Pre-commissioning and Commissioning

JW MARRIOT ABU DHABI RESORT & SPA

OTAK INTERNATIONAL

16080 PRE-COMMISSIONING AND COMMISSIONING 1.0

REFERENCE

1.1

GENERAL

A.

Conform to General Requirements for Electrical Services of Division 16.

1.2

DESCRIPTION OF WORK

A.

Prior to acceptance, inspect, operate and test all electrical equipment, materials and components, whether such tests are detailed in this specification or not. Tests will be witnessed by THE CONSULTANT, to ensure that the operation of the systems and components satisfies the requirements of the Contract Documents.

B.

Include any specific testing required by the Authorities, or any other body having jurisdiction over the installation, and as directed by THE CONSULTANT.

C.

Provide all tools, equipment, labour and materials required to perform the electrical testing. Provide three copies of the test reports to THE CONSULTANT. THE CONSULTANT reserves the right to witness factory testing of all equipment. Coordinate with the equipment manufacturers and notify the CONSULTANT 21 days before any factory testing, to confirm the presence of the CONSULTANT.

D.

Report any deficiencies in test results immediately to the CONSULTANT. Test in accordance with the applicable standards issued by the governing organisations (e.g. IEC, UL, NFPA, IEE), and with the recommendations of the manufacturers.

E.

Include the cost of all testing in the bid price, whether performed in the field or at the factory. Inform the manufacturers of the factory and site testing requirements.

F.

Make test records in a neat and legible manner, fully identifying the equipment or system being tested, type of test equipment, calculation, and expiry date for the same, the test results and the date of the test. Submit 3 copies to the CONSULTANT at the end of each test.

G.

Do not energize distribution or control equipment until the test results have been reviewed, passed and approved by the CONSULTANT. Ensure that phasing and phase rotation is the same throughout the system. Ensure that all devices are wired for the same polarity.

H.

Test all electrical systems and installation in accordance to the related standards and in accordance to the equipment manufacturers testing procedure.

I.

Carryout all tests in accordance to an approved procedure by the CONSULTANT and all necessary data and results which may be requested by the CONSULTANT.

J.

The testing and commissioning for electrical system shall cover the following as a minimum:

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2.0

TESTING AND COMMISSIONING

2.1

GENERAL

A

The testing and commissioning shall be carried out in accordance with contract requirements, by a firm specializing in this work, under no circumstances shall the Contractor be allowed to use his own staff or affiliated companies for the Capital plant such as switchboards, power factor correction equipment, fire alarm system, lighting control and dimming system, central emergency lighting system, lifts, and specialized ELV systems including CCTV and security systems etc.

B.

The contractor shall submit to the CONSULTANT for approval his schedule of program for the works, the program shall address the following: a) b) c) d) e) f)

Planned date of commencement of testing and commissioning. Expected date of completion of testing and commissioning. Power ON date. Fire alarm ON date. Telephone/Data system ‘ON’ date. Actual testing and commissioning date and duration for each system.

C.

The contractor shall submit for approval, a detailed method statement for each testing and commissioning activity.

D.

The contractor shall maintain written records of all tests.

E.

Successful test records shall be counter signed by the CONSULTANT and bound into the Operation and Maintenance Manual. Upon completion of the testing and commissioning the Contractor shall demonstrate to the CONSULTANT the following: a) b) c) d) e) f) g) h)

Voltage within correct tolerances in accordance with the contract Documents. Power factor and harmonics in accordance with the Contract Documents. Earthing in accordance with the contract Documents. Illumination levels in accordance with the Contract Documents. Correct control of all plant. Structured cabling of telephone and data communication system Fire alarm system. Correct functioning of the following specialist systems and their integration: i. PA and Music System ii. Security and Access Control System iii. CCTV system iv. Central Emergency Lighting System v. Central Clock System

An audit inspection at factory before dispatch and at site after receipt of the switchgear for any manufacturing / transit defects. 2.2

PRECOMMISSIONING AND COMMISSIONING CHECKS Precommissioning/Commissioning check sheets for the following shall be submitted for the CONSULTANT review: a)

