DALLAS-FORT WORTH
INTERNATIONAL AIRPORT
ADDENDUM NO. 1
TO THE REQUEST FOR BIDS
Contract No. 9500540
Terminal B High Gates Electrification
August 12, 2014
THE REQUEST FOR BIDS (RFB) FOR THE ABOVE IS HEREBY REVISED AS FOLLOWS:
THIS ADDENDUM CONSISTS OF 68 PAGES (INCLUDING ATTACHMENTS).
THE CONTRACT DOCUMENTS AND SPECIFICATIONS FOR THE ABOVE TITLED
PROJECT ARE HEREBY AMENDED OR REVISED AS FOLLOWS:
Item 1: The preliminary Commissioning Plan as referenced by Specification 01 91 00 – Commissioning,
is attached (dated July 29, 2014).
END OF ADDENDUM NO. 1
Terminal B High Gates Electrification
Addendum No. 1
Contract No. 9500540
THIS PAGE INTENTIONALLY BLANK
TERMINAL B HIGH GATES
ELECTRIFICATION
Preliminary Commissioning Plan
Bid Phase
Project No: 9500540
Permit Numbers: A14-158B
Prepared for:
Dallas/Fort Worth
International Airport
July 29, 2014
Swayzer Engineering, Inc.
3102 Maple Ave. Suite 450
Dallas, Tx 75201
Table of Contents
Commissioning Plan ............................................................................................................................. 1
1.0 Overview
............................................................................................................................. 1
1.1 Abbreviations and Definitions ........................................................................................... 1
1.2 Commissioning Plan Purpose........................................................................................... 2
1.3 Commissioning Scope ...................................................................................................... 2
1.4 Commissioned Systems ................................................................................................... 2
1.5 Form ............................................................................................................................. 2
2.0 General Project Information .................................................................................................... 3
3.0 Design, Commissioning, and Construction Team Data ....................................................... 3
4.0 Roles and Responsibilities ...................................................................................................... 4
4.1 Role and Responsibility Descriptions and Explanations .................................................. 4
4.2 Team Members ................................................................................................................. 4
4.3 General Management Plan ............................................................................................... 4
4.4 General Role Descriptions ................................................................................................ 4
5.0 Commissioning Process.......................................................................................................... 5
5.1 Commissioning Scoping Meeting ..................................................................................... 5
5.2 Preliminary and Final Commissioning Plan Updates........................................................ 5
5.3 Site Observation ............................................................................................................... 5
5.4 Miscellaneous Meetings ................................................................................................... 6
5.5 Miscellaneous Management Protocols ............................................................................. 6
5.6 Progress Reports and Logs .............................................................................................. 7
5.7 Submittals and Documentation ......................................................................................... 7
5.7.1 Standard Submittals ............................................................................................. 7
5.7.2 Special Submittals, Notifications, and Clarifications ............................................ 7
5.8 Pre-functional Checklists, Pre-functional Testing, and Start-up Plan ............................... 8
5.8.1 Pre-functional Testing and Start-up Plan ............................................................. 8
5.8.2 Pre-functional Testing and Start-up Execution .................................................... 9
5.8.3 Deficiencies and Non-Compliance ....................................................................... 9
5.9 Functional Testing and Verification Development ............................................................ 9
5.9.1 Functional Testing Overview................................................................................ 9
5.9.2 Functional Testing Plan Overview .....................................................................10
5.9.3 Functional Testing Scope ..................................................................................10
5.9.4 Development Process ........................................................................................10
5.10 Functional Testing Execution........................................................................................11
5.10.1 Functional Testing Procedure Overview and Process .....................................11
5.10.2 Deficiencies and Retesting ..............................................................................11
5.10.3 Facility Staff Participation.................................................................................11
5.10.4 Sampling ..........................................................................................................11
5.11 O&M Manuals, Warranties, and Commissioning Record Book ....................................11
5.11.1 O&M Manual and Warranty Overview .............................................................11
5.11.2 Commissioning Record Book...........................................................................11
5.12 Owner Personnel Training and Orientation ..................................................................12
5.13Commissioning Cost Benefits Matrix .............................................................................12
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
i
Commissioning Plan
Bid Phase
Issued July 29, 2014
6.0 Summary Report .....................................................................................................................12
7.0 Schedule
...........................................................................................................................13
7.1 General Issues ................................................................................................................13
7.2 Project Schedule .............................................................................................................13
Table 7.0 Commissioning Process Schedule Summary ..........................................................13
Exhibit A: Cost Benefits Matrix ...................................................................................................16
Exhibit B: Cx Progress Record / Equipment Summary ............................................................18
Appendix 1:
Form
C-01
C-02
C-03D
C-03E
C-05C
C-06
C-07
C-17
C-18
C-21
C-22
Sample Commissioning Application Forms .................................................20
Title
Construction Issues Log / Issues Log Photos ...................................................21
Documentation Tracking and Control Log.........................................................23
Commissioning Request for Information ...........................................................25
Request for Information Log ..............................................................................26
Staff Training and Orientation Log ....................................................................27
Corrective Action Report ...................................................................................28
Commissioning Progress Record / Equipment Summary .................................29
Submittal Review / Submittal Review Log.........................................................30
Field Observations and Tests ...........................................................................32
Operation and Maintenance Manual and Warranty Log ...................................34
Pre-functional Checklist Review........................................................................35
Appendix 2:
Form
PFC-201
PFC-202
PFC-203
Sample Pre-Functional Checklists ................................................................36
Title
Pre Functional Checklist – Ground Power Unit ...............................................37
Pre Functional Checklist – Pre Conditioned Air Unit .........................................42
Pre Functional Checklist – Condensate / Sump Pump .....................................46
Appendix 3:
Form
FPT-201
FPT-202
FPT-203
Sample Functional Performance Testing Procedures ................................49
Title
Functional Performance Test – Ground Power Unit .......................................50
Functional Performance Test - Pre Conditioned Air Unit ..................................56
Functional Performance Test – Condensate/Sump Pump................................61
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
ii
Commissioning Plan
Bid Phase
Issued July 29, 2014
Commissioning Plan
Project:
Terminal B High Gates Electrification
Contact:
Ron Wesolak, DFW Airport PM
Date:
7/29/14
1.0
Commissioning Plan Version
Preliminary – DRAFT
X Preliminary – Bid Phase
Construction Phase
Final Acceptance Phase
Overview
Fundamental Equipment Systems Commissioning Tasks:
1. Engage a Cx Agent
2. Review design intent and Basis of Design
3. Include Cx Requirements in construction documents
4. Develop and utilize a Cx Plan
5. Verify installation, functional performance, training and documentation for each
commissioned system and/or component
6. Complete a Commissioning Report
1.1
Abbreviations and Definitions
The following are common abbreviations used in this document.
A/E
CC
CM
Cx
CxAg
CxAu
Cx Cord
Cx Plan
EC
1.2
-
Architect & Engineer Design Team
Controls Contractor
Construction Manager
Commissioning
Commissioning Agent
Commissioning Authority
Commissioning Coordinator
Commissioning Plan document
Electrical Contractor
FPT
GC
LC
MC
PFC
PM
SMC
Subs
TAB
-
Functional Performance Test
General Contractor
Louver Contractor
Mechanical Contractor
Pre-Functional Test
Project Manager
Sheet Metal Contractor
Subcontractors
Test and Balance Contractor
Commissioning Plan Purpose
The Commissioning Plan purpose is to provide clear and concise procedures for the
commissioning process and to provide a record of the results of the commissioning process. It is
a means of issue resolution, describes the roles of parties, means of reporting, means of
approval, and coordination.
