PURPOSE
The purpose of this procedure is to provide guidelines for completing the Various Equipment & Facility Performance Testing. Equipment functional testing or validation is a test of each separate piece of equipment to make sure that it operates as specified in the Contract Documents. The Facility Performance Test is a complete system end–to-end test to demonstrate and verify that all related components and sub-systems are fully integrated and functioning as intended. The Performance Acceptance Test demonstrates and verifies that the system and project equipment meets intended objectives.
REFERENCES
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RESPONSIBILITIES
Project Manager (PM): The PM is responsible to see verify that all projects have a successful startup phase including all performance testing. The PM is responsible for coordinating the testing.
Project Engineer (PE): On large or complex projects, the PM may bring on a PE to assist the PM with his/her responsibilities.
Construction Manager (CM): The CM is responsible for administering the project Plans and Specifications. He/she is also responsible for the day-to-day management activities on the project and coordination of these activities with the project team. During facility startup and testing, the CM is also responsible for approving the Contractor’s final facility startup and test plans and verifying that Facility Performance and Performance Acceptance Tests are successfully completed. The PM may decide to include a Bid Item Allowance for start-up assistance to cover the expense of starting up specialized equipment and/or facility.
Contractor: It is the Contractor’s responsibility to provide the expertise, equipment, labor, and materials to properly startup the facility, perform the Facility Performance Test and pass the Performance Acceptance Tests specified in the project’s Technical Specifications. The Contractor is also responsible for preparing a written Facility Performance Test Plan and at the conclusion of the test, a Facility Performance Test Report.
Bureau of Contract Administration: It is the Lead Inspector or his/her delegated representative’s (Inspector) responsibility to monitor the facility startup and testing to ensure that startup and testing are performed in accordance with the Contract Documents. During facility startup and testing, the Inspector, in cooperation with the Owner’s representative, CM and PM, is also responsible for reviewing the Contractor’s submitted test plans and reports.
PROCEDURE
The functional testing or validation is conducted after the equipment has been certified by the manufacturer. This testing occurs on each separate piece of equipment. The Contractor performs the test and the test is witnessed by the Project Team, consisting of the Inspector, PM, and CM (or their designees).
The Facility Performance Test is performed by the Contractor under actual operating conditions at facility design capacity using process fluids, as specified in the Contract Documents. The purpose of the Facility Performance Test is to demonstrate the ability of the entire system to operate continuously for an extended period of time without failure. Duration of the test is stated in the Contract Documents and is typically 7 – 30 days.
The Contractor prepares a written Draft Facility Performance Test plan. The plan should include a step-by-step procedure, list of supplies needed to conduct the test, success criteria, failure criteria, staffing required, and type and quantity of data to be collected. This is not an all inclusive list.
The Project Team reviews the Draft Facility Performance Test plan for completeness and potential conflicts with routine plant or facility operations and maintenance. They provide written comments back to the Contractor. The Contractor then prepares the Final Facility Performance Test Plan.
On approval of the Final Facility Performance Test Plan, the Contractor mobilizes staff to perform the test. The Project Team, in coordination with the client agency, coordinates supplying water or other process fluid for the test. The Contractor bears all costs for oils, lubricants, process chemicals and consumables required to complete the test.
At the conclusion of the test, the Contractor submits a draft Facility Performance Test Report containing the daily operating data and pertinent performance data. The draft report is reviewed by the Project Team for completeness and accuracy. The Contractor then prepares the final Facility Performance Test Report based on the review comments. The Final Facility Performance Test Report is then submitted to the CM for acceptance.
The Performance Acceptance Test demonstrates and verifies that the system has the ability to meet the intended objectives. For treatment process type projects, the treatment objectives may include, but are not limited to, hydraulic and solids loading rates, inorganic and organic substrate removal rates, oxygen transfer rates, and disinfection capabilities. For other projects, the objectives may include, but are not limited to, LEED Certification requirements, air change requirements, air balancing, and minimum heating or cooling capacities. The Performance Acceptance Test is typically performed by the Contractor, in coordination with the City, under actual operating conditions at facility design capacity using process fluids. The Performance Acceptance Test may be performed concurrently with the Facility Performance Test.
Performance Acceptance Test Criteria are derived from the project Contract Documents. The criteria are typically stated in terms of the system to achieve a specified level of treatment or performance. A member of the Project Team shall develop a written Draft Sampling and Laboratory Analysis Plan for monitoring system performance. The draft is reviewed by the Project Team. Based on comments of the review, the Final Sampling and Laboratory Analysis Plan is prepared and included in the Contract Documents. Costs for sampling and laboratory testing shall be included in the Contractors Bid Price.
At the conclusion of the Performance Acceptance Test, the Contractor compiles all laboratory analysis results and prepares a written Draft Performance Acceptance Test Report. The Draft is reviewed by the Project Team and comments are provided. The Final Performance Acceptance Test Report is prepared based on the review comments. The Final Report is submitted to the CM for acceptance.
RELATED PROCEDURES
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