INSTALLATION, TESTING, COMMISSIONING AND TRAINING

INSTALLATION, TESTING, COMMISSIONING AND TRAINING


PART 1 - GENERAL

1.1       DESCRIPTION

A. The requirements specified in General Conditions, Supplementary General Conditions, and General Requirements form a part of this Section.

1.2 QUALITY ASSURANCE
A. Testing
1. General Requirements:  All equipment and partially complete or fully completed portions of the work included in this contract shall be tested and inspected to prove compliance with the Contract Documents.  Unless otherwise specified, all costs of off-site witness testing or special inspections, shall be borne by the Contractor. For  the  purpose  of  this  Section,  equipment  shall  mean  any mechanical, electrical, instrumentation, or other device with one or more moving parts or devices requiring an electrical, electronic, pneumatic or hydraulic connection. Installed structural tanks and channels shall be tested for water tightness as specified in Section 03936.  Installed tests for equipment shall be in accordance with Division 11. Installed leakage tests and other piping tests shall be as specified  in  Division  15.     Installed  tests  for  heating,  ventilation,  and  air conditioning systems shall be as specified in Division 15.   Installed tests for electrical devices and systems shall be in accordance with Division 16.  Installed tests  for  instrumentation  devices  and  systems  shall  be  in  accordance  with Division 17.  No tests specified herein shall be applied until the item to be tested has been inspected for the application of such test.

2.         Tests and inspection shall include:

a.         The delivery acceptance test and inspections.
b.         The installed tests and inspections.
c. The operational testing of completed sections of the plant, using plant water or City water.
d. The  commissioning  of  completed  sections  of  the  plant.    Tests  and inspections, unless otherwise specified or accepted, shall be in accordance  with  the  recognized  standards  of  the  industry. The Contractor shall verify that scheduling and performance of all tests are coordinated with involved subcontractors and suppliers. The form of evidence of satisfactory fulfillment of delivery acceptance test  and  inspection  requirements  shall  be,  at  the  discretion  of  the Resident Project Representative, either by tests and inspections carried out in his presence or by certificates or reports of tests and inspections carried out by approved persons or organizations.  The Contractor shall use forms which include all test information, including specified operational parameters.   The Contractor shall develop the necessary forms  designed  specifically  for  this  contract.     The  forms  shall  be submitted to the Resident Project Representative for his review. A master test logbook shall be maintained by the Contractor which shall cover  all  tests  including  piping,  equipment,  electrical,  and instrumentation.  The master test logbook shall be provided with loose- leaf pages that shall be copied weekly after updating for transmittal to the Resident Project Representative.

3. Delivery Acceptance Tests and Inspections:  Where specified for specific pieces of equipment, the delivery acceptance tests and inspections shall include the following.

Test of items at the place of manufacture during and/or on completion of manufacture,  comprising  hydraulic  tests,  electric  and  instrumentation subsystems   tests,   performance   and   operating   tests   and   inspections   in accordance with the relevant standards of the industry and more particularly as details in individual clauses of these specifications to satisfy the Owner that the items tested and inspected comply with the requirements of this contract.   All costs for such tests and inspections shall be borne by the Contractor.

Inspection of all items delivered at the site or to any authorized place of storage in order that the Owner may be satisfied that such items are of the specified quality and workmanship and are in good order and condition at the time of delivery.  The Contractor shall be prepared to remove all coverings, containers or crates to permit the Resident Project Representative to conduct his verification. Should the Resident Project Representative, in his opinion, see an indication of damage or deficient quality of workmanship, the Contractor shall provide the necessary documentation or conduct such tests deemed necessary by the Resident Project Representative to demonstrate compliance.  Compensation for tests and work related thereto arising out of this requirement shall be borne by the Contractor.

1.3       INSTALLED TESTS AND INSPECTIONS

A. General:   All equipment shall be tested by the Contractor to the satisfaction of the Resident Project Representative before any facility is put into operation.  Tests shall be as specified herein and shall be made to determine whether the equipment has been properly assembled, aligned, adjusted and connected.   Any changes, adjustments or replacements required to make the equipment to operate as specified shall be carried out by the Contractor as part of the work.