HV Switchgears

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b) c) d) e) f) g) h) i) j) k) l) m) n) o) p)

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Transformers MDB/SMDBs / MCC's DB / Final Light & Power Points Specified Lighting Controls Power And Control Cables Grounding and Bonding Lightning Protection System Fire Alarm System Public Address System Emergency Lighting System Programmable lighting control system Security access control system CCTV System Central Clock System Telephone and Data Communication System

Once the procedures are agreed up on, the Inspection and testing reports for the above systems shall be submitted for CONSULTANT review/approval. The following inspections have to be carried out for any manufacturing defects/transit damages and inform the supplier immediately if found any defects A.

Manufacturing Defects: a) b) c) d) e) f)

B.

Inspect the doors of cubicles for proper opening/closing including door inter locks. Ensure the bus bar supports and insulation are free from cracks and damages. Ensure that the correct rating of the components such as fuses, contactors and over load relays are as per the approved drawings. Ensure that the physical condition of all meters, protection relays are good and ranges are as per approved layouts. Ensure all components are properly installed including CTs. Ensure the over all dimension and colour of the cubicle is as per approved layout.

Transit Damages Inspect the external and paint scratches.

surface

of

the

cubicle

for

any

transit

damages

Inspect that batteries and chargers are not damaged during transit. C.

The following pre-requisites have to be ensured before pre-commissioning / commissioning of the respective panels: a) b) c) d) e) f) g) h)

Colour coding / ferruling Tightening all bus bar joints with torque wrench Tightening of all connections Termination of cables on the panels Interlocks as per approved drawings Inter panel wiring between various cubicles Operation of space heaters Control & power diagram of respective switchgear is readily available on the panel board for reference

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i) j)

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No loose tools left inside the panel Availability of first aid / fire fighting equipment

2.3

MDB / SMDB / MOTOR CONTROL CENTRE

A.

Testing and commissioning shall be in accordance with specification section 16440 part 3.2 and including the following:

B.

The contractor shall arrange for the witnessing of the following tests on the fully equipped switchboard including primary bus bars and connections at the factory, in accordance with IEC 439-1: 1. 2. 3. 4. 5. 6. 7. 8. 9.

C.

The following tests shall be carried out after the equipment has been completely erected and connected up on site: 1. 2. 3. 4. 5.

6. 7. 8. D.

High voltage power frequency tests on main and auxiliary circuits Dielectric/insulation resistance tests Ground fault tests Electrical operation of circuit breakers control circuits at the appropriate voltage limits Mechanical operations tests and tests to certify correct functioning of interlocks. Primary injection tests Secondary injection tests Millivolt drop tests Any other tests required by the CONSULTANT

Power frequency voltage tests on the completed switchgear Insulation resistance tests on all main and secondary circuits Secondary injection tests Calibration checks on ammeters, voltmeters and any other instruments Testing at normal voltage to prove that closing and tripping from local and remote control points, tripping from relays and protective gear, interlocks, alarm and indications, etc are satisfactory. Any other test required to prove compliance with the specification At the end of tests, the protective relays and breaker tripping times shall be set in accordance with the CONSULTANT approved discrimination coordination. Contact resistance test for busbar by means of equipment with minimum 10A

Detailed Check List a) b) c) d) e) f) g) h) i) j) k) l)

Effectiveness of mechanical actuating elements Door interlocks Interconnection conductor sizes, laying and clamping/screwing Visual inspection of degree of protection, creepage and clearance distances Labels for feeders and circuit indications Supply of operational instructions, wiring diagrams, technical data of equipment used. Inspection and operational testing of the factory built assembly Electrical controls and sequence of operation Physical verification of drawings, including front and internal layouts Single line diagrams & Control schemes Check for cracks on components and housings Correctness of sizes and terminations. Torque tables shall be followed.

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Bolt size M6 M8 M10 M12 M14 M16 m) n) o) p) q) r) s) t) u) v) w) E.