The structure of this Commissioning Plan is a main body and appendices. The specific sections
include:
•
Project and Contact Information: Proper communication is critical for the success of any
project. This section lists the contact information for the commissioning team members.
•
Roles and Responsibilities: The roles and responsibilities of each commissioning team
member are clearly defined in this section. The goal of this section is to have each
individual understand what they must do and how they fit into the entire process.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
1
Commissioning Plan
Bid Phase
Issued July 29, 2014
1.3
•
Communication Structures: The communication paths to be used by the commissioning
team members are detailed in this section.
•
Commissioned Systems and Equipment: The commissioned systems include those that
are in the commissioning authority’s contract. These systems were expanded using the
drawings and specifications to develop a detailed listing of each type of equipment in
each system to be commissioned.
•
Commissioning Process Description: This section provides a detailed description of the
tasks to be accomplished during the commissioning process. Focuses specifically on
what must be accomplished during the design, construction, turnover, and operation
phases of the project.
•
Commissioning Process Schedule: there are specific sequences of events that must
occur during the commissioning process. These events are detailed in this section.
Appendices: The appendices present the information developed during the
commissioning process. As work is completed, the results are added to the proper
appendix and the status and date of the document are inserted into Exhibit B found on
page 19
20.
Commissioning Scope
Commissioning is a systematic process ensuring equipment to be commissioned performs in
accordance to the contract documents. For this project, this is achieved by beginning in the
construction phase and continuing through the acceptance period with performance verification.
The commissioning process is intended to achieve the following specific objectives in
accordance with contract documents
1.4
•
Ensure applicable equipment and systems are installed properly and receive
adequate operational checkout by installing contractors.
•
Verify and document proper equipment and system functional testing.
•
Ensure O&M documentation is complete.
•
Ensure Owner’s operating personnel are adequately trained.
Commissioned Equipment / Systems
Table 1: The following equipment / systems shall be commissioned.
Systems to be Installed
Quantity to be Installed
Ground Power Units / 400Hz-28v
12
PBB Pre-Conditioned Air Unit
6
Condensate / Sump Pump
12
1.5
Forms
Commissioning (application) forms are referred to in this plan by: Form C-xx, where “C”
represents Construction phase.
Blank forms are found in Appendix 1 at the end of this document.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
2
Commissioning Plan
Bid Phase
Issued July 29, 2014
2.0
3.0
General Project Information
Project Name:
Terminal B High Gates Electrification
Project Location:
DFW International Airport
Project Agency:
Airport Development and Engineering Department
Construction Period:
TBD
Design, Commissioning, and Construction Team Data
Table 2: Team Data
Team Member
Company and
Office / Cell, Fax,
and E-mail Address
Contact Names
Owner
DFW International Airport
3200 East Airfield Dr.
DFW Airport, TX 75261-9428
Phone:
972-973-3112
DFW Airport
Project
Manager
Ron Wesolak, PM
ADE Building
3003 S Service Rd
DFW Airport, Tx 75261
Parsons
1301 West President George
Bush HWY Suite 350
Richardson, Tx 75080
Phone:
Email:
972-973-1820
rwesolak@dfwairport.com
Phone:
972-244-6000
Harold John Vetter II
Agurirre Roden
10670 N. Central Expressway
Dallas, Tx 75231
Jeff Gulrich
Phone:
972-788-1508
Phone:
Email:
Phone:
Email:
Phone:
Email:
972-973-6119
jgulrich@dfwairport.com
972-973-6162
sbelaye@dfwairport.com
972-973-6167
ramartinez@dfwairport.com
Design Project
Management
Engineer
Commissioning
Authority
Designee
Shure Belaye
Raul Martinez
AM Building
3010 East Airfield Dr
DFW Airport, Tx 75261
DFW
Construction
Manager
General
Contractor
TBD
Phone:
Email:
TBD
TBD
TBD
Phone:
Email:
TBD
TBD
Commissioning
Agent,
Representative
Michele Swayzer, P.E., QCxP
Swayzer Engineering, Inc.
3102 Maple Ave, Suite 450
Dallas, TX 75201
Phone:
Cell:
214-880-7929
214-878-7929
E-mail:
michele.swayzer@swayzer.com
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
3
Commissioning Plan
Bid Phase
Issued July 29, 2014
4.0
Roles and Responsibilities
4.1
Role and Responsibility Descriptions and Explanations
Role and responsibility descriptions and explanations are found in the following locations:
Team Members:
General Management Plan Outline:
General Role Descriptions:
A/E; CM; PM:
General Contractor:
Mechanical Contractor,
TAB Contractor, Controls Contractor:
Electrical Contractor, Communications
Contractor, Security Contractor:
CxAg:
CxAu:
Manufacturer’s Representative:
4.2
Cx Plan, Section 4.2.
Cx Plan, Section 4.3.
Cx Plan, Section 4.4.
Cx Plan, Section 4.4.
Cx Plan, Section 4.4.
Cx Plan, Section 4.4.
Cx Plan, Section 4.4.
Cx Plan, Section 4.4
Cx Plan, Section 4.4
Cx Plan, Section 4.4
Team Members
Commissioning team members consist of Dallas Fort Worth Airport Development and
Engineering Department (ADE) personnel, Dallas Fort Worth Airport Energy, Transportation,
and Asset Management Department (ETAM), CxAu, CxAg, PM, and CM assigned members.
Also included are mechanical, electrical, and controls contractors, installing subcontractors
and/or equipment suppliers.
4.3
General Management Plan
Dallas Fort Worth Airport Development Department contracted the CxAg on behalf of Dallas
Fort Worth Airport Development and Engineering Department (ADE). The CxAg coordinates
commissioning activities and reports to the Dallas Fort Worth Airport Development and
Engineering Department (ADE). All members work together to fulfill their contracted
responsibilities and meet contract document objectives.
4.4
General Role Descriptions
General commissioning role descriptions are:
CxAg:
CxAu:
Coordinates Cx process, performs limited construction observations, identifies
concerns and issues to A/E & PM, writes Cx plan; pre-functional checklists; and
functional testing requirements and procedures, functional testing status record,
oversees, and documents performance verification tests, and provides limited
problem resolution assistance.
Reviews and approves Cx Plan. As is the case, when need be, attends meetings.
Reviews and approves Final Cx Report.
CxAu
Designee: Performs the function of the CxAu in their absence.
PM:
Facilitates and supports the Cx process, approves Cx work, and approves test
plans.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
4
Commissioning Plan
Bid Phase
Issued July 29, 2014
CM:
GC:
A/E:
Subs:
Mfr.:
5.0
Facilitates Cx process, ensures Subs perform their responsibilities, and integrates
Cx into construction process, schedule, and approves test plans.
Responsible for and demonstrates proper system installation and performance
(typically through the use of its installers, subs, and/or manufacturer.
Performs construction observation, during testing a design issues may result in a
request for information from the A/E. The A/E or Contractor provide written
response to the CxAg listing their disposition on each issue and their planned
actions, reviews, modifies and issues Cx Specifications, approves O&M manuals,
and assists in resolving problems.
Demonstrates proper system installation and performance.
Equipment manufacturers and vendors provide documentation to facilitate
commissioning work and perform contracted start-up services.
Commissioning Process
This section sequentially details the commissioning process by commissioning task or activity.
The intent of this section is to document how the tasks are accomplished as part of the
commissioning effort for this project. This information is prescriptive and stepwise in nature to
focus the commissioning efforts on verifying the owner’s project intent has been met.
5.1
Commissioning Scoping Meeting (K/O)
The CxAg conducts a commissioning scoping meeting prior to acceptance phase testing.
