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Organization
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COMMISSIONING PROCESS

1. DESCRIPTION

This Document describes the overall commissioning process of the K2S back up power project installations.
Commissioning requires the participation of all members of a Commissioning Team as described in this
Document. The goal of Commissioning is to ensure that all systems are operating in a manner consistent with
the Contract Documents. Each contractor designated as responsible for a commissioned system shall be familiar
with all parts of this Document and the responsibilities that are required of each contractor as relates to all other
Commissioning Team members. Each contractor shall be responsible for following the Commissioning Plan
prepared by the commissioning team and shall execute all Commissioning responsibilities assigned to them in
this and all other related Contract Documents.

1.1 COMMISSION TEAM AND COMMISSIONING TERM DESCRIPTIONS

A. Project Engineers (PEs): The prime consultant (PEs) and sub-consultants who comprise the design
team, generally the Project Mechanical designer/engineer and the Electrical designer/engineer.

B. Commissioning Lead (CL): The CL directs and coordinates the commissioning activities. The CL
does not take an oversight role. The CL is part of the project management team.

C. Commissioning Plan (CP): An overall plan that provides the structure, schedule and coordination
planning for the commissioning process.

D. Commissioning Team (CT): The members of the commissioning team consist of the Commissioning
Lead, the Project Manager, the Commissioning Team Contractor Staffs, Subcontractor’s(staffs),
equipment Vendors and the Facility owner. The owner and the plant operator/engineer also may be
members of the commissioning team.

E. Commissioning Vendors (CV): (Team Contractor) Contractors responsible for providing the systems
specified for Commissioning, General Commissioning Requirements for their installed packages, of
their respective contracts. The vendors are totally responsible for their various Subcontractors.

F. Project Manager (PM): The Person in Charge of the Construction project, acting on behalf of
MORPOL.

G. Commissioning Mechanical Engineer (CME): CME is responsible for all Commissioning activities
associated with the Mechanical contract, and all those of the subcontractors and Mechanical equipment
vendors MANTRAC for Commissioned equipment supplied under the Mechanical contract 2 x 2.5MVA
Gas Generators, including all piping installation.

H. Commissioning Electrical & Instrumentation Engineer (CEIE): CEIE is responsible for all
Commissioning activities associated with the Electrical & instrumentation contract, and all those of

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 Electrical & instrumentation subcontractors and Electrical equipment vendors for Commissioned
equipment supplied under the Electrical contract.

 SIEMENS: Packaged Substations (33/11/0.42kV)

 SCHNEIDER: 8MVA transformer and associated NER
 ABB: 33kV Ring Main Units
 AOS Orwell:  Integration of entire facility
 Generators associated NERs

I. Owner: Client or facility representatives.

J. Subcontractors (Subs): The contractors to the vendors who manufactured and provided the installed
components and systems.

K. Vendor: Supplier of equipment.

L. Functional Performance Test (FT): Test of the dynamic function and operation of equipment and
systems using manual (direct observation) or monitoring methods. Functional testing is the dynamic
testing of systems (rather than just components) under full operation. Systems are tested under various
modes, such as during low cooling or heating loads, high loads, component failures, unoccupied, varying
outside air temperatures, fire alarm, power failure, etc. The CL develops the functional test procedures
in sequential written form. The CL coordinates, oversees and documents the actual testing. The
Contractor performs the functional tests. FTs are performed after pre-commissioning checklists and
startups are complete.

M. Pre-commissioning Checklist (PC): A list of items to inspect and component tests to conduct to verify
proper installation of equipment. (Covered by A check sheet)

N. Commissioning Testing (CT): Functional test procedures approved by the CL and PM to be performed
after Functional Completion and post Substantial Completion of the project. All discrepancies will be
approved for correction at a later date by the PM.

O. Commissioning Completion (CC): Final written approval by the Commissioning Lead that all
Commissioning work is complete.

1.2 SUMMARY

A Commissioning: Commissioning is a systematic process of ensuring that (selected) systems perform

interactively according to the design intent and the Owner’s operational needs. Commissioning during
the construction phase is intended to achieve the following specific objectives according to the Contract
Documents:

1. Verify that applicable equipment and systems are installed according to the manufacturer’s
recommendations and to industry accepted minimum standards and that they receive adequate
operational checkout by installing contractors.
2. Verify and document proper performance of (selected) equipment and systems.
3. Verify that O&M documentation left on site is complete.
4. Verify that the Owner’s operating personnel are adequately trained.

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 B. The commissioning process does not take away from or reduce the responsibility of the installing
contractors to provide a finished and fully functioning System.