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Tightening torque Nm 8 20 40 70 110 170

Tightening Force kN 3 6 13 22 26 35

Cable entry/tray provisions, top and bottom Ventilation, anti-condensation heaters, and fans Sealing/pad locking for meter cabinet Phase barriers for incoming and outgoing breakers Size of bus bars - neutral/earth Gland plates Colour codes for cables Ferrules, labels etc. Termination of ECCs with copper lugs Wiring connections of CT meter - load side of incomer Mounting height of Meter, max 2M min 0.8M

Dielectric tests (excluding components, lamps etc.) All control fuses and electronic components shall be isolated Test voltage of 2.5kV for 1 minute shall be applied between Phase to phase Phase to neutral Phase to earth Neutral to earth

F.

Protective measures check/Electrical continuity of protective circuits Capacity and continuity between: a) b) c) d) e)

G.

All metal parts and main earth bar Door and main earth bar Continuity test according to control circuit diagram Checking of indicator lamps (with transformers), voltmeter etc. Outgoing circuits check with hand lamp

Physical Check Check general arrangements of the components, internal wiring and complete cleanliness. Check the panel against approved shop drawing to ensure that right components (ACB, MCCB) of correct ratings are installed. Check the tray riser, cable drops cable overlapping and dressing of cable to MDB. Check all the bolts / nuts and bus bar connection to ensure that all are in good and tight condition. Check earth bonding of components and other related connection.

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Check all meters and selector switches to ensure the correct selection & rating. Check the phase barriers are properly fixed for separation of circuits. Check all cables and panels are properly labelled and identified. H.

Insulation Resistance Check Check and measure insulation resistance between phases, neutral and earth with 500 volts megger (the values to be verified with the permissible limits). Check the terminal insulation. cable gland termination and shrouding.

I.

Functional Test (Panel to be temporarily energised) Check the control circuit of each system for its correct operation. Switch ON and OFF of all MCCBs, contactors, relays to verify for the desired operation. Check draw out mechanism of main incomer ACB. Check operation of the indication lamps & meters to ensure proper functioning. Check functions of motor operated ACB/MCCBs Check for any abnormal rise in temperature on bus bars. jumper cables, terminals and various devices by using an infrared scanner.

J.

Earth Leakage Test a)

b) c) K.

Check earth leakage circuit breakers by means of RCCB tester, selecting 50% 100%, 150% of the rated sensitivity currents and the respective trip time to be recorded. Check the rating of core balance CTS and EL relays for earth leakage protection. Tabulate the readings taken.

Earth Fault Loop Impedance Test Measure the earth loop impedance across phase and protective conductor with earth loop impedance tester. Tabulate the reading taken and check with permissible values.

L.

Polarity Test Check the polarity of incomer supply by polarity tester before energising panels. Check all fuses/circuit breakers and single pole control devices are connected to phase conductors only.

M.

Test on Capacitor Panels

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a)

Check the operation and indications of contactors in manual mode

b)

Check the operation and indications of contactors in auto mode by setting various power factor in the regulators.

Overall Performance Test - Check and ensure the satisfactory operation of the boards at full load. Any other tests as requested by the CONSULTANT.

2.4

FINAL DB LIGHT & POWER POINTS

A.

Physical Check

B.

C.

a)

Check the electrical components such as conduits, wires, trunking, light fixtures, socket outlets are connected to the final circuit of the distribution board.

b)

Check the installation of distribution boards and internal wiring.

c)

Check the identification and labelling of each final circuits.

d)

Check that all metallic components are earthed/bonded.

e)

Check the terminal insulation, cable gland termination and shrouding.

Polarity Check a)

Check the polarity of power / light points to ensure the light switches (single pole) are installed in the line conductor.

b)

Check for screw type lamp holders. The outer or screwed conductor is connected to the neutral conductor.

Continuity Check a)

Check the continuity of the protective conductor from the farthest point to main earth terminal of the DB for each final circuit by means of a DC ohm meter verify the values are within permissible limit).

b)

Check the continuity between the open ends of each of the three rings of circuit (ie. phase, neutral and earth) for all ring final circuits conductors with a multi meter and the value to be within the permissible limit.

D.