B.         Procedures

1. General:  Contractor shall submit to the Engineer, in quintuplicate, details of the installed tests and inspection procedures he proposes to adopt for testing and
start-up of all equipment to be operated singly and together, except when such procedures have been covered in the technical specifications.

The procedures shall be divided into two distinct stages: pre-operation checkout and water test.  Testing procedures shall be designed to duplicate, as nearly as possible, all conditions of operation and shall be carefully selected to ensure that the  equipment  is  not  damaged.    Once  the  testing  procedures  have  been reviewed by the Engineer, the Contractor shall produce checkout, alignment, adjustment and calibration signoff forms for each item of equipment to be used in the field by the Contractor and the Engineer jointly to ensure that each item of electrical, mechanical and instrumentation equipment has been properly installed and tested.  The Contractor is advised that failure to observe these precautions may place the acceptability of the subject equipment in question.

2. Pre-operation Checkout:   The installed tests and inspection procedures shall incorporate  all  requirements  of  these  specifications  and  shall  proceed  in  a logical,  step-wise  sequence  to  ensure  that  all  equipment has been properly serviced, aligned, connected, calibrated and adjusted prior to operation.   Pre- operation checkout procedures shall include, but not necessarily be limited to:

a.         Piping system pressure testing and cleaning as specified in Division 15.
b.         Electrical system testing as specified in Division 16.
c.          Instrumentation system testing as specified in Division 17.
d.         Alignment of equipment.
e.         Pre-operation lubrication.

3. Clean Water Test:   Once all affected equipment has been subjected to the required preoperational checkout procedures and the Resident Project Representative has witnessed and has not found deficiencies in that portion of the work, individual systems may be started and operated under simulated operating conditions to determine as nearly as possible whether the equipment and systems meet the requirements of these specifications. Clean water shall be employed for the testing of all liquid systems except gaseous, oil, or chemical systems.   Test media for these systems shall be either the intended fluid or a compatible substitute.  The equipment shall be operated for a sufficient period of time to determine machine operating characteristics, including temperatures and vibration; to observe performance characteristics; and to permit initial adjustment of operating controls.  When testing requires the availability of auxiliary systems such as electrical power, compressed air, liquefied petroleum gas, control air, or instrumentation which have not yet been placed in service, the Contractor shall provide acceptable substitute sources, capable of meeting the requirements of the machine, device or system, at no additional cost to the Owner.   Disposal methods for test media shall be subject to review by the Resident Project Representative.

If under test, any portion of the work should fail to fulfill the contract requirements and is adjusted, altered, renewed or replaced, tests on that portion when so adjusted, altered, removed or replaced, together with all other portions of the work as are affected thereby, shall, if so required by the Resident Project Representative, be repeated within reasonable time and in accordance with the specified conditions.  The Contractor shall pay all reasonable expenses incurred by the Owner as a result of repeating such tests.
Once simulated operation has been completed, all machines shall be rechecked for  proper  alignment,  realigned,  if  necessary,  and  doweled  in  place.    All equipment shall be checked for loose connections, unusual movement or other indications of improper operating characteristics.   Any deficiencies shall be corrected  to  the  satisfaction  of  the  Resident  Project  Representative.     All machines or devices which exhibit unusual or unacceptable operating characteristics  shall  be  disassembled  and  inspected.    They  shall  then  be repaired or removed from the site and replaced at no cost to the Owner.

Test results shall be within the tolerances set forth in the detailed specification sections of this contract document.   If no tolerances have been specified, test results shall conform to tolerances established by recognized industry practice. Where, in the case of an otherwise satisfactory installed test, any doubt, dispute, or difference should arise between the Resident Project Representative and the Contractor regarding the test results or the methods or equipment used in the performance of such test, then, the Resident Project Representative may order the test to be repeated.   If the repeat test, using such modified methods or equipment as the Resident Project Representative may require, substantially confirms the previous test, then all costs in connection with the repeat test will be paid by the Owner, otherwise the costs shall be borne by the Contractor.  Where the results of any installed test fail to comply with the contract requirements for such test, then such repeat tests as may be necessary to achieve the contract requirements shall be made by the Contractor at his expense.