Representatives of CxAg, CM, PM, A/E, MEP engineers and Subs should attend. The agenda
shall be as follows:
•
•
•
•
•
•
5.2
Commissioning party introduction.
Commissioning process overview.
Preliminary Cx Plan overview.
Management and reporting line overview.
Roles and responsibilities.
Proposed commissioning schedule.
Preliminary and Final Commissioning Plan Updates
The CxAg prepares the Preliminary Commissioning Plan prior to the Scoping meeting. The
Commissioning Plan is then updated from information gathered from the scoping meeting and
throughout the project. The initial commissioning schedule is also developed in Section 7. The
commissioning schedule shall be adjusted as construction progresses. Prior to primary
equipment start-up, the CxAg shall meet with CM and PM to develop a detailed commissioning
schedule. The ETAM Cx Authority designees review and approve the final commissioning plan
and report.
5.3
Site Observation
The CxAg, PM, and selected DFW personnel make periodic site visits as necessary to witness
equipment and system installations. As construction progresses and mechanical and electrical
system installation activities increase; the CxAg may increase the frequency of site observations
as required. A site observation report will provide an overview for each site observation.
Observed deficiencies shall be documented on Form C-06, Commissioning Corrective Action
Report, and tracked on form C-01, Construction Issues Log, Form C-06 shall be forwarded to
the design team for coordination of system deficiency resolution with a copy being sent to the
project manager.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
5
Commissioning Plan
Bid Phase
Issued July 29, 2014
5.4
Miscellaneous Meetings
The CxAg attends selected planning and job-site meetings and shall provide meeting minutes
thereof. The PM and CM provide the CxAg with information regarding substitutions, change
orders, or any Design Change Notices (DCN’s) that may affect commissioned equipment and
systems, or the commissioning schedule. The CxAg shall review construction-meeting minutes,
or change orders, for the same purpose.
The CxAg shall schedule commissioning team member meetings through the PM as required
during construction.
5.5
Miscellaneous Management Protocols
The following protocols shall be used on this project:
Issue
Protocol
Requests for information (RFI) or
formal documentation requests:
The CxAg forwards to Design Team or CM as appropriate.
Minor or verbal information and
clarifications:
The CxAg communicates to Design Team or CM as
appropriate.
Deficiency notification:
The CxAg documents deficiencies through A/E, but may
discuss deficiency issues with the CM prior to notifying
A/E. Copies of deficiency reports shall be provided to PM.
FPT’s or Training Scheduling:
The CxAg may provide input for (and do some
coordination of) training and testing, but does not schedule
tests or training.
Commissioning meeting
scheduling:
The CxAg coordinates date and schedules through PM
and CM.
Significant change requests:
The CxAg has no authority to issue contract changes.
Minor change requests:
The CxAg may suggest (through PM to go to A/E for
approval) changes in sequences of operations to improve
efficiency or to control or correct deficiencies.
Engineer approved changes shall be documented and
forwarded to CM for modification by responsible
subcontractor.
Disagreements between
contractors and CxAg’s requests
or interpretations:
First works with CxAg. Second through CM.
The CM shall work with CxAg directly or through PM for
resolution as required.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
6
Commissioning Plan
Bid Phase
Issued July 29, 2014
5.6
Progress Reports and Logs
The CxAg provides PM with periodic commissioning progress reports. Progress report
frequency may be increased to twice per month, as necessary, just prior to initial major
equipment start-up and continuing until functional testing is complete and all non-compliance
issues are resolved.
Progress reports contain:
• Schedule update with requested schedule changes and newly scheduled items.
• New and outstanding deficiency list described on Form C-06, Commissioning Corrective
Action Report and tracked on form C-01, Construction Issues Log.
• Commissioning progress that may include Form C-07, Commissioning Progress Record /
Equipment Summary.
The CxAg regularly communicates with commissioning team members keeping them apprised
of outstanding issues, commissioning progress, and scheduling through memos, progress
reports, etc. The CxAg maintains all commissioning related materials to become part of final
commissioning report.
5.7
Submittals and Documentation
5.7.1
Standard Submittals
The CxAg provides subcontractors responsible for commissioned equipment and systems with
respective commissioning documentation requirements through the CM and PM. Subcontractor
documentation submissions typically coincide with the Engineer submittal process.
At a minimum, documentation submissions shall contain:
• Manufacturer’s installation instructions.
• Start-up and checkout procedures.
• Operation and Maintenance data.
• Performance data.
• Control drawings.
• Sequence of Operations
The CxAg reviews commissioning related submissions specified in contract documents. Form
C-02, Documentation Tracking Control Log, shall be used to track documents. Form C-02 shall
also be used for part of the final O&M documentation review checkoff.
5.7.2
Special Submittals, Notifications, and Clarifications
Sub-contractors, CM, or A/E shall notify CxAg within one week of approval of any design intent
or operating parameter changes, commissioned system changes, added control strategies and
operation sequences, or other change orders that may affect commissioned systems. The GC
provides CxAg with a complete points list including details requested by CxAg. Thirty (30) days
prior to performing any applicable DFW-contracted tests, the sub’s must provide CxAg with full
procedural details.
These submittals do not constitute O&M manual submittal compliance. O&M manual
documentation requirements are discussed in Commissioning Plan, Section 5.11.
The CxAg may request additional design narrative clarification from A/E and/or the Contractor
depending on completeness of original bid documents. The CxAg may submit written RFIs to
contractors through CM using Form C-03D, Commissioning Request for Information.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
7
Commissioning Plan
Bid Phase
Issued July 29, 2014
5.8
Pre-functional Checklists, Pre-functional Testing, and Start-up Plan
Pre-functional checklists (PFCs) augment and are combined with manufacturer’s installation
instructions, start-up instructions, and checkout plans. PFCs help to document that systems
have been installed and operate in accordance with contract documents and manufacturer’s
recommendations and to ensure functional testing proceeds with minimal delays. Responsible
contractors must fill in each commissioned equipment and system pre-functional checklist. No
pre-functional testing sampling strategies shall be used. System pre-functional testing must be
successfully completed prior to formal respective equipment, subsystem or assembly functional
testing.
PFCs are primarily static inspections and procedures to identify installation requirements,
equipment, or system initial operation requirements (e.g., light levels OK, labels affixed, gages
in place, sensor Calibration, etc.). However, some pre-functional items entail simple testing of
component function, equipment, or a system piece (such as measuring voltages on a 5-step
constant current regulator). As the term implies, “pre-functional” testing refers to testing that
takes place prior to functional testing.
Contractors perform all pre-functional items recommended by CxAg as part of start-up. This
project requires written documentation of the installing contractor’s procedures. The CxAg
witnesses selected pre-functional testing and start-up procedures and some spot-checking
thereof.
The intent of these checklists is to verify the proper equipment was delivered prior to
acceptance. If problems are not identified at this stage, then schedules and budgets are often
compromised for both the owner and contractors.
There are system-based (ductbanks, cabling, etc.) and component-based (light fixtures, CCR’s,
etc.) installation checklists. System-based check lists are developed to be used regularly on the
systems for which work is on-going, and component-based checklists are separated based on
the task being completed (e.g. hanging the box, hooking ductwork up, etc.) and are to be
completed during a particular installation step.
Pre-functional checklists are provided in Appendix 2 at the end of this document.
5.8.1
Pre-functional Testing and Start-up Plan
The CxAg assists commissioning team members to develop detailed equipment pre-functional
testing and start-up plans. Responsible parties are identified in Form C-07, Commissioning
Progress Record / Equipment Summary, and in PFCs.