Insulation Resistance Test - Check and measure the insulation resistance between phase, neutral and earth through a 500 Volts, Megger.

E.

RCCB and Polarity Test a)

Switch on and off all MCB’s and Contactor relay to verify for the desired operation.

b)

Check earth leakage circuit breakers by means of RCCB tester.

c)

Check the circuit performance by switching on the MCB in the DB.

d)

Check the light and power points by operating all the switches connected in the circuits.

e)

Check all the sockets outlets of ring/radial circuits with 3 pin socket tester

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(13A)/test lamp. f) F.

Tabulate the readings taken.

Earth Fault Loop Impedance Test a)

Measure the earth loop impedance across phase and protective conductor with earth loop impedance tester.

b)

Tabulate the readings taken and compare with permissible values.

2.5

LIGHTING CONTROL SYSTEM

A.

Testing and commissioning shall be in accordance with specification section 16570 part 3.2 and including the following:

B.

Physical Check

C.

a)

Check the breakers are properly grouped to the appropriate contactors for on/off control.

b)

Check the system cables are properly terminated to the corresponding lighting group.

c)

Check the identification and labelling of different lighting groups are provided.

d)

Check the operation of override switch.

Function Test a)

Check the system time channel settings required for night reduction.

b)

Monitor the system operation during time channel set time period.

2.6

LV power and Control Cables

A.

Physical Check Check the cable installation and ensure the following: a) Proper laying and dressing cable cleating /tying cable.

B.

b)

Tray supports are adequate.

c)

Cable identification and labelling.

d)

Glanding and gland earthing termination is correct.

e)

No physical damage.

Insulation Resistance Test a)

Conduct insulation resistance test recommendations, and test requirements.

b)

Measure insulation resistance between cores of all LV cable with a 500 V Megger and tabulate readings, the readings to be verified with permissible limits (min. 10 Mega ohms)

c)

Measure insulation resistance between cores and ECC and earth terminal with a 500 V Megger and tabulate readings. The readings to be verified with

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permissible limit. C.

Phase Rotation Test- Phase rotation at all points should be same other wise rectify.

D.

Performance Test (to be energised temporarily) a)

Switch on all isolators and run all equipment, for 2 hours and verify complete performance.

b)

Check for any unusual temperature rise in cables, terminals and switches and protective devices.

2.7

MV CABLES

A.

Physical Check Check the cable installation and ensure the following are in accordance with the approved shop drawings and applicable Codes and Standards: a) b) c) d) e) f)

B.

Spacing between cables and depth of laying. Cable tiles, warning tapes. Cable identification and labelling. Bending radius Glanding and gland earthing. No physical damage.

Voltage check of the MV cable Apply the voltage 24 KVDC for 1 minutes, test voltage as per related Codes and Standards: a) b)

c) d) e) f)

Use approved and valid certified test equipment. This test requires a coordination with the manufacturer of transformer, switchgear etc. if the MV cable ends at a transformer or a switchgear (disconnect main transformer and all CT, PT). Insulation resistance test using approved insulation tester (2.5KV megger). Continuity test using approved resistance tester. Phase rotation test (in the LV side of PTs). Performance test

Energise the cable temporarily, apply load for 2 hours and verify complete performance. Check for any unusual temperature rise in cables, terminals and protective devices. 2.8

GROUNDING AND BONDING

A.

Testing and commissioning shall be in accordance with specification section 16645 part 3.2 and including the following:

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B.

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Physical Check Check all the earth electrodes in earth pits for proper installation and connection. a)

C.

D.

Check all the protective conductors from the earth electrodes to the MDB’s and DB’s for proper installation and connection.

Earth Electrode Resistance a)

Remove the protective conductor connection from the electrode.

b)

Measure earth electrode resistance by using an earth megger.

c)

Repeat the above for all pits and tabulate readings.

Continuity Test a)

Check proper earth bonding by checking continuity of protective conductor by a D.C. ohm meter.

b)

The above to be checked for all protective conductors to various equipment.

c)

Check the continuity resistance between the main earth terminal of the MDB/DB and the farthest equipment by a DC ohm meter.