1.3 COMMISSIONING PROCESS

A. Management:
1. The CL is hired by, and works for, the Project Manager and/or Owner. The CL directs and
coordinates the commissioning activities. All Commissioning Team members work together to fulfill
their contracted responsibilities and to meet the objectives of the Contract Documents.
2. It is noted that the services for the PM and Commissioning Authority are not provided for in this
contract. That is, the Commissioning Team contractors are not responsible for providing the CL’s or
PM services. Their responsibilities and tasks are listed in this Document to clarify the commissioning
process.

B. Commissioning Process:
The following narrative provides a brief overview of the typical commissioning tasks during
construction and the general order in which they occur.
1. Commissioning begins prior to construction with a scoping meeting planned, scheduled and
conducted by the CL where the commissioning process is reviewed with the commissioning team
members. The CL will provide the initial schedule of primary commissioning events at the
commissioning scoping meeting. Meeting minutes will be distributed to all parties by the CL.
2. The CL will develop a commissioning plan to provide guidance in the execution of the
commissioning process. A draft copy of the plan will be presented at the scoping meeting for
discussion.
3. The CL will work with the Commissioning Team contractors according to established protocols to list
and schedule the commissioning activities, using his initial listing of events from the draft
Commissioning Plan as a basis. The CL will integrate all commissioning activities into the
Construction Progress or Master Schedule.
4. Additional meetings will be required throughout construction, scheduled by the CL with necessary
Commissioning Team members attending, to plan, scope, coordinate, schedule future activities and
resolve deficiencies. These meetings will be held monthly or bi-weekly during initial construction
and can increase in frequency to as often as one per week in the final months or critical periods of
each phase of construction.
5. After the initial commissioning scoping meeting the CL will update the plan which is then considered
the “final” plan, though it may be revised as the project progresses. The Contract Specifications will
take precedence over the Commissioning Plan.
6. Equipment documentation, including O&M manuals are submitted to the CL during the submittal
process, including detailed start-up procedures. The CL reviews the O&M documentation for
completeness.
7. The CL works with the Commissioning Team contractors and their subcontractors to develop startup
plans and startup documentation formats for commissioned equipment and systems. This includes
providing pre-commissioning checklists to be completed, during the startup process.
8. The CL develops specific equipment and system functional performance test procedures. The
Commissioning Team contractors and Subs review the procedures and submit suggestions or
comments. Procedures are finalized by the CL.
9. The Commissioning Team contractors and their subcontractors, under their own direction, execute
and document the pre-commissioning checklists and perform startup and initial checkout for all

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 commissioned systems. The CL documents that the checklists and startup were completed according
to the approved plans and will spot check selected equipment prior to performing functional testing.
10. The procedures for Functional Testing are executed by the Commissioning Team contractors and
subcontractors, under the direction of, and documented by the CL.
11. In general, the checkout and performance verification proceeds from simple to complex; from
component level to equipment to systems and subsystems levels with pre-functional checklists (A
check-sheet) being completed before functional testing.
12. Items of non-compliance in material, installation or setup are corrected at the Commissioning Team
contractors’ expense and the system is retested.
13. Commissioning (Functional Completion) is completed before Project Substantial Completion.
14. The CL reviews, pre-approves and coordinates the training provided by the Commissioning Team
contractors and their subcontractors and verifies that it is completed.
15. Functional testing is conducted, as specified or required.

1.4 COMMISSIONING RESPONSIBILITIES

A. All Commissioning Team Members:

1. Follow the Commissioning Plan.
2. Attend commissioning scoping meeting and additional meetings, as necessary.

B Project Engineer (PE):

1. Pre-Construction and Construction Phase:

a. Attend the commissioning scoping meeting and selected commissioning team meetings as
needed.
b. Provide Design Intent and Basis of Design documents.
c. Provide any design narrative documentation requested by the CL.
d. Perform normal submittal review, construction observation as contracted.
e. Any on-site observations required by contract should be completed just prior to system
startup.
f. Coordinate resolution of system deficiencies identified during commissioning, according to
the contract documents.
g. Prepare and submit final as-built design intent documentation for inclusion in the O&M
manuals.

C. Commissioning Lead (CL):

1. The CL is not responsible for design concept, design criteria, compliance with codes, design or
construction scheduling, cost estimating, or construction management. The CL may assist with
problem-solving, non-conformance or deficiencies, but ultimately that responsibility resides with
the Project Manager, the Commissioning Team contractors and the PE. The primary role of the
CL is to develop and coordinate the execution of a testing plan and to observe and document that
systems are functioning in accordance with the documented design intent, in accordance with the
Contract Documents. The Contractors will provide all tools or the use of tools to start, check-out
and functionally test equipment and systems, except for specified testing with portable data-
loggers, which shall be supplied and installed by the CL.