The following procedures shall be used:
1. The CxAg obtains manufacturer’s installation instructions, start-up instructions, and
checkout plans, along with field technician checkout sheets from CM. Contractors shall
provide supplemental detail and documentation to CxAg for systems with inadequate
manufacturer’s start-up and checkout procedures, particularly components integrated with
other equipment.
2. The CxAg develops a pre-functional checklist for each equipment piece from these
materials.
3. Pre-functional checklist, manufacturer’s installation instructions, start-up instructions, and
checkout plans along with field technician checkout sheets become the Start-up and
Checkout Plan.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
8
Commissioning Plan
Bid Phase
Issued July 29, 2014
4. The CxAg transmits the complete Start-up and Checkout Plan to the CM, who designates
which trade or contractor is responsible to fill out each line item as indicated in the “Contr”
column on the PFC form. The CM then transmits the full start-up plan to Subs for their
review and use. (This usually means PFCs, alone, goes to more than one Sub, while the
full plan goes to the primary installing contractor.)
5.8.2
Pre-functional Testing and Start-up Execution
Subs and vendors schedule pre-functional testing and start-up with PM, CM, and CxAg four
weeks prior to execution. Pre-functional testing and start-up are directed and executed by Subs
and/or vendors. The CxAg, assisted by selected Owner Staff and PM, if necessary, observes
selected pre-functional testing and start-up procedures.
To document pre-functional testing and start-up processes, site technicians performing line item
tasks initial and date each pre-functional checklist paragraph, start-up plan, and manufacturer’s
field checkout sheets. Only individuals having direct knowledge of a line item being completed
shall check and initial forms.
Subs and vendors execute and submit signed pre-functional checklist and start-up tests to CxAg
for approval/acceptance. The CxAg may review pre-functional testing in progress. Each
responsible trade shall fill out their portion of the pre-functional checklist form and provide them
to CxAg through CM. The CxAg and/or selected Owner’s Staff may conduct spot-checks of
completed forms.
5.8.3
Deficiencies and Non-Compliance
Subs must clearly identify incomplete start-up and pre-functional checklist items at bottom of
procedure form or attach sheets as required. The procedure form and deficiencies must be
provided to CxAg within 7 days of test completion. The CxAg works with Subs and vendors to
correct deficiencies or incomplete items and retest, involving CM and others as necessary.
Installing Subs or vendors correct deficient or incomplete areas according to checklists and
tests. The CxAg completes Form C-7, Commissioning Progress Record, to recommend system
start-up approval and forwards it to PM. The CxAg records all issues/deficiencies on Form C-01,
as well as tracking of the cost benefits of commissioning.
5.9
Functional Testing and Verification Development
The CxAg uses a formal acceptance phase for use in the commissioning process that helps to
facilitate the closeout of a project and helps minimize problems upon occupancy. The two items
that are critical to this phase is the completion of functional testing and the completion of
additional training.
5.9.1
Functional Testing Overview
Functional testing is equipment and system dynamic testing under all specified operation modes
in lieu of individual system components (e.g., associated airfield lighting fixture is tested
interactively with airfield lighting controls to verify consistent performance under various
conditions). Systems shall be tested under various modes in accordance with industry
established test procedures, such as low or high load, component failure, unoccupied mode,
varying outside air temperatures, fire alarm, power failure, etc. Equipment and system
responses to all specified operation sequences shall be verified. The CxAg develops functional
testing procedures in a sequential written format and coordinates, oversees, and documents
installing contractor and/or vendor performed testing.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
9
Commissioning Plan
Bid Phase
Issued July 29, 2014
5.9.2
Functional Testing Plan Overview and Status Record
The CxAg prepares the functional testing schedule and to integrate functional testing into the
construction schedule. The CxAg will identify testing prerequisites, required contractors, and
estimated time required for each test. The CxAg shall record results during functional testing.
5.9.3
Functional Testing Scope
The following equipment / systems shall be commissioned.
1.
2.
3
Ground Power Units
Pre-Conditioned Air Units
Condensate / Sump Pumps
Sample functional performance testing procedures are presented in Appendix 3 at the end of
this document.
Table 3. List of Systems and Equipment to be Commissioned by the General Contractor (GC).
GC to provide Qualified Personnel to commission equipment identified. Pre-functional Checklists and
Functional Tests shall be provided to the GC for review and completion prior to scheduling functional tests.
See items  below.
Reviews
Checklists
Cx’ed
System
Electrical
Equipment Included
Ground Power Units
-
HVAC
Pre- Conditioned Air Units
-
Mech
Condensate / Sump Pumps
-
* NC
Represents items not completed to date and “C” represents items completed
** FPT
Functional Performance Test
5.9.4
Design
Spec
Submtl
Sys
Equip
Field
Review
FPT
**
Development Process
Before writing testing procedures, the CxAg shall obtain all required documentation and change
orders affecting commissioned equipment and systems, including updated points list, control
sequences, and set points. The CxAg shall develop specific testing procedures to verify proper
operation of all equipment and systems listed in the Commissioning Plan and Specifications.
The CxAg shall obtain additional clarification from contractors and/or the Engineer regarding
operation sequences as required.
Prior to functional testing execution, the CxAg shall provide a copy of equipment, and systems
functional testing forms to the PM, who forwards them to installing Subs through the CM. The
subs review tests for feasibility, safety, warranty, and equipment protection. Blank test
procedure copies are included in O&M manuals for later use by facility operation staff.
Functional testing and verification may be performed manually in accordance with FAA, State
and Regulatory Guidelines or by manipulating equipment and observing performance. The
CxAg follows the specified test procedures when given and uses discretion when test
procedures are not given to determine which method is most appropriate. The CxAg reviews
Owner-contracted and factory required tests where applicable to determine if further testing is
required for specification compliance verification.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
10
Commissioning Plan
Bid Phase
Issued July 29, 2014
5.10
Functional Testing Execution
5.10.1 Functional Testing Procedure Overview and Process
The CxAg schedules functional testing through PM and CM. Prior to performing any equipment
or system functional testing, the CxAg obtains PFCs with signatures confirming systems are
ready for functional testing. The CxAg oversees, witnesses, and documents all equipment and
system functional testing according to Cx Specifications and Plan. The Subs execute tests,
unless otherwise specified. Testing proceeds from components, to subsystems, to systems,
and finally to system interlocks. Refer to Commissioning Plan, Section 5.9 for additional
functional testing scope details.
5.10.2 Deficiencies and Retesting
Minor deficiencies discovered during functional testing may be corrected during testing at the
CxAg’s discretion. The CxAg records test results on the functional testing procedure form.
Deficiencies and non-compliance issues are noted and reported to CM and PM on Form C-6,
Commissioning Corrective Action Report. Subs correct deficiencies, notify CxAg of correction,
and return Form C-6 certifying correction.
The CxAg schedules re-testing through the CM. Decisions regarding deficiencies and
corrections are made between CxAg or CM and Sub. Primary dispute resolution authority
resides with the Owner followed by the Engineer. The CxAg recommends test acceptance to
CM who gives final approval for each test using Form C-22, Pre-functional Checklist Review.
Form C-07, Commissioning Progress Record / Equipment Summary, is provided for progress
tracking and status.
5.10.3 Facility Staff Participation
DFW personnel may/shall assist the CxAg in facilitating and participating in the testing process,
e.g. Facility Maintenance may provide access to equipment rooms for testing. The CxAg shall
notify the PM, who shall then notify facility staff when commissioning events will occur.
5.10.4 Sampling
No sampling strategies will be used.