2.9

LIGHTNING PROTECTION SYSTEM

A.

Testing and commissioning shall be in accordance with specification section 16605 part 3.2 and including the following: Physical Check

B.

C.

a)

Check the proper jointing of copper tapes with accessories and earth electrodes.

b)

Clean and tighten all joints.

Earth Electrode Resistance a)

Remove the lightning system continuity conductor connection from the earth electrodes.

b)

Measure the earth electrode resistance by using an earth megger.

c)

Repeat the above for all pits and tabulate readings.

Continuity Test a)

Check proper connection by checking continuity between lightning protection conductor at the selected farthest points and the earth electrode by using a DC ohm-meter.

b)

Check continuity resistance between the lightning protection conductor and the metallic frame works bonded with the lightning protection system by using DC ohm-meter.

c)

Repeat the above for entire network and record the readings.

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2.10

FIRE ALARM SYSTEM

A.

Testing and commissioning shall be in accordance with specification section 13850 part 3.4 and including the following:

B.

Visual Checks

C.

D.

a)

Check installation of fire alarm system cables for proper laying, termination, clipping, labelling, identification.

b)

Check cable connection to the F.A.C.P. battery, repeater panel.

Insulation Resistance Test a)

Check insulation resistance between cores with a 500 V megger.

b)

Tabulate readings.

Functional Checks Fire Alarm: a) Put the system into operation as per manufacturer’s recommendation. b)

Simulate fire conditions by generating smoke/heat to activate the detectors.

c)

Check display of detector number check operation of LED on the detector Check display on network. Check the printer operation.

Fault Alarm: a) Simulate fault situations like power failure, battery on, open circuit. b) E.

F.

Check visual display in the panel.

Interlock Check a)

Simulate fire conditions in each zone.

b)

Check that the FAHU/AHU in that zone cuts out.

c)

Check the operation of fire roller shutters pressurization fans & extract fans.

Monitoring Features a)

Activate the sprinklers/fire hose reel

b)

Check panel monitoring facility for fire pumps/sprinkler pump/zone control valves.

2.11

PUBLIC ADDRESS SYSTEM

A.

Testing and commissioning shall be in accordance with specification section 16820 part 3.2 and including the following:

B.

Pre-commissioning Procedures

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C.

a)

On completion of cabling and prior to termination, check all the cables to ensure that they are free from any short circuits,

b)

Identify and label all the cables using cable markers.

c)

Check for proper termination at the junction boxes.

d)

Check and ensure that all types of speakers are mounted properly.

e)

Ensure that all speakers are terminated properly and set at appropriate tappings (Wattage).

f)

Check the back panel terminations of the equipment.

g)

Check the terminations in the zone selector.

h)

Ensure that all zones are clearly identified on the microphone console.

i)

Check for the functional features of the equipments in PA rack.

j)

Check termination of cables at the equipments in PA rack.

Functional Test a)

Put the system on as per manufacturer’s recommendation.

b)

Check Performance of the system for TS configuration.

c)

Tabulate observation.

2.12

EMERGENCY LIGHTING SYSTEM

A.

Visual Checks

B.

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a)

Check the cable entries with regards to their tightness.

b)

Check the general arrangements of components and wiring.

c)

Rating and details of components.

d)

Labels and identifications.

e)

Earthing of components and related connections.

f)

Check the polarity.

Insulation Resistance Test a)

Disconnect and bridge the mains connecting lead.

b)

Disconnect and bridge the cable to the emergency lights.

c)

Carry out insulation measurement to PE.

d)

Remove the bridges after the insulation resistance measurement.

e)

Reconnect the mains connecting lead and cable the emergency lights.

2.13

LIGHTING

A.

Verify the correct lamps, position, ballast and operation of all fixtures.

B.

With all lighting in operation, measure the average illuminance on the floor/working plane by establishing the maximum and minimum levels in the following locations:

C.