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2. Pre-Construction and Construction Phase
a. Coordinates and directs the commissioning activities in a logical, sequential and efficient
manner using consistent protocols and forms, centralized documentation, clear and regular
communications and consultations with all necessary parties, frequently updated timelines,
schedules and technical expertise.
b. Coordinate the commissioning work and, with the PM and Commissioning Team, ensure that
all commissioning activities are scheduled into the Construction Progress Schedule.
c. Plan and conduct a commissioning scoping meeting and other commissioning meetings.
d. Revise, as necessary, the Commissioning Plan.
e. Request and review information (including O&M materials) required to perform
commissioning tasks and develop system start-up and checkout procedures.
f. Review and approve normal Contractor submittals applicable to systems being commissioned
for compliance with commissioning needs, concurrent with the PE reviews.
g. Develop an enhanced start-up and initial systems checkout plan with Commissioning Team.
h. Write and distribute pre-commissioning tests and checklists.
i. With necessary assistance and review from installing contractors, write the functional
performance test procedures for equipment and systems. This may include energy
management control system trending, stand-alone data logger monitoring or manual
functional testing. Submit to Commissioning Team for review.
j. Perform site visits, as necessary, to observe component and system installations. Attend
selected planning and job-site meetings to obtain information on construction progress.
Review construction meeting minutes for revisions/substitutions relating to the
commissioning process. Assist in resolving any discrepancies.
k. Witness all or part of any test, flushing or start-up procedures, sufficient to be confident that
proper procedures were followed. Document this testing and include the documentation in
O&M manuals. Notify PM of any deficiencies in results or procedures.
l. Approve pre-commissioning tests and checklist completion by reviewing pre-commissioning
checklist reports and by selected site observation and spot checking.
m. Approve system startup by reviewing start-up reports and by selected site observations.
n. Oversee and approve functional testing of Commissioned systems.
o. Coordinate, witness, and approve manual functional performance tests performed by
installing contractors. Coordinate retesting as necessary until satisfactory performance is
achieved.
p. Analyze any functional performance trend logs and monitoring data to verify system
performance.
q. Approve systems balancing by spot testing, by reviewing completed reports or by selected
site observation.
r. Maintain a master deficiency and resolution log and a separate testing record. Provide the
PM with written progress reports and test results with recommended actions.
s. Review and approve the preparation of the O&M manuals.
t. Review equipment warranties to ensure that the PM’s responsibilities are clearly defined.
u. Oversee and approve the training of the Owners operating personnel.
v. Compile and maintain a commissioning record and systems book(s).
w. Provide a final commissioning report (as described in this Document).

3. Warranty Period:
a. Coordinate and supervise required seasonal or functional testing.
b. Remain on the site during the 90-Days Reliability Run and review with facility staff the
current operation and the condition of outstanding issues related to the original and seasonal

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 commissioning. Also interview facility staff and identify problems or concerns they have
operating the systems as originally intended. Make suggestions for improvements and for
recording these changes in the O&M manuals. Identify areas that may come under warranty
or under the original construction contract. Assist facility staff in developing reports,
documents and requests for services to remedy outstanding problems.

D. Project Manager:

1. Pre-Construction and Construction Phase:

a. Manage the contract of the PE and of the Commissioning Team.
b. Attend a commissioning scoping meeting and other commissioning team meetings.
c. Arrange for facility operating and maintenance personnel to attend various field
commissioning activities and field training sessions according to the Commissioning Plan.
d. Facilitate the coordination of the commissioning work by the CL and the Commissioning
Team; ensure that commissioning activities are being scheduled into the Construction
Progress schedule.
e. Review and approve the final Commissioning Plan.
f. Furnish a copy of all construction documents, addenda, change orders and approved
submittals and drawings related to commissioned equipment to the CL.
g. Observe and witness pre-commissioning checklists, startup and functional testing of selected
equipment.
h. Review commissioning progress and deficiency reports.
i. Coordinate the resolution of non-compliance and design deficiencies identified in all phases
of commissioning.
j. Assist in coordinating the training of Owner’s personnel.
k. Provide final approval for the completion of the commissioning work.

