: PRELIMINARY: ISSUES FOR IDENTIFICATION AND AGREEMENT BETWEEN PARTIES

Details of Each Test Applicable Standards, Codes Practices, etc. Rules of Interpretation of Results and Criteria of Acceptability Method of Resolving Disputes as to Interpretations, etc. Identities and Particulars of Various

Other Relevant Matters/Details

Source from Engineering and Construction Contracts Management, Ir. Harbans Singh K.S


12


4.2.3.1.1

Notifi cation by the Contracto r

Once the Contractor has successfully carried out the preliminary testing and is ready for the final tests, he must notify the Qualified Person on his willingness to proceed with the letter.

4.2.3.1.2

Qualif ied Person to Respon d

Upon the receipt of the Contractor’s notice, the Qualified Person must respond accordingly within stipulated time.

4.2.3.1.3

Failur e on Testi ng

If upon testing, should the works or any section fail to pass the tests the following consequences generally ensue: (a) If it is a material or structural failure, the Qualified Person shall: i. Order a retesting or repetition of tests as necessary; or ii. Rejects the works or section involved; or iii. Refuse to certify completion of the whole works or particular section. (b) Should the failure be not a material failure, the Qualified Person shall: i. Order re-testing or repetition of testing of the relevant part as necessary; or ii. Issue a Completion Certificate notwithstanding the works are not fully complete; or iii. The Contract Price shall then be accordingly reduced by diminution in value.

4.2.3.1.4

Retesting

Where the works or any section fails to pass the tests; either: (a) The Qualified Person shall order the Contractor to carry out the necessary retesting or repeat the relevant test; or (b) The Contractor shall on his own volition request for retesting or repeat of the relevant tests. In both instances all costs and/or time implications are wholly shouldered by the Contractor.

4.2.3.1.5

Interpretation of Test Results

Save for any express contract provisions to the contrary, in the event of any disagreement as to the recording, interpretation and acceptability of the test results, the views of the Qualified Person prevails subject to final determination through the appropriate dispute resolution procedure, e.g. arbitration, litigation, etc. Testing and Commissioning Guidelines Issue 01/ Revision 00 July 2007

13


4.2.3.1.6

Successf ul Completio n of Test: Procedures

In the event that all relevant tests on completion are successfully completed, the Qualified Person must certify the said test results within a reasonable period of their completion, i.e. at least prior to or at the date of issue of the Certificate of Practical Completion. Accordingly all test results must be signed off by the: (a) The Tester (e.g. Contractor, Independent Tester, etc.); (b) The Contractor’s authorized representative; (c) The Qualified Person; (d) Certifying Agency; (e) Individual Service Licensee; and (f) Any other relevant party or parties. Copies of the certified test results must be: (a) Distributed to all relevant parties; and (b) Included in the final Operation and Maintenance manuals. The said test results shall be used as a reference during the defect liability period and as part of the facilities management subsequently by the users.

4.2.3.2

Final Tests : Tests on Completion Stages

Final test during commissioning consists of three stages namely stage one: Dry Testing, stage two: Wet Testing and stage three: Endurance Test and Final Document Submission.

4.2.3.2.1

Stage One – Dry Testin g

Dry testing covers all tests that are carried out to demonstrate the functionality of plant and equipment before the introduction of fluid. Dry test is similar to stage three (3) of PreCommissioning phase except that the Statutory Authorities shall be invited to witness the test. Only when dry testing is completed and approved to the satisfaction of the Certifying Agency, Individual Service Licensee etc. will the wet testing be allowed to proceed. The Contractor, Certifying Agency, Individual Service Licensee etc. shall attend. A checklist similar to the Pre-Commissioning Inspection checklist shall be used to document the dry-run inspection. These checklists shall be filled and approved by the Qualified Person prior to the inspection. Testing and Commissioning Guidelines Issue 01/ Revision 00 July 2007

14


4.2.3.2.2

Stage Two – Trial Wet Test

Wet testing covers all tests that are carried out to demonstrate the functionality of individual unit processes. It can be divided into two main scenarios; with or without adequate medium. In the circumstances where the medium operational medium is available, the system shall be tested by using the operational medium. However, in the event where no medium i.e. sewage, sludge or water is present in the area of facilities to be tested, the Contractor is deemed responsible to provide suitable and adequate medium for the purpose of testing mentioned. Trial wet test is conducted to precede the actual wet test to assist in weeding out any remaining fault and fine tune the process so that the plant can be ready for a formal wet test.