5.11
O&M Manuals, Warranties, and Commissioning Record Book
5.11.1 O&M Manual and Warranty Overview
The CxAg reviews commissioned systems O&M manuals, documentation, and as-built drawings
for specification compliance verification. The CxAg recommends O&M manual approval and
acceptance to CM. The CxAg also reviews equipment warranties for clear Owner requirement
descriptions to keep warranties in force.
5.11.2 Commissioning Record Book
The CxAg compiles, organizes, and indexes listed commissioning data by equipment into
labeled, indexed, and tabbed three-ring binders. Binders and O&M manuals shall be delivered
to the CM upon construction completion. Correspondence, meeting minutes, progress reports,
miscellaneous notes, etc. shall be kept in only the Construction Phase Commissioning Record
Book. The manual format shall be as follows:
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
11
Commissioning Plan
Bid Phase
Issued July 29, 2014
General
Tab – 1
Tab - 2
Tab - 3
Tab - 4
Tab - 5
Executive Summary
Commissioning Plan
Exhibit A:
Cost benefit Matrix
Appendix 1
Commissioning Applications Forms
Cx Request For information
Construction Issues Log (Form C-01)
Submittal reviews (Form C-17)
Equipment Specific
Tab - 6
Pre-functional Checklists
Pre-functional Checklist Ground Power Units (Form PFC-201)
Pre-functional Checklist Pre-Conditioned Air Units (Form PFC-202)
Pre-functional Checklist Condensate / Sump Pump (Form PFC-203)
Tab - 7
Functional Performance Testing Reports
Functional Performance Testing Ground Power Units (Form FPT-201)
Functional Performance Testing Pre Conditioned Air Units (Form FPT-202)
Functional Performance Testing Condensate/Sump Pumps (Form FPT-203)
5.12
Owner Personnel Training and Orientation
Refer to Bid Document Specifications.
5.13
Commissioning Cost Benefits Matrix
As commissioning is a highly variable process, it is important to develop a consistent and
sufficiently specific framework for describing the problems (deficiencies) discovered through the
commissioning process and the measures applied to address them. SEI has developed the
Commissioning Benefits Matrix,” shown in Exhibit A, which captures information on deficiencies
and characterizes a specific commissioning measure with a unique code. The table in Exhibit A
lists commissioned components and possible measures for increasing the cost benefits of
commissioning. This table will be updated throughout the project capturing all issues, how they
were resolved, and an estimate on the cost savings.
6.0
Summary Report
The CxAg shall provide PM with a summary report WITHIN 30 days of completion of functional
performance testing. The report shall include an executive summary, participant list, participant
roles, and brief building description, commissioning scope, testing scope, and testing method
description. For all commissioned equipment and systems, the report shall contain the CxAg’s
opinion regarding the commissioning team meeting contractual obligations for:
•
•
•
•
Equipment performing in accordance with design intent.
Correct equipment installation.
Functional performance and efficiency.
Operator training.
All outstanding non-compliant items shall be specifically listed. Recommendations for
equipment or operation improvement, future actions, commissioning process changes, etc. shall
also be included. Each non-compliance issue shall be referenced to specific functional test,
inspection, trend log, etc. where deficiency is documented. Equipment functional performance
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
12
Commissioning Plan
Bid Phase
Issued July 29, 2014
and efficiency shall include a brief verification method description (manual testing, building
control system trend log, data loggers, etc.) and include observations and conclusions.
Appendices shall contain control sequence documentation, logs, meeting minutes, progress
reports, deficiency lists, site visit reports, findings, unresolved issues, communications, etc.
Pre-functional checklists and functional tests (along with blanks for operators), and monitoring
data and analysis shall be provided in a separate labeled binder.
The commissioning plan, pre-functional checklists, functional tests, and monitoring reports shall
be included in the Commissioning Record.
7.0
Schedule
7.1
General Issues
The following sequential priorities shall be followed:
1. Equipment shall not be used until pre-start checklist items and all manufacturers’ pre-start
procedures have been completed.
Moisture, dust, and other environmental and building integrity issues must also have been
addressed.
2. System functional testing shall begin only after pre-functional testing, and start-up work has
been completed. This requirement is not intended to preclude phased functional testing.
3. Functional testing of control system and its controlled equipment shall begin only after all
points have been calibrated and pre-functional testing has been completed.
7.2
Project Schedule
Refer to master project schedule.
Table 7.0 - Commissioning Process Schedule Summary
Tasks / Activity
Estimated Start Date
Estimated End Date
Design Phase
Project Intent
N/A
-
Initial basis of Design
N/A
-
Commissioning Plan (draft)
7/29/14
-
Develop Cx Specifications
7/29/14
-
65% Design Review
N/A
-
100 % Design Review
N/A
-
IFB Design Reviews
N/A
-
Final Basis of Design
N/A
-
Construction documents review
N/A
-
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
13
Commissioning Plan
Bid Phase
Issued July 29, 2014
Tasks / Activity
Estimated Start Date
Estimated End Date
General Tasks / Activities
CxAg to prepare Pre-Scoping Meeting
Preliminary Construction Phase
Commissioning Plan. (Cx Plan, Section
5.2)
-
-
CxAg to conduct scoping meeting. (Cx
Plan, Section 5.1)
-
-
CxAg to provide commissioned
equipment and system documentation
requirements to CM. (Cx Plan, Section
5.7.1)
-
-
Begin construction site visits and
inspections. (Cx Plan, Section 5.3)
-
-
Start-up and Checkout Tasks / Activities
CM to compile manufacturer’s installation
instructions, start-up instructions, and
checkout plans and deliver to CxAg. (Cx
Plan, Section 5.8.1)
-
-
CxAg to prepare start-up and checkout
plans and deliver to CM. (Cx Plan,
Section 5.8.1)
-
-
CM to deliver notification of pre-functional
testing and start-up execution to CxAg.
(Cx Plan, Section 5.8.2)
4 weeks prior to
scheduled pre-functional
testing and start-up
-
Execute pre-functional testing and startup. (Cx Plan, Section 5.8.2)
Upon completion of each
Equipment / System
installation
-
CM to forward completed pre-functional
checklists to CxAg. (Cx Plan, Section
5.8.2)
Upon completion of
checklist; but at least 72
hrs prior to scheduled
FPT
-
Functional testing Tasks / Activities
CM to forward all documentation and
change orders affecting commissioned
equipment and systems to CxAg. (Cx
Plan, Section 5.7.2)
-
-
CM to prepare control sequences and
deliver to CxAg.
N/A
-
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
14
Commissioning Plan
Bid Phase
Issued July 29, 2014
Tasks / Activity
Estimated Start Date
Estimated End Date
CxAg to prepare functional testing forms
and deliver to CM. (Cx Plan, Section
5.9.4)
-
-
CxAg to prepare functional testing
schedule to CM. (Cx Plan, Section
5.10.1)
-
-
Execute functional performance tests.
(Cx Plan, Section 5.10.1)
-
-
O&M Manuals and Training Tasks / Activities
CxAg to review O&M manuals and
provide approval recommendation to CM.