2. Warranty Period:
a. Assist the CL as necessary in the seasonal or functional testing.

E. Commissioning Team (Includes Subcontractors and Vendors):

1. Pre-Construction and Construction Phase

a. Designate in writing a company representative to act as “coordinator” for all commissioning
activities. (Coordinator be project supervisor or manager).
b. Facilitate the coordination of the commissioning work by the CL, and with the CL ensure that
commissioning activities are being scheduled into the Construction Progress Schedule.
c. Include the cost of commissioning responsibilities in the total contract price. Provide
requested documentation, prior to or during the submittal period (prior to normal O&M
manual submittals), to the CL for development of start-up and functional testing procedures.
1) Typically this will include detailed manufacturer installation and start-up, operating,
troubleshooting and maintenance procedures, fan and pump curves, full factory testing
reports, if any, and full warranty information, including all responsibilities of the Owner to
keep the warranty in force clearly identified. In addition, installation, start-up and checkout
materials that are shipped inside the equipment and field checkout sheet forms to be used by
the factory or field technicians shall be submitted to the Commissioning Company.
2) The commissioning company may request further documentation necessary for the
commissioning process.

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 d. In each purchase order or subcontract written, include appropriate requirements for submittal
data, O&M data, commissioning tasks and training.
e. Ensure that all subcontractors execute their commissioning responsibilities according to the
Contract Documents and schedule.
f. Provide a copy of the O&M manuals and submittals of commissioned equipment, through the
PM, to the CL for review and approval.
g. Provide assistance to the CL in preparing the specific functional performance test procedures.
The Commissioning Team shall review test procedures to ensure feasibility, safety and
equipment protection and provide necessary written alarm limits to be used during the tests.
Assist in clarifying the operation and control of commissioned equipment in areas where the
specifications, control drawings or equipment documentation is not sufficient for writing
detailed testing procedures.
h. Develop a full start-up and testing plan using manufacturer’s start-up procedures and the pre-
commissioning checklists from the CL for all commissioned equipment. Submit to CL for
review and approval prior to startup.
i. During the startup and initial checkout process, execute all portions of the pre-commissioning
checklists for all commissioned equipment.
j. Perform and clearly document all completed startup and system operational checkout
procedures, providing a copy to the CL.
k. Address current punch list items before functional testing. Systems shall be completed with
deficiencies and problems remedied before functional testing of the respective related
systems.
l. Provide skilled technicians to execute starting of equipment and to execute the functional
performance tests under the direction of the CL. Ensure that they are available and present
during the agreed upon schedules and for sufficient duration to complete the necessary tests,
adjustments and problem-solving. Assist the CL in interpreting the monitoring data, as
necessary.
m. Correct deficiencies (differences between specified and observed performance) as interpreted
by the CL, PM and PE and retest the equipment.
n. Prepare O&M manuals according to the Contract Documents, including clarifying and
updating the original sequences of operation to as-built conditions.
o. Coordinate with equipment manufacturers to determine specific requirements to maintain the
validity of all warranties.
p. During construction, maintain as-built red-line drawings for all drawings and provide final
as-built for contractor-generated coordination drawings. Update after completion of
commissioning (excluding functional testing).
q. Provide training of the Owners operating staff using expert qualified personnel, as specified.

2. Warranty Period
a. Execute seasonal or functional performance testing, witnessed by the CL, according to the
specifications.
b. Ensure that Commissioning Team contractors correct deficiencies and make necessary
adjustments to O&M manuals and as-built drawings for applicable issues identified in any
seasonal testing.

F. Vendors:
1. Provide all requested submittal data, including detailed start-up procedures and specific
responsibilities for the Owner to keep warranties in force.

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 2. Provide information requested by CL regarding equipment sequence of operation and testing
procedures.
3. Through the contractors they supply products to, analyze specified products and verify that
the designer has specified the newest most updated equipment reasonable for this project’s
scope and budget.
4. Review test procedures for equipment installed by factory representatives.
5. Assist in equipment testing per agreements with the Commissioning Team contractors and
subcontractors.
6. Include all special tools and instruments (only available from vendor and specific to a piece
of equipment) required for testing equipment according to these Contract Documents, except
for stand-alone data logging equipment that may be used by the CL.

1.5 PREREQUISITES TO FUNCTIONAL COMPLETION

A. All Commissioning must be complete prior to Functional Completion, unless approved in writing by the
PM. Exceptions to this are planned system training performed after handover and any required seasonal
or approved functional testing. This includes for all systems, but is not limited to:
1. Completed and signed start-up and pre-commissioning checklist documentation.
2. Requested trend log data
3. Submission of final approved systems report.
4. Completion of all required controls work.
5. Completion of all functional testing.
6. Required training of O&M personnel completed and approved.
7. Submission of the approved O&M manuals.
8. All identified deficiencies have been corrected or are approved as exceptions to this
milestone by the PM.