4.2.3.2.3

Stage Three – Wet Test

The stage three wet test shall verify the overall performance of the plant using the following means: i. Manually control the plant from the control panel; - Each equipment is switched on at random either singly or in combination with other equipment. Reading will be recorded and flow timed. ii. Using PLC; - All equipments are tested/checked to see if they operate to the design and programme sequence. iii. Flow. - The flow of the fluid shall be observed from the point of entry to the point of discharge. This stage also subject to two typical scenarios, with or without adequate medium i.e. sewage, sludge or water. In the scenario where the operational medium is available, the whole system shall be tested by using the operational medium. However, in the event where no medium is present in the area of facilities to be tested, the Contractor is deemed responsible to provide suitable and adequate medium for the purpose of testing mentioned. All deficiencies found during the inspection and testing should be corrected before start-up. All equipment not to be used immediately is properly protected, and all laboratory equipment is inspected for proper calibration and operation.

4.2.3.2.4

Stage Four – Endur ance Testin g

The plant shall be operated for seven (7) consecutive days under full working conditions in accordance to relevant standard to check that the efficiency and performance of the plant complied with the specified guarantees. At the end of seven (7) days providing the endurance test is satisfactorily completed and the all final O&M manuals and as-built drawings are issued by the Contractor, the Certificate of Practical Completion will then be issued to the Contractor. The plant shall then be officially handed over to the Individual Service Licensee. Testing and Commissioning Guidelines Issue 01/ Revision 00 July 2007

15


(a) Sewerage Works Operation Perfor mance Period The design Qualified Person shall be responsible for the O&M of the sewerage works during the required performance period. The Qualified Person shall demonstrate efficient operation of the sewerage works, in compliance with the project performance standards. The Qualified Person responsibilities shall include, but are not limited to, the following tasks: i. Directing the operation of the treatment works; (Note: to "direct" does not mean to establish a daily "in charge" presence at the treatment works or to assume the role of employee supervisor or chief operator.) ii. Revising the O&M manual to reflect actual operating experience; iii. Training operators; iv. Providing engineering consultation; v. Reviewing laboratory procedures; vi. Conducting periodic site visits to ensure proper operations; vii. Checking process units, sewers, facilities, flows, etc., to ensure proper operation; viii. Preparing ongoing records of plant performance, including tables and graphs monitoring influent quantity and quality, effluent quality, and unit processes control parameters.

(b) Perfor mance Certif icatio n The plant performance criteria developed by the design Qualified Person during design of the facilities shall be tested, and a performance certification report shall be prepared. During the performance period, the Qualified Person shall observe and evaluate plant operations and provide advice and assistance to achieve satisfactory plant performance. The Qualified Person shall advise the Individual Service Licensee if the project is meeting performance standards. If it is not, the Qualified Person shall provide the reasons for not meeting these standards. The Qualified Person shall be responsible for any corrective action necessary to bring the project into compliance with performance criteria. If plant operation does not meet the criteria, the Qualified Person shall prepare and submit the following items: i. A corrective action report;


16


This report shall include an analysis of the cause of the project's failure to meet the performance criteria and an estimate of the nature, scope, and cost of corrective action required to bring the project into compliance. ii. A schedule for undertaking corrective action in a timely manner. The scheduled date by which the Qualified Person will be able to certify the project meets performance criteria. At the end of the performance period, and after performance certification, the Individual Service Licensee accepts responsibility for the sewerage works.


17


Figure 6: Flow chart of Commissioning

Stages

Description

Stage One

Dry Testing Dry Testing

To demonstrate the functionality of Individual Unit Process before the introduction of fluid Testing criteria of equipment Shall be tested mechanically and electrically Functionality shall be in accordance with the design Checklist of testing is similar to Stage 3 of precommissioning



NO

Complete & Approve





Trial Wet Testing

Stage Two Trial Wet Test



NO

Complete & Approve







-

To demonstrate the functionality of STP and equipment using Non -Operational Fluid Note: Operational Fluid may be allowed for exceptional circumstances Functional tests are carried out once the tanks are filled with fluid Type of tests Tes t E quipment

YES

Stage Three

Wet Testing

Wet Testing 



Manual Operate

Using PLC

Flow NO

Fully equipped sewerage facilities shall demonstrated to receive full f low w ithout disruption If the operational liquid is not available and adequate , the testing can used non-operational liquid as a medium

