PURPOSE
The purpose of this procedure is to provide a guideline on equipment installation and testing and to ensure that the appropriate types and amount of manufacturer’s services are specified in the Contract Documents. This procedure will discuss the types of services that can be provided by manufacturers and establishes the responsibilities of the parties involved in the performance and administration of the services.
REFERENCES
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RESPONSIBILITIES
Project Manager (PM): The PM is responsible for the overall completion of the project. Equipment installation and testing is a key component of a successful project. The PM is also responsible for working with the various design disciplines and specialty designers to incorporate in the contract documents the type and extent of services required from the equipment manufacturer. The PM should also coordinate with the CM to see that these specified services are satisfactorily provided.
Project Engineer (PE): On complex projects the PM may bring in a PE to assist the PM with his/her responsibilities.
Construction Manager (CM): The CM is responsible for ensuring that all the manufacturer’s services specified in the contract documents are satisfactorily performed. It is important that test scheduling and notification of the various parties involved are coordinated well in advance so that adequate manpower can be mobilized and the facility operation can be adjusted to avoid any possible disruption or process upset.
Contractor: The Contractor is responsible for installing the equipment in accordance with the manufacturer’s requirements and in accordance with approved Shop Drawings and Submittals. The Contractor is also responsible for mobilizing its equipment suppliers for the specified services. The Contractor shall notify the CM, a specified number of days in advance, of any manufacturer’s services that may require the presence of qualified personnel from design, construction, inspection, and operations and maintenance groups. Such lead time will prevent any disruption or process upset in the facility operation.
Bureau of Contract Administration (BCA): The BCA provides construction inspection services to ensure that the requirements of the contract documents are satisfied. The responsibility of BCA includes facilities testing witnessing, pre-delivery inspection and testing of materials, inspection of fabricated products, and equipment at the source, and witnessing functional and performance testing.
Startup Team: It is the responsibility of the startup team to help the CM to facilitate the startup of the facility. The startup team shall have expertise in the areas of control systems, electrical, instrumentation, mechanical and operations disciplines. The team shall use this expertise to facilitate the startup activities. The team may include representatives from the owner/client/operations groups as well as construction management and field engineering groups. The startup team may also include an independent third party.
PROCEDURE
The Contractor and CM should develop a manufacturer’s services plan early in the construction stage. Prior to the installation of equipment requiring manufacturer’s services, the Contractor should ensure that all parties involved with the project are notified in advance of the manufacturer being on site.
There are two types of contracts in which manufacturer’s services may be required. The first is a construction contract, where a general contractor is the principal party to the contract. The CM deals directly with the general contractor.
The second type of contract is a supply or procurement contract where the City procures the equipment directly from the manufacturer or authorized supplier. In this case, the equipment manufacturer or supplier is party to the contract and is considered to be the principal contractor. The City will coordinate all testing activities with the Procurement contractor.