Unless otherwise specified, the Contractor shall provide, at no expense to the Owner, all power, fuel, compressed air supplies, labor and all other necessary items and work required to complete all tests and inspection specified herein. The Contractor shall provide, at no expense to the Owner, temporary heating, ventilating  and air conditioning  for  any  areas  requiring it in the case where permanent facilities are not complete and operable at the time of installed tests and  inspections.    Temporary  facilities  shall  be  maintained  until  permanent systems are in service.

1.4.      OPERATIONAL TESTING AND TEST WATER

A. After  completion  of  all  installed  testing  and  agreement  by  the  Resident  Project Representative that all equipment complies with the requirements of the specifications, the Contractor shall fill all process units and process systems, except those employing domestic water, oil or chemicals, with plant water.  Chemical systems shall be filled with the specified fluid.

B. The Contractor is allowed to use the chlorinated plant secondary effluent (plant water), at no charge.  The Contractor shall provide all temporary equipment, pumps, piping, valves, and connections at no cost to the Owner.  The Contractor shall submit a plan showing the method of delivering the plant water to various process units requiring test water.

C. Upon completion of the filling operations, the Contractor shall circulate water through the completed facility for a period of not less than 96 hours, during which all systems shall be operated as a complete facility at various loading conditions, as directed by the Resident Project Representative.  Should the operational testing period be halted for any reason related to the facilities constructed or the equipment furnished under this contract, or the Contractor's  temporary  testing  systems,  the  operational  testing  program  shall  be repeated   until   the   specified   continuous   period   has   been   accomplished   without
interruption.   All process units shall be brought to full operating conditions, including temperature, pressure and flow.

D. All costs required during this plant operational test shall be borne by the Contractor.  The Contractor will supply operational manpower for the 24-hour-per-day testing.   The Contractor shall provide the Owner with system testing/validation reports on the operational testing results.

1.5       COMMISSIONING

A. After completion of the operational testing and approval or certification by the Owner that the systems did meet all performance requirements, commissioning will begin.   The commissioning period for all systems shall be 15 days.  The Contractor shall remove all temporary piping that may have been in use during the operational testing.   The Contractor’s personnel will be responsible for operation of the plant or portion of the plant being operated during this period of time.   The plant or portion thereof shall be fully operational, accepting all normal flow called for in design and performing all functions as designed.

B. The Contractor shall be available at all times during commissioning periods to provide immediate assistance in case of failure of any portion of the system being tested.  At the end of the commissioning period, all corrections required by the Resident Project Representative  to  assure  a  reliable  and  completely  operational  facility  shall  be completed.

C. The  Contractor  shall  bear  the  cost  of  all  chemicals  that  are  used  during  the commissioning period.   Unless a greater quantity is called for on the drawings.   At a minimum, provide the following quantities of chemicals:

Ferric Chloride               500 gallons

D. During  the  commissioning  period,  the  Owner  shall  be  responsible  for  all  normal operational costs (excluding chemicals), and the Contractor shall bear the costs of all necessary repairs or replacements, including labor and materials, required to keep the portion of the plant being commissioned, operational.

1.6       TRAINING

A.   Where specified for specific pieces of equipment, the Contractor shall make available, during the freshwater   testing   phase,   experienced   factory-trained   representatives   of   the manufacturers of all the various pieces of equipment, to train the Owner's personnel in the operation and maintenance thereof.  The time required for this training shall be as specified in the specifications for the equipment items.  The Contractor shall notify the Owner of the time of the training at least 14 days prior to the time of training.

B.   The Contractor shall provide PLC training.  This training shall include an 8-hour session for primary treatment and another 8-hour session for digestion process.   The training shall include PLC graphics and operator interface with outline submitted prior to the scheduled training sessions.

C.  The Contractor shall provide two SCADA training.   The first 8-hour session shall include hands-on application of the SCADA software utilizing databases and graphics to track plant operation. The  second  8-hour  session  shall  include  importing  and  exporting  data  and customizing reports.