Complete & Approve

Stage Four

YES 

Endurance Test

Complete & Approve

NO

-

YES

-

Submission of Final Documents NO

Complete & Approve

-

Endurance Test Requirements for Endurance Test Sewerage Facilities shall be operated for 7 consecutive days (24 hrs a day ) under normal working condition Sewerage facilities shall be proven to fulfill their specified duties under full design capacity without exhibiting and defects within the period The endurance test shall be done within the agreed time period as stipulated in the contract A testing shall be carried out by using operational liquid if it is available. However, in the event w here operational liquid not available , non-operational liquid is acceptable In the event where the medium is not adequate , endurance test could be done separately based on individual unit processes

YES

Issuance of Certificate of Practical C ompletion Handing Over


18


TEST ON COMPLETION: AN OVERVIEW

TYPE

PURPOSE

• • • •

PRELIMINARY

•

To Show compliance with the Performance Specification/Contract Requirements To meet applicable statutory requirements As a pre-condition to issue of CPC As a pre-condition to certification by Independent 3rd Party Specialist

FINAL TESTS

• Normally undertaken by

• Normally undertaken by

Contractor on his own

either: Contractor in the presence of Qualified Person b) Independent 3rd Party Specialist • Is usually a pre-condition to issue of CPC

• Prior to Final Tests on

• Contractually, responsible

for: • Preliminary and Final

Testing and Commissioning • Satisfactory Completion

FAILURES

Contractual Consequences if material/structural: a) Qualified Person may refuse to issue CPC b) Employer may refuse to take over works/installation. Contractual consequences if not material: a) CPC may be issued; and/or b) Reduction in Contract Price; and/or c) Repetition of tests

•

CONTRACTOR

a)

Completion • Is a necessary prelude to the Final Tests

RESPONSIBILITY

QUALIFIED PERSON

INDEPENDENT TESTER

• Active participant and

• Scope as expressly stipulated

certifier of Final Testing and Commissioning • Default/negligence does not relieve Contractor’s obligations

in Contract • E.g SIRIM, DNV, Lloyds,

TUV, Statutory authorities, etc. • May also be required under

Source from Engineering and Construction Contracts Management, Ir. Harbans Singh K.S

Figure 7: Flow chart of Final Test: Test on Completion


19


4.3

Standard Operation Procedur es (SOPs)

4.3.1 SOP Submissi on The Qualified Person shall provide the Individual Services Licensee a draft of the SOPs at 50 percent construction completion and the final draft of the SOPs 30 days prior to construction completion. At the end of the performance period, the Qualified Person shall also provide a site-tested, final SOP for each major component of the treatment plant.

4.3.2 Processes Requirin g SOPs The SOPs are part of the system O&M manuals and shall require revision to reflect actual operating experience. SOPs shall be prepared for all processes including, but not limited to, those listed below: (a) Pumping stations; (b) Screening removal and disposal; (c) Grit removal;


4.3

Standard Operation Procedur es (SOPs)

4.3.1 SOP Submissi on The Qualified Person shall provide the Individual Services Licensee a draft of the SOPs at 50 percent construction completion and the final draft of the SOPs 30 days prior to construction completion. At the end of the performance period, the Qualified Person shall also provide a site-tested, final SOP for each major component of the treatment plant.

4.3.2 Processes Requirin g SOPs The SOPs are part of the system O&M manuals and shall require revision to reflect actual operating experience. SOPs shall be prepared for all processes including, but not limited to, those listed below: (a) Pumping stations; (b) Screening removal and disposal; (c) Grit removal; (d) Primary treatment; (e) Biological treatment; (f) Advanced treatment; (g) Sludge handling system; (h) Tank drainage system; (i) Fuel storage and distribution system; (j) Potable water system; (k) Plant water system; (l) Power distribution system; and (m) Standby power system.

4.3.3 Element s of SOPs Each SOP shall contain, at a minimum, the following elements: (a) A component numbering identification system for each valve, control point, and unit process; (b) Descriptions of normal valve settings, flow diversions, and operational requirements; (c) Descriptions of routine operating procedures including startup, break-in, normal operation, regulating, controlling, stopping, shutdown, emergency, special visual observations, and record keeping; (d) Descriptions of routine safety procedures and potential danger areas.


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Testing Commissioning

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