B. The PM will determine the date of Functional Completion after reviewing the Commissioning
Company’s recommendation for Commissioning Completion.

2. EXECUTION

2.1 REPORTING

A. The CL will provide regular reports to the PM with increasing frequency as construction and
commissioning progresses. Standard forms will be provided and/or referenced in the Commissioning
Plan.

B. The CL will regularly communicate with all members of the commissioning team, keeping them
apprised of commissioning progress and scheduling changes through memos, progress reports, etc.

C. Testing or review approvals and non-conformance and deficiency reports are made regularly.

D. A final summary report by the CL will be provided to the PM, focusing on evaluating commissioning
process issues and identifying areas where the process could be improved. All acquired documentation,
logs, minutes, reports, deficiency lists, communications, findings, unresolved issues, etc., will be
compiled in appendices and provided with the summary report. Pre-commissioning checklists,

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 functional tests and monitoring reports will not be part of the final report, but will be stored in the
Commissioning Record in the O&M manuals.

2.2 SUBMITTALS

A. The CL will provide appropriate contractors with a specific request for the type of submittal
documentation the CL requires facilitating the commissioning work. These requests will be integrated
into the normal submittal process and protocol of the construction team. At minimum, the request will
include the manufacturer and model number, the manufacturer’s printed installation and detailed start-up
procedures, full sequences of operation, O&M data, performance data, any performance test procedures,
control drawings, wiring diagrams and details of factory tests. In addition, the installation and checkout
materials that are shipped inside the equipment and the field checkout sheet forms to be used by the
factory or field technicians shall be submitted to the Commissioning Lead. All documentation requested
by the CL will be included by the Commissioning Team contractors in their O&M manual contributions.

B. The CL may request additional design narrative from the PE and the Commissioning Team Contractors,
depending on the completeness of the design intent documentation and sequences provided with the
Specifications.

C. The Commissioning Lead will review and approve submittals related to the commissioned equipment for
conformance to the Contract Documents as it relates to the commissioning process, to the functional
performance of the equipment and adequacy for developing test procedures. This review is intended
primarily to aid in the development of functional testing procedures and only secondarily to verify
compliance with equipment specifications. The Commissioning Lead will notify the PM of items
missing or areas that are not in conformance with Contract Documents which may affect the
commissioning and which require resubmission.

D. Submittals to the CL do not constitute compliance for O&M manual documentation. The compilation
and submission of O&M manuals is the responsibility of the Contractor. The CL will review and
approve individual O&M documents.

2.3 START-UP, PRE-COMMISSIONING CHECKLISTS AND INITIAL CHECKOUT

A. The following procedures apply to all equipment to be commissioned.

B. The project will require startup and initial checkout to be executed in phases. This phasing will be
planned and scheduled in a coordination meeting of the CL, PM and the Commissioning Team
contractors. Results will be added to the Construction Progress Schedule and Commissioning Plan.

C. General. Pre-commissioning checklists are important to ensure that the equipment and systems are
installed and operational. It ensures that functional performance testing (in-depth system checkout) may
proceed without unnecessary delays. The pre-commissioning testing for a given system must be
successfully completed prior to formal functional performance testing of equipment or subsystems of the
given system.

D. Start-up and Initial Checkout Plan. The CL shall assist the Commissioning Team contractors
responsible for startup of any equipment in developing detailed start-up plans. The primary role of the
CL in this process is to ensure that there is written documentation that each of the manufacturer-
recommended procedures have been completed.

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 1. The pre-commissioning checklists and procedures indicate required procedures to be executed as part
of startup and initial checkout of the systems and the party responsible for their execution.
2. The pre-commissioning checklists and tests are provided by the CL to the Contractor. The Contractor
determines which trade is responsible for executing and documenting each of the line item tasks and
notes that trade on the form. Each form will have more than one trade responsible for its execution.
3. Any Commissioning Team contractor responsible for providing equipment and systems designated
for Commissioning, develops the full start-up plan by combining (or adding to) the CL’s pre-
commissioning checklists with the manufacturer’s detailed start-up and checkout procedures. The
Commissioning Team contractor shall make use of the manufacturers O&M manual and the normally
used field checkout sheets in developing the complete start-up plan. The plan will include checklists
and procedures with specific boxes or lines for recording and documenting the checking and
inspections of each procedure and a summary statement with a signature block at the end of the plan.
The full start-up plan could consist of something as simple as:
a. The CL’s pre-commissioning checklists.
b. The manufacturer’s standard written start-up procedures copied from the installation manuals
with check boxes by each procedure and a signature block added by hand at the end.
c. The manufacturer’s normally used field checkout sheets.
4. The contractor submits the full startup plan to the CL for review and approval.
5. The CL reviews and approves the procedures and the format for documenting them, noting any
procedures that need to be added.
6. The full start-up procedures and the approval form may be provided to the PM for review and
approval, depending on management protocol.