Exits, public corridors, corridors leading to exits, electrical equipment rooms, elevator machine rooms and hoistway pits, offices, storage rooms, service rooms, garages,

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washrooms and stairways. Class rooms and all laboratories. every place of assembly rooms and areas as directed by the CONSULTANT. With only the emergency lighting in operation, measure the average illumination at exits, public corridors, floor areas where the public may congregate and other rooms and areas as directed by the CONSULTANT. Take readings at night, with no outside light contribution. Take readings with a cosine corrected portable digital illuminance meter, or with a video camcorder with suitable software for illuminance measurements. Measuring instruments shall be tested, calibrated and certified accurate to within 2%. Submit technical, testing and calibration data as well as certification on the photometer. All readings results should match the required illuminance levels as specified in relevant sections. Plot lighting results on a set of reproducible plans for review by THE CONSULTANT and submission to the authorities. 2.14

STRUCTURED CABLING SYSTEM

A.

Testing and commissioning shall be in accordance with specification section 16710 part 3.6.7 and including the following: Visual inspection to ensure the items as indicated below: 1. 2.

Horizontal and backbone cabling are installed in accordance with the applicable codes and standards. Labelling and identification are in accordance with ANSI/TIA/EIA-606

3.

Earthing and bonding are provided as per related codes/standards and to local authority requirement.

4.

Connecting hardware and all other cabling system components are installed by proper cable preparation, termination practices, orientation, proper cable management, and mounting that are in full compliance with manufacturer’s guide lines to avoid signal impairment.

5.

Circuit protectors are provided for all cabling which enter or exit the building in comply with applicable codes and standards.

6.

Enough clearance and separation from electrical cabling and equipment in accordance with applicable codes/standards and manufacturer’s recommendations are provided to avoid electromagnetic interference(EMI)

7.

The maximum cable pulling tension and minimum bending radius exceeds manufacturer’s specification and applicable codes/standards.

8.

The amount of untwisting in a pair for UTP copper cable as a result of

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termination to connecting hardware is less than 13mm or as per manufacturer’s guidelines.

2.15

9.

Cables of different transmission performance categories are terminated in different termination fields.

10.

No more than two pieces of connecting hardware in a cross connect.

11.

All fiber cables are connected straight with no transpositions of fiber pairs or cores/strands.

12.

Section length in compliance with the maximum length requirement.

13.

The no. of bends in the installation are the minimal.

TESTING OF UTP COPPER CABLES All transmission testing shall be performed with an approved UTP field tester which shall be factory calibrated by the field test equipment manufacturer. Calibration certificate shall be submitted for CONSULTANT approval. All UTP test cords, adapters, etc to be used for testing shall be supplied and verified by the test equipment manufacturer to meet or exceed the requirements of TSB-67 and qualified to test CAT 6 cabling system. Following shall be included in the testing: a) b) c) d)

Horizontal Basic Link Model Backbone Basic Link Model Horizontal Channel Test Model Backbone Channel Test Model

Following transmission parameters shall be tested for the installed structured cabling system using the filed tester: a) b) c) d) e) f) g) h) i) j) k)

WIRE MAP LENGTH NEXT Loss ( pair to pair) NEXT Loss ( power sum) FEXT ELFEXT ( pair to pair) ELFEXT Loss ( power sum) ATTENUATION RETURN LOSS PROPAGATION DELAY DELAY SKEW

All ‘PASS’ test result shall be down loaded into the database software that has been provided by the field test equipment manufacturer. 2.16

OPTICAL FIBER TESTING

A.

Verify the integrity of all optical fiber link including single mode and multimode fiber cables using the following tests:

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Continuity test ATTENUATION test Testing shall include but not limited to the following: a)

Link loss measurements

b)

Fiber Attenuation (dB/KM)

c)

Splice and connector loss

d)

Reflectance and optical return loss measurement

e)

Length measurement

Test equipment shall be: a) b)

Laser source and Power Meter OTDR

OTDR shall be a multi tester with built in power meter, equipped with laser source, suitable for any field testing and shall be with data storage and PC emulation software. All test equipment shall be from the manufacturer of structured cabling system or from CONSULTANT approved test equipment manufacturer. All test equipment shall be factory calibrated by the field test manufacturer and calibration certificate shall be submitted for CONSULTANT approval.

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