(Cx Plan, Section 5.11.1)
-
-
CxAg to prepare training and orientation
agenda and forward to CM. (Cx Plan,
Section 5.12)
-
-
Prepare training and orientation materials
and forward to CxAg for review. (Cx Plan,
Section 5.12)
-
-
Execute training and orientation. (Cx
Plan, Section 5.12)
-
-
CxAg to prepare final commissioning
summary Report and forward to PM. (Cx
Plan, Section 6.0)
-
-
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
15
Commissioning Plan
Bid Phase
Issued July 29, 2014
Exhibit A
Cost Benefits Matrix
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
16
Commissioning Plan
Bid Phase
Issued July 29, 2014
DFW Commissioning Benefits Matrix
PROJECT : Terminal B High Gates Electrification
PROJECT No. 9500540
Ref
Date
Issue Log Ref Description of Issue
Date Updated: 8/8/14
LEGEND
I
D
E
A/T
System
Issue Type
Installation
Design
Existing Condition
Acceptance / Testing
Issue Type
Closure Status/ Remarks
Resolution
Date
$ Estimated Cost Benefit
Avoidance
Totals
Operational
$0.00
Notes: This form is to be utilized by the CxAg is exact format provided
Ensure that as may issues as possible are allocated ESTIMATED costs
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
17
Commissioning Plan
Bid Phase
Issued July 29, 2014
Exhibit B
Commissioning Report Status and
Equipment Summary
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
18
Commissioning Plan
Bid Phase
Issued July 29, 2014
Commissioning Report Status
Date Updated: 8/8/14
PROJECT : Terminal B High Gates Electrification
PROJECT No. 9500540
Date
I/D
N/A
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
Commissioning Process
Project Intent
Basis of Design
Commissioning Specifications / Cx Plan
Design Review 65%
Design Review 95%
IFB Design Review
Scoping Cx Meetings
Submittal Reviews
Commissioning Process Issues / Issues Log
Pre Functional Checklists
Factory Tests and Start Up Reports
Site Visits / Cx Meeting Reports
O&M Manual Reviews
Test & Balance Reports (TAB)
Systems Manual
Training Documentation
Functional Performance Testing
Transition Meetings
Warranty Review
Draft Cx Report
Cx Report Addendum
Lessons Learned Workshop
Complete
Issues or deficiencies
Not applicable
Started
Completed
N/C
N/S
Status
Not complete
Not started
Comments
Notes: This form is to be utilized by the CxAg is exact format provided
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
19
Commissioning Plan
Bid Phase
Issued July 29, 2014
Appendix 1
Sample Commissioning Application Forms
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
20
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-01 Construction Issues Log
Date Updated: 8/8/14
PROJECT : Terminal B High Gates Electrification
PROJECT No. 9500540
Issue Ref
Date
System
Description of Issue
LEGEND
Issue Type
I
D
E
O
Photo Ref
Installation
Design
Existing Condition
Other
Issue Type
OPEN ITEMS
Closed
Open
Status Open /
Closed
Response
Closed Items
Open Items
Closed items to be greyed out and struckout
Open Items
Resolution
Verified Closure
Date
Remarks / Notes
0
0
Notes: This form is to be utilized by the CxAg is exact format provided.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
21
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-01 Construction Issues Log Photos
Date Updated: 8/8/14
PROJECT : Terminal B High Gates Electrification
PROJECT No. 9500540
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
22
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-02 DOCUMENTATION TRACKING & CONTROL LOG
Legend:
D= Design Team
C= Contractor
CxAg= Commissioning Agent
Discipline
Required
By
Plans and Specs
Current Addendums
ALL
ALL
D
D
For Commissioning Use
For Commissioning Use
Schedules Showing
Commissioning Activities
ALL
C
For Review and Comments
D-ALL
D
D
For Review and Comments
For Review and Comments
ALL
C
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
C,D
C,D
D,O
Required Document
Date Received
By CxAg
O=Owner
Date Required
Comments
Notes
Design and Construction Documents
Design Intent Document
Design Criteria
Equipment submittal
Schedule
Product Submittals
Shop Drawings
Coordination Drawings
Submittal Log or Registry
RFI's
RFI's with responds
RFI Log
ASI's, SIs, Bulletins,
PCOs
CCDs
Change Orders
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
4 weeks prior to contract
award
For Review and Comments
Approved with Comments
Information Only
Information Only
Information Only
Information Only
Information Only
Information Only
Information Only
Information Only
Information Only
Information Only
O
D,O
C,D
D,O
O
O
O
23
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-02 DOCUMENTATION TRACKING & CONTROL LOG
Legend:
Required Document
D= Design Team
Discipline
Required
By
C= Contractor
CxAg= Commissioning Agent
Date Received
By CxAg
Date Required
O=Owner
Comments
Notes
Design and Construction Documents
Equipment Documents for Verification Testing procedures (VTPs)
400Hz/28V DC Units
Electric
C
At 50% construction
schedule
Pre Cooled Air Units
(PCA)
Mechanical
C
At 50% construction
schedule
Condensate Sump Pumps Mechanical
C
At 50% construction
schedule
Manufacturer Start up and
recommendations. O&M
Material
Manufacturer Start up and
recommendations. O&M
Material
Manufacturer Start up and
recommendations. O&M
Material
Contractor Required Tests and Documentation
NPD incorporated in VTP
form
Inclusive of OAC and
Progress meetings
Name Plate Data
All
C
Prior to FPT
Construction Meeting
Minutes
All
C
Weekly
Contractor Required
Testing Reports
All
C
Within 1 week of
succesful completion of
each test
Required by Specifications
Verification Testing
Schedule
All
Disciplines
involved in
FPT
C
Four (4) weeks prior to
testing
For Review and Approval
All systems
requiring
training per
specifications
C
Attach to O&M Materials
at 50% construction
schedule
For Review and Approval
Mech
C
All
C
O&M Training Schedule
and plans
Test Adjust and Balance
Report
System readiness
checklist
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
2 weeks prior to start of
system FPTs
10 days prior to
commencement of FPTs
24
For Review and Approval
For Review and Approval
Commissioning Plan
Bid Phase
Issued July 29, 2014
FORM C-03D COMMISSIONING REQUEST FOR INFORMATION
A. Request for Information (RFI) Identification:
RFI ID:
RFI Date:
General Description
Equipment Identification
(ID Number / Tag)
(Equipment Description)
Equipment Location
RFI Initiated From:
Attachments Included
Equipment/System Test
Observation
No
Yes
Description:
Document Review
Discussion
B. Information Sought For:
Developing construction checklist
Maintaining functional performance testing schedule
Resolving other issue
Developing functional performance testing
Resolving functional performance testing issue
C. RFI Authored By:
(Requestor’s Name)
(Company)
D. RFI Addressed To:
Architect
Electrical Engineer
Owner
Mechanical Engineer
Construction Manager/General Contractor
Other:
E. Copied To:
(Name)
F.
(Company)
Requested Information:
G. Addressee’s Response:
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
25
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-03E RFI Log
Date Updated: 8/8/14
PROJECT : Terminal B High Gates Electrification
PROJECT No. 9500540
Review Document :
RFI
Number
RFI Responses
Date
Reference
Document
RFI Request
RFI Response
Status
Open/Closed
Open
Remarks / Notes
Notes: This form is to be utilized by the Cx Agent is exact format provided.
Different Documents Reviewed may require different logs, i.e. O&Ms one log, training videos another.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
26
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-05C Staff Training and Orientation Log
Date Updated: 8/8/14
LEGEND
PROJECT : Terminal B High Gates Electrification
PROJECT No. 9500540
Date
I/D
N/A
Specification Requirements
#
System or Equipment Involved
Maintained
Spec Section
By
Hours of
Training
Specified
Complete
Issues or deficiencies
Training not required
N/C
Not complete
N/S
T/C
Not started
Training completed; required notifications or documents not provided
Prior to Training
Notification
20 Days Prior
to Training
Agenda
provided
Syllabus/
Training
Manuals
Training Information and Closeout
Trainer Name
Proposed
and Contact
Training Date
Info
Date Of
Training
Hours of
Training
Provided
List of attendees
Electronic
Copies of all
handouts
Video
recording
DVD in MP4
format
Comments
Notes: This form is to be utilized by the CxAg is exact format provided
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
27
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-06 CORRECTIVE ACTION REPORT
A. Report Identification:
Correction Action ID:
Report Date:
Equipment Identification:
Issue Date:
(ID Number / Tag)
Equipment Location:
Information Source:
Attachments Included:
(Equipment Description)
Equipment/System Test
No
Yes
Observation
Document Review
Discussion
Description _______________________________________
B. Deficiency and/or Issue and Resulting Effects (To Be Completed By Commissioning Agent):
The above equipment has been tested, observed, reviewed, or was discussed and was found to not comply with
the contract document.