E. Execution of Pre-commissioning Checklists and Startup.

1. Prior to startup, the Commissioning Team contractors, subcontractors and vendors schedule startup
and checkout with the PM and CL. The performance of the pre-commissioning checklists, startup
and checkout are directed and executed by the Commissioning Team Contractor, subcontractor or
Vendor responsible for the equipment.
2. The CL shall observe, at minimum, the procedures for each piece of primary equipment, unless there
are multiple units, (in which case a sampling strategy may be used as approved by the PM). In no
Case will the number of units witnessed be less than four nor less than 20% of the total number of
identical or very similar units.
3. For lower-level components of equipment, (e.g., sensors, controllers), the CL shall observe a
sampling of the pre-commissioning and start-up procedures. The sampling procedures are identified
in the commissioning plan.
4. The Commissioning Team contractors, subcontractors and vendors shall execute startup and provide
the CL with a signed and dated copy of the completed start-up and pre-commissioning tests and
checklists.
5. Only individuals that have direct knowledge and witnessed that a line item task on the pre-
commissioning checklist was performed shall initial or check that item off.

F. Deficiencies, Non-Conformance and Approval in Checklists and Startup.

1. The contractors shall clearly list any outstanding items of the initial start-up and pre-commissioning
procedures that were not completed successfully, at the bottom of the procedures form or on an
attached sheet. The procedures form and any outstanding deficiencies are provided to the CL within
two days of test completion.
2. The CL reviews the report and submits either a non-compliance report or an approval form to the PM.
The installing Commissioning Team contractors, subcontractors or vendors shall correct all areas that
are deficient or incomplete in the checklists and tests in a timely manner, and shall notify the CL as
soon as outstanding items have been corrected and resubmit an updated start-up report and a
Statement of Correction on the original non-compliance report. When satisfactorily completed, the

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 CL recommends approval of the execution of the checklists and startup of each system to the PM
using a standard form.
3. Items left incomplete, which later cause deficiencies or delays during functional testing may result in
back-charges to the responsible party.

G. Functional testing is intended to begin upon completion of a system. Functional testing may proceed
prior to the completion of systems or sub-systems at the discretion of the CL and PM. Beginning system
testing before full completion does not relieve the Contractor from fully completing the system,
including all pre-commissioning checklists as soon as possible.

H. The Commissioning Team contractors have start-up, pre-commissioning and functional testing
responsibility and are required to complete systems and sub-systems so they are fully functional,
meeting the design objectives of the Contract Documents. The commissioning procedures and
functional testing do not relieve or lessen this responsibility or shift that responsibility partially to the
Commissioning Company or PM.

2.4 FUNCTIONAL PERFORMANCE TESTING

A. This article applies to all commissioning functional testing for all divisions.

B. Objectives and Scope.

1. The objective of functional performance testing is to demonstrate that each system is operating
according to the documented design intent and Contract Documents. Functional testing facilitates
bringing the systems from a state of physical completion to full dynamic operation. Additionally,
during the testing process, areas of deficient performance are identified and corrected, improving the
operation and functioning of the systems. In general, each system should be operated through all
modes of operation (seasonal, warm-up, cool-down, part- and full-load) where there is a specified
system response. Verifying each sequence in the sequences of operation is required. Proper
responses to such modes and conditions as power failure, Hot condition, low oil pressure, no flow,
equipment failure, etc. shall also be tested.

C. Test Methods.
1. Functional performance testing and verification may be achieved by manual testing (persons
manipulate the equipment and observe performance). When a control system is part of the project,
functional performance testing may use the controls to monitor the performance and analyze the
results using the control system’s trend log Capabilities or by stand-alone data loggers. The CL may
substitute specified methods or require an additional method to be executed, other than what was
specified, with the approval of the PM. The CL will determine which method is most appropriate for
tests that do not have a method specified.
2. Setup. Each function and test shall be performed under conditions that simulate actual conditions as
close as is practically possible. The Contractor executing the test shall provide all necessary
materials, system modifications, etc. to produce the necessary flows, pressures, temperatures, etc.
necessary to execute the test according to the specified conditions. At completion of the test, the
Contractor shall return all affected equipment and systems, due to these temporary modifications, to
their pre-test condition.
3. Simulated Conditions. Simulating conditions (not by an overwritten value) shall be allowed, though
timing the testing to experience actual conditions is encouraged wherever practical.
4. Overwritten Values. Overwriting sensor values to simulate a condition, such as overwriting the
outside air temperature reading in a control system to be something other than it really is, shall be