PART 2 - MATERIALS AND METHODS

2.1       MATERIALS

A.         Testing Materials

1. Gages,  Meters,  Recorders,  and  Monitors:    Gages,  meters,  recorders,  and monitors shall be provided by the Contractor to supplement or augment the instrumentation system provided under this contract to properly demonstrate that all equipment fully satisfies the requirements of this project manual.  All devices employed  for  the  purpose  of  measuring  the  performance  of  the  facility's equipment and systems shall be specifically selected to be consistent with the variables to be monitored.  All instruments shall be recently calibrated, and the Contractor shall be prepared at all times to demonstrate, through recalibration, the accuracy of all instruments employed for testing purposes.   Calibration procedures shall be in accordance with applicable standards of ASTM, ISA, and IEEE. The adequacy of all gages, meters, recorders and monitors shall be subject to review of the Resident Project Representative.

2. Records:    The  Contractor  shall  provide  signoff  forms  for  all  installed  and operational testing to be accomplished under this contract.   The signoff forms shall be produced in quadruplicate on pressure sensitive paper.  Signoff forms shall be provided for each item of mechanical, electrical and instrumentation equipment provided or installed under this contract and shall contain provisions for recording relevant performance data for original testing and not less than three retests.  Separate sections shall be provided to record values for the pre- operation checkout, initials of representatives of the equipment manufacturers, the Contractor, and the Resident Project Representative.

The Contractor shall maintain a master file of all equipment signoff sheets, which shall be available for inspection by the Owner.  Upon completion of testing, the Contractor shall furnish the Owner with the original and three (3) copies of the signoff sheet for each equipment item.

2.2       METHODS

A. Installation:  All equipment and apparatus used in testing shall be installed by specialists properly skilled in the trades and professions required to assure first-class workmanship. Where required by detailed specifications, the Contractor shall cause the installation of specific equipment testing items to be accomplished under the supervision of factory- trained installation specialists furnished by the equipment manufacturers.  The Contractor shall be prepared to document the skills and training of all workmen engaged in the installation of all testing equipment furnished either by the Contractor or the Owner.

B. Testing:     Testing  shall  proceed  on  a  step-by-step  basis  in  accordance  with  the Contractor's written testing procedures.   The Contractor's testing work shall be accomplished by a skilled team of specialists under the direction of a coordinator whose sole responsibility shall be the orderly, systematic testing of all equipment, systems, structures, and the complete facility as a unit.   Each individual step in the procedures shall be witnessed by the Resident Project Representative.  During the plant operational testing period, all equipment and systems in operation shall be operated to the greatest extent practicable, at conditions which represent the full range of operating parameters as defined by this contract document.

C. Training:    Training  of  the  Owner’s  personnel,  where  specified,  shall  be  done  by experienced  technical  manufacturers'  representatives.    These  representatives  shall follow the outline presented here:

1.         Familiarization

a.         Show  catalog,  parts  lists,  drawings,  etc.  in  the  plant  files  and  O&M
manuals.

b.         Check out the installation of the specific equipment items.

c. Demonstrate the unit and show that all parts of the specifications are met.

d.         Answer questions.

2.         Safety

a.         Point out safety references.

b.         Discuss proper precautions around equipment.

3.         Operation

a.         Point out reference literature.

b.         Explain all modes of operation (including emergency).

c. Check out Owner's personnel on proper use of the equipment (let them do it).

d. Provide a detailed Operational Plan for the Primary treatment including control strategies.

e. Provide a detailed Operational Plan for the Digestion treatment including gas handling equipment including control strategies.

4.         Preventive Maintenance (PM)

a. Pass out PM list including:
(1) Reference material.
(2)        Daily, weekly, monthly, quarterly, semi-annual and annual jobs.
b.         Show how to perform preventive maintenance jobs.
c. Show Owner's personnel what to look for as indicators of equipment problems.

5.         Corrective Maintenance

a.         List possible problems.

b.         Discuss repairs - point out special problems.

c.          Open up equipment and demonstrate procedures, where practical.


6. Parts  

a. b.
Show how to use parts list and order parts.

Check over spare parts on hand.  Make recommendations.

7.         Local Representatives

a.         Where to order parts:  Name, address, telephone.
b.         Service problems.

8.         Who to call.

9.         How to get emergency help.

END OF SECTION