1. Deficiencies or Issues:
2. Resulting Effects:
C. Corrective Actions and Dates (To Be Completed By Commissioning Agent):
The below listed corrective actions are:
Required
Recommended
For testing to proceed in a timely manner, it is imperative that the required corrective action be completed by
(Date or Event)
D. Design Team Action (To Be Completed By Design Team If Indicated):
No Design Team action required, information provided for record purposes only.
Design Team Corrective action plan required.
Design Team Concurrence requested but not required for corrective action execution
Design Team Concurrence required prior to corrective action execution
(Design Team
Concurrence)
E. Contacts Relevant to Corrective Actions:
Address To:
Cx Agent:
Owner’s Rep:
Report Copied To:
(Name)
F.
(Company)
Contractor’s Statement of Correction (To Be Completed By Contractor):
Deficiencies identified above have been correct with the following actions:
(Signature
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
(Company)
28
(Date)
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-07 Commissioning Progress Record / Equipment Summary
Date Updated: 8/8/14
PROJECT : Terminal B High Gates Electrification
PROJECT No. 9500540
Equipment
Item
#
Equipment
ID
Type
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
Manufacturer Model No. Factory Test
LEGEND
Complete
N/C
Not complete
I/D
Issues / Deficiencies
N/S
Not started
N/A
Not applicable
I/R
In Review
Date
Start-Up
Start Up
Closeout
PFCs
29
FPTs
O&M
Warranty
Spare Parts
Comments
Commissioning Plan
Bid Phase
Issued July 29, 2014
FORM C-17 SUBMITTAL REVIEW
A. Submittal Review Identification:
Submittal Date:
Review Date:
Received Date:
Submittal Review Index:
Specification Number:
Submittal Number:
Specification Name:
B. Submittal Review Disposition:
Approval recommended
Approval recommended with comments herein
Additional information requested
Reviewed for Commissioning Consideration
Not reviewed
Disapproval and entire resubmittal recommended
Disapproval and partial resubmittal recommended
Other: _______________________________________
C. Submittal Review Executed By:
(Name)
(Discipline)
D. Submittal Review Disposition Forwarded To:
Architect
Electrical Engineer
Owner
Project Manager
Mechanical Engineer
Construction Manager/General Contractor
Other:_______________________________________
E. Submittal Review Disposition Copied To:
(Name)
F.
(Discipline)
Submittal Review Comments:
COMMENT
NUMBER
RELEVANT
SPECIFICATION/
DRAWING
A/E
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
COMMENT
SUBMITTAL
30
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-17 Submittal Review Log
Date Updated: 8/8/14
PROJECT : Terminal B High Gates Electrification
PROJECT No. 9500540
Review Document :
Ref
Date
Approved Submittals
Reference Document Review Comment
Response
Status Open/ Remarks / Notes
Closed
Notes: This form is to be utilized by the CxAg is exact format provided
Different Documents Reviewed may require different logs, i.e. O&Ms one log, training videos another.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
31
Commissioning Plan
Bid Phase
Issued July 29, 2014
FORM C-18
FIELD OBSERVATIONS AND TESTS
A. Field Observations and Tests Identification:
Report Number:
Observation Date:
Issue Date:
Observation Description:
Attachments Included:
No
Yes
Number(s):
Description:
B. Field Observations and Tests Executed By:
(Name)
(Discipline)
C. Field Observations And Tests Disposition Forwarded To:
Architect
Electrical Engineer
Owner
Mechanical Engineer
Construction Manager/General Contractor
Other:
Project Manager
D. Field Observations And Tests Copies To:
(Name)
(Discipline)
E. Field Observations And Tests Comments:
Classification
The purpose of this observation/test report is to document site observation, start-up results, and/or to summarize
system Functional Performance Testing (FPT). Information is classified as follows:
F.
•
Back-check
System refinement resulting from testing or site observation requiring future backchecking
•
Correction
Clarification of previously issued report.
•
Corrective Action
System deficiency found during site observation or system FPT requiring corrective
action prior to system initial FPT execution or FPT re-execution.
•
Designer Input
Designer input requested.
•
Req Information
Requested information.
•
Terminal
Previously identified issue planned to be pursued no further.
•
Information
For informational purposed only.
•
Start-up
Equipment Start-up Observation
•
Summary
Test Results Summary
Field Observations And Tests Areas of Concern:
Areas of Concern
Cited observations are classified according as follows:
•
GEN
General Comment
•
IEQ
Indoor Environmental Quality Issue
•
COD
Code Issue
•
QC
Quality Control Issue
•
CON
Contract Requirement Issue
•
INST
Installation Issue
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
32
Commissioning Plan
Bid Phase
Issued July 29, 2014
FORM C-18
OBSERV
ATION /
TEST
NO.
CLASSIFICATION
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
FIELD OBSERVATIONS AND TESTS
AREA OF
CONCERN
OBSERVATION/TEST
33
Commissioning Plan
Bid Phase
Issued July 29, 2014
C-21 OMM & WARRANTY LOG
Date Updated: 8/8/14
PROJECT : Terminal B High Gates Electrification
PROJECT No. 9500540
LEGEND
Date
I/D
N/A
Specification Requirements
#
System or Equipment Involved
O&M Ref
Warranty Ref
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
Complete
Issues or Deficiencies
Not Applicable
N/S
L
R
Not Started
Late
Required
OMM Submission
O&M
Required
OMM BP Ref Submitted
Under
Review
Due Date 90 Days Prior to TOC Unless Specified Otherwise
Warranty Information
Returned to
CMAR
Complete
34
Warranty
Required
Special
Warranty
required
OMM BP Ref
Under
Review
Returned to
CMAR
Complete
Comments
Commissioning Plan
Bid Phase
Issued July 29, 2014
FORM C-22 PRE-FUNCTIONAL CHECKLIST REVIEW
A. Pre-functional Checklist Review Identification:
Received Date:
Review Date:
Submittal Date:
Submittal No:
B. Pre-functional Checklist Review Disposition:
Approval recommended
Approval recommended with comments herein
Additional information requested
Reviewed for Commissioning Consideration
Not reviewed
Disapproval and entire resubmittal recommended
Disapproval and partial resubmittal recommended
Other: _______________________________________
C. Pre-functional Checklist Review Executed By:
(Name)
(Discipline)
D. Pre-functional Checklist Review Disposition Forwarded To:
Architect
Electrical Engineer
Owner
Project Manager
Mechanical Engineer
Construction Manager/General Contractor
Other:_______________________________________
E. Pre-functional Checklist Review Disposition Copied To:
(Name)
F.