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 allowed, but shall be used with Caution and avoided when possible. Such testing methods often can
only test a part of a system, as the interactions and responses of other systems will be erroneous or not
applicable. Simulating a condition is preferable (i.e., for the above Case, the outside air sensor could
be heated with a hair blower rather than overwriting the value, or by altering the appropriate set-point
to see the desired response). Before simulating conditions or overwriting values, sensors, transducers
and devices shall have been calibrated.
5. Simulated Signals. Using a signal generator which creates a simulated signal to test and Calibrate
transducers and DDC constants is generally recommended over using the sensor to act as the signal
generator via simulated conditions or overwritten values.
6. Altering Set-points. Rather than overwriting sensor values, and when simulating conditions is
difficult, altering set-points to test a sequence is acceptable.
7. Indirect Indicators: Relying on indirect Indicators, for responses or performance shall be allowed only
after visually and directly verifying and documenting, over the range of the tested parameters, that the
indirect readings through the control system represent actual conditions and responses. Much of this
verification is completed during pre-commissioning testing.

D. Problem Solving. The CL will recommend solutions to testing problems; however the burden of
responsibility to solve, correct and retest problems is with the Commissioning Team contractors,
subcontractors and PE.

2.5 DOCUMENTATION, NON-CONFORMANCE AND APPROVAL OF TESTS

A. Documentation.
1. The CL shall witness and document the results of all functional performance tests using the specific
procedural forms developed for that purpose. Prior to testing, these forms are provided to the PM for
review and approval and to the Commissioning Team contractors for review. The CL will include the
filled out forms in the Final Commissioning Report.

B. Non-Conformance.
1. The CL will record the results of the functional test on the procedure or test form. All deficiencies or
non-conformance issues shall be noted and reported to the PM.
2. Corrections of minor deficiencies identified may be made during the tests at the discretion of the CL.
In such Cases the deficiency and resolution will be documented on the procedure form.
3. Every effort will be made to expedite the testing process and minimize unnecessary delays, while not
compromising the integrity of the procedures.
4. As tests progress and a deficiency is identified, the CL discusses the issue with the executing
contractor.
a. When there is no dispute on the deficiency and the Contractor accepts responsibility to correct it:
1) The CL documents the deficiency and the Contractor’s response and intentions and they go on to
another test or sequence. The CL submits the non-compliance reports to the PM for signature, if
required. A copy is provided to the Commissioning Team contractors and CL. The
Commissioning Team contractors correct the deficiency, sign the statement of correction at the
bottom of the non-compliance form certifying that the equipment is ready to be retested and send
it back to the CL.
2) The CL reschedules the test and the test is repeated.
b. If there is a dispute about a deficiency, regarding whether it is a deficiency or who is responsible:
1) The deficiency shall be documented on the non-compliance form with the Commissioning Team
contractor’s response and a copy given to the PM and to the Commissioning Team contractor.

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 2) Resolutions are made at the lowest management level possible. Other parties are brought into
the discussions as needed. Final interpretive authority is with the PM. Final acceptance
authority is with the PM.
3) Once the interpretation and resolution have been decided, the appropriate party corrects the
deficiency, signs the statement of correction on the non-compliance form and provides it to the
CL. The Contractor reschedules the test and the test is repeated until satisfactory performance is
achieved.
5. Cost of Retesting.
a. The cost for the Commissioning Team contractor to retest a pre-commissioning or functional test,
if they are responsible for the deficiency, shall be theirs. If they are not responsible, any cost
recovery for retesting costs shall be negotiated with the DR.
b. For a deficiency identified, not related to any pre-commissioning checklist or start-up fault, the
following shall apply: The CL will direct the retesting of the equipment once at no “charge” to the
project for their time. However, the CL’s time for a second retest will be charged to the
Commissioning Team contractors.
c. The time for the CL to direct, attend or witness any retesting required because a specific pre-
commissioning checklist or start-up test item, reported to have been successfully completed, but
determined during functional testing to be faulty, will be back-charged to the Commissioning
Team contractors.
6. The Contractor shall respond in writing to the CL and PM concerning the status of each apparent
outstanding discrepancy identified during commissioning. Discussion shall cover explanations of
any disagreements and proposals for their resolution.
7. The CL retains the original non-conformance forms until the end of the project.
8. Any required retesting by any contractor shall not be considered a justified reason for a claim of
delay or for a time extension by the prime contractor.