Depending on which type of contract is involved, the type and extent of the manufacturer’s services and the corresponding certification, validation and training required may vary. Manufacturer’s Services: There are three basic types of manufacturer’s services associated with the construction, startup, and operation of new equipment. The three types are as follows:
Certification: Certification is a written acknowledgement by the manufacturer that the equipment supplied has been properly installed and tested, and is capable of being placed into service. Certification of equipment and systems is required for all types of contracts. Certification requires one or more jobsite visits by the manufacturer’s representative and a physical determination as to the adequacy of the Contractor’s installation. Manufacturer’s certification of mechanical equipment installation includes, but is not limited to the following:
Physical inspection
Alignment and balancing (vibration)
Lubrication
Programming (controllers)
Calibration
Overload protection demonstration
Compliance with noise criteria
Training
Safety requirements and procedures
Acquisition of permits showing compliance with applicable CAL/OSHA requirements and other regulatory agencies such as the Air Quality Management District (AQMD)
Recommended spare parts list
Manufacturer’s certification for electrical equipment installation includes, but is not limited to the following:
Acquisition of Underwriters Laboratory (UL) or City of Los Angeles Laboratory certification
Physical inspection
Motor winding integrity (megger), performed by the electrical contractor or subcontractor
Feeder and branch wire integrity (hi-pot), performed by the electrical contractor or subcontractor
Protection demonstration (protective relay schemes and fault current protection)
Load testing (power generation and distribution)
Verify pump rotation
Panel fabrication
Training
Safety requirements and procedures
Recommended spare parts list
Manufacturer’s certification of instrumentation and control (I&C) equipment installation includes, but is not limited to the following:
Acquisition of UL or City of Los Angeles Laboratory certification
Physical inspection
Instrument calibration
Signal tracing
Software debugging (computerized control)
Panel fabrication
Training
System compatibility testing
Safety requirements and procedures
Recommended spare parts list
Prior to startup, the Contractor shall submit shall provide the City a written certificate of proper installation and operation from the equipment manufacturer, on their official letterhead. The certificate will indicate the date of the verifications, that the equipment has been properly installed, that proper electrical and mechanical connections have been made, and that the equipment is operating in accordance with specified performance requirements. The certificate must also state that all items of the equipment satisfy all legal requirements for the various regulatory agencies and possess UL labels or other approved certification labels.
Validation: Validation is the process of demonstrating that the equipment and system supplied under the contract meets the requirements specified in the contract documents and approved during the submittal process. Validation occurs after certification and prior to the startup process and is often referred to as functional testing. The ability of equipment to deliver the required capacity or otherwise serve the intended purpose must be determined before startup is initiated.
The Contractor performs all functional testing. The testing is monitored by the Inspector, the City’s operation and maintenance staff and the CM. The Contractor is responsible for supplying water or other process fluid for functional testing. The Contractor bears the costs for all oils, lubricants, process chemicals and consumables required to complete the test. The Contractor prepares and submits a written Draft Functional Test Procedure to the CM. The Draft Functional Test Procedure should include, but is not limited to the following items:
Brief equipment description
Control loop description
Step-by-step procedures for demonstrating manual and automatic mode operation
Success criteria
Failure criteria
At a minimum, failure criteria should include, but not be limited to the following:
Failure of a pumping unit or motor
Performance of a mechanical unit (e.g. pump and motor) outside of its specified acceptable ranges for vibration, noise, temperature, cavitation, efficiency, and capacity
A failure of any ancillary component that cannot be returned to service within 30 minutes of failure
Three failures of an ancillary component regardless of the amount of time it takes to return to service and regardless of whether or not the failures are due to the same cause
Bypassing, deactivating, or in any way disabling a protective device, alarm, or control to facilitate the completion of the test
The Inspector, CM, and Startup Team if formed, review the Draft Functional Test Procedure for completeness and potential conflicts with routine facility operations and maintenance. Written review comments are prepared and forwarded to the Contractor. The Contractor prepares a Final Functional Test Procedure based on the comments and submits it to the CM for approval. Upon approval of the Final Functional Test Procedure, the Contractor mobilizes staff to perform the test. The functional test would be witnessed by the Inspector, CM, and Startup Team if formed.
Only after successful validation should equipment be placed into service.
Training: Training of operation and maintenance personnel, when specified, may be a service to be provided by the manufacturers. The manufacturer must provide an experienced, competent and authorized representative to perform the services during the period of testing and startup. The contract documents should require the Contractor to have the manufacturer’s representative revisit the job site as often as necessary until the equipment installation and operation are satisfactory to the CM and the inspector. The number of days necessary for the manufacturer’s representative to perform the required services, such as installation, testing, inspection, and training should be specified in the contract documents. The CM should determine this by coordination with the designer, equipment supplier, and facility operations and maintenance staff. An adequate number of workdays should be specified for the following: Inspection, adjustment, and certification of the equipment installation, functional and performance testing pre-startup classroom and hands on training for operations and maintenance personnel, startup and startup training.
RELATED PROCEDURE
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