C. Failure Due to Manufacturer Defect:

1. If 10 percent, or three units, whichever is greater, of identical pieces (size alone does not constitute
a difference) of equipment fail to perform to the Contract Documents (Mechanically or
substantively) due to manufacturing defect, not allowing it to meet its submitted performance
specification, all identical units may be considered unacceptable by the PM. In such Case, the
Contractor shall provide the PM with the following:
a. Within one week of notification from the PM, the Contractor or manufacturer’s representative
shall examine all other identical units making a record of the findings. Within two weeks of the
original notice, a signed and dated, written explanation of the findings, problems, cause of
failures, etc. and all proposed solutions shall be provided to the PM. The proposed solutions
shall not significantly exceed the specification requirements of the original installation.
b. The PM will determine whether a replacement of all identical units or a repair is acceptable.
c. Two examples of the proposed solution will be installed by the Contractor and the installations
will be tested for up to one week, upon which the PM and CL will decide whether to accept the
solution.
d. Upon acceptance, the Contractor and/or manufacturer shall replace or repair all identical items,
at their expense and extend the warranty accordingly, if the original equipment warranty had
begun. The replacement/repair work shall proceed with reasonable speed beginning within one
week from when parts can be obtained.

D. Approval:
1. The CL notes each satisfactorily demonstrated function on the test form. Formal approval of the
functional test is made later after review by the CL and by the PM, if necessary. The CL

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 recommends acceptance of each test to the PM using a standard form. The PM gives final
approval on each test using the same form, providing a signed copy to the CL and the Contractor.

2.6 OPERATION AND MAINTENANCE MANUALS

A. Standard O&M Manuals.

1. Additional content and format requirements for the standard O&M manuals are detailed in
individual equipment sections.
2. The following O&M manual requirements do not replace O&M manual documentation
requirements elsewhere in these specifications.

B. Review and Approvals.

1. CL review and approval. Prior to substantial completion, the CL shall review the O&M manuals,
documentation and redline as-built for systems that were commissioned, concurrently with the PE.
The CL will communicate concerns about the manuals to the PM. Upon a successful review of the
corrections, the CL recommends approval and acceptance of these Sections, with respect to the
commissioning, to the PM. The CL also reviews each equipment warranty and verifies that all
requirements to keep the warranty valid are clearly stated. This work does not supersede the PE’s
review of the O&M manuals according to the PE’s contract.

2.7 TRAINING OF OWNERS OPERATING AND MAINTENANCE PERSONNEL

A. The Commissioning Team contractors and CL shall be responsible for training coordination, scheduling
and ultimately for ensuring that training is completed.

B. The CL shall be responsible for reviewing and approving the content and adequacy of the training of
Owners personnel for commissioned equipment.
1. Hands-on training shall include start-up, operation in all modes possible, including manual, shut-
down and any emergency procedures and preventative maintenance for all pieces of equipment.
2. Training shall occur after functional testing is complete, unless approved otherwise by the PM.
3. Duration of Training: The Commissioning Team contractor shall provide training on each piece of
equipment according to the durations in individual equipment specifications.

2.8 WRITTEN WORK PRODUCTS

A. The commissioning process generates a number of written work products described in various Sections
of the Specifications. The Commissioning Plan lists all the formal written work products, describes
briefly their contents, who is responsible to create them, their due dates, who receives and approves them
and the location of the specification to create them. In summary, the written products are:
1. Product Developed By:
a. Final Commissioning Plan: CL.
b. Commissioning Meeting Minutes: CL.
c. Commissioning Schedules: CL with Commissioning Team contractors and PM.
d. Equipment Documentation Submittals: Commissioning Team contractors.
e. Sequence Clarifications: Commissioning Team contractors and PE as needed.
f. Pre-commissioning Checklists: CL.
g. Startup and Initial Checkout Plan: Commissioning Team contractors and CL (compilation of
documents).
h. Startup and Initial Checkout Forms Filled Out: Commissioning Team contractors.

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i. Commissioning Progress report: CL.
j. Deficiency Reports: CL.
k. Functional Test Forms: CL.
l. Filled Out Functional Tests: CL.
m. O&M Manuals: Commissioning Team contractors.
n. Overall Training Plan: CL and Commissioning Team contractors.
o. Final Commissioning Report: CL.

END OF SECTION

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