(Discipline)
Construction Checklist Review Comments:
COMMENT
NUMBER
PRE-FUNCTIONAL
CHECKLIST IDENTIFICATION
NUMBER
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
COMMENT
DESCRIPTION
35
Commissioning Plan
Bid Phase
Issued July 29, 2014
Appendix 2
Sample Pre-functional Checklist Forms
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
36
Commissioning Plan
Bid Phase
Issued July 29, 2014
PFC-201 PRE-FUNCTIONAL CHECKLIST - GROUND POWER UNIT
Project Information
PROJECT:
Terminal B High Gates Electrification
PROJECT NUMBER: 9500540
UNIT DESIGNATION:
The above equipment and systems integral to them are complete and ready for functional testing. The checklist items
are complete and have been checked off only by parties having direct knowledge of the event, as marked below,
respective to each responsible contractor. This pre-functional checklist is submitted for approval and is subject to an
attached list of outstanding items yet to be completed. A Statement of Corrections (SOC) will be submitted for any
outstanding items to be completed prior to functional testing. None of the outstanding items preclude safe and reliable
operation of the unit(s) being tested. _____ SOC list attached.
Sign-off
TEST DATE:
COMPANY
START TIME:
NAME
CONTACT INFORMATION
Mechanical Contractor
Electrical Contractor
TAB Contractor
Controls Contractor
Certified Start-up Technician
CMAR
• Pre-functional checklist is to be completed as part of startup & initial checkout, preparatory to functional
testing.
• Checklist does not take the place of the Manufacturer's recommended checkout and startup procedures or
report.
•
Items that do not apply shall be noted with the reasons on this form (N/A - not applicable, BO - by others).
• Contractor shall be responsible to see that checklist items by their subcontractors are completed and checked
off.
Approvals
CX APPROVAL DATE:
COMPANY
OAR APPROVAL DATE:
NAME
CONTACT INFORMATION
Commissioning Agent
Owner's Authorized Representative
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
37
Commissioning Plan
Bid Phase
Issued July 29, 2014
PFC-201 PRE-FUNCTIONAL CHECKLIST - GROUND POWER UNIT
Project Data
Project: Terminal B High Gates Electrification
Name:
System:
Date:
Building Equipment Identification
Type:
Identification:
Manufacturer:
400 Hertz and 28 Volt Ground Power Unit
Unit Data
Model No:
Input Voltage:
Output Voltage:
Phase:
Input Frequency:
Output Frequency:
ITEM
Observations
YES
NO
COMMENTS
General
1
Cabinet and components mounted in weather-proof
enclosure
2
Unit housing and components undamaged
3
Mounting provided on underside of PBB
4
400 Hz Frequency converter installed
5
Unit wired for power
6
Working bundles in control cabinet installed in
workmanlike manner
7
Line drop compensator installed
8
Cable installed with molded head
9
Fault isolation features installed
10
Phase models cooled by a sealed fan
11
LCD Display with contrast adjustment
12
Single grounding installed for AC source/output
power
13
Cable of sufficient length to reach aircraft connection
Memory Storage
14
RS-232 connection installed for memory record
downloads
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
38
Commissioning Plan
Bid Phase
Issued July 29, 2014
ITEM
Observations
YES
NO
COMMENTS
Controls & Special Features
15
Major components & subassemblies shall be visibly
marked/labeled with ID/codes
16
Alarms and indicator lights installed and visible
17
Active operation warning light installed and visible
18
Voltage Adjustment
Diagnostics
Unit contains diagnostic test system with associated
output display
19
Controls
20
600 V, 3-pole 10-amp manually operated disconnect
isolation switch provided
21
Step down transformer provided to the low voltage
circuits
22
Remote push button station mounted on the outside
of the PBB lift column
23
Cable hoist counter disconnects power from the
motor when the "raise" and "lower" travel limits have
been reached
Unit to include On/Off/Up/Down
controls
Hoist Components
24
Input power cable installed
25
Tunnel mounted cable hoists installed with brackets
26
Remote push button installed for operator controls
27
Hoist is constructed with removable or hinged cover
28
Hoist contains an electric open drip proof gear-motor
installed and operational
29
Hoist disc brake installed and operational
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
Allow raising and lowering the cable
to power aircraft
39
Commissioning Plan
Bid Phase
Issued July 29, 2014
ITEM
Observations
YES
NO
COMMENTS
System Monitoring/ Built-in Test Equipment
Panel display contains the following parameters:
a. Input Voltage (A-Bm B-C, C-A, 3 phase)
b. DC Bus Voltage
Adjustable
c. Output Power
30
d. Power Factor
e. Output Factor
f. Run Time
g. GPU Settings
h. GPU Memory Data
i. Setup Values
j. Phase "A" Output Voltage
k. Phase "B" Output Voltage
l. Phase "C" Output Voltage
m. Average Output Current
30
n. Phase "A" Output Current
o. Phase "B" Output Current
p. Phase "C" Output Current
q. Average Output Current
Overloads and System Protection
Minimum of 3 lights mounted on the front of the unit:
a. Red Light: Presence of fault
31
b. Green Light: Unit working/ power on
c. Amber Light: Output contactor on
32
Input & Output Over and Under voltage
33
Output overload
34
Loss of E/F
35
E/F Over voltage
36
Bus discharge fault
37
Heat sink over temperature
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
40
Commissioning Plan
Bid Phase
Issued July 29, 2014
ITEM
38
Output frequency fault
39
IGBT fault
40
DC link capacitor fault
Observations
YES
NO
COMMENTS
Notes
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
41
Commissioning Plan
Bid Phase
Issued July 29, 2014
PFC-202 PRE-FUNCTIONAL CHECKLIST - PRE-CONDITIONED AIR UNIT
Project Information
Terminal B High Gates Electrification
PROJECT:
PROJECT NUMBER: 9500540
UNIT DESIGNATION:
The above equipment and systems integral to them are complete and ready for functional testing. The checklist items
are complete and have been checked off only by parties having direct knowledge of the event, as marked below,
respective to each responsible contractor. This pre-functional checklist is submitted for approval and is subject to an
attached list of outstanding items yet to be completed. A Statement of Corrections (SOC) will be submitted for any
outstanding items to be completed prior to functional testing. None of the outstanding items preclude safe and reliable
operation of the unit(s) being tested. _____ SOC list attached.
Sign-off
TEST DATE:
COMPANY
START TIME:
NAME
CONTACT INFORMATION
Mechanical Contractor
Electrical Contractor
TAB Contractor
Controls Contractor
Certified Start-up Technician
CMAR
• Pre-functional checklist is to be completed as part of startup & initial checkout, preparatory to functional
testing.
• Checklist does not take the place of the Manufacturer's recommended checkout and startup procedures or
report.
•
Items that do not apply shall be noted with the reasons on this form (N/A - not applicable, BO - by others).
• Contractor shall be responsible to see that checklist items by their subcontractors are completed and checked
off.
Approvals
CX APPROVAL DATE:
COMPANY
OAR APPROVAL DATE:
NAME
CONTACT INFORMATION
Commissioning Agent
Owner's Authorized Representative
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
42
Commissioning Plan
Bid Phase
Issued July 29, 2014
PFC-202 PRE-FUNCTIONAL CHECKLIST - PRE-CONDITIONED AIR UNIT
Project Data
Project:
Name:
System:
Date:
Terminal B High Gates Electrification
Building Equipment Identification
Type:
Identification:
Manufacturer:
Pre-Conditioned Air Unit
Unit Data
Motor Nameplate Data
Filter Data
Model No:
Blower Type:
Input Power:
Manufacturer:
Model No:
Motor HP:
Quantity:
Type:
Size:
Blower RPM:
Design Airflow:
Operating Static Pressure:
Motor RPM:
Voltage:
Amperage:
Hydronic Coil Data
Coil Fluid:
Coil Flow:
Air Temp (◦F):
Condensate Pump Data
VFD Data
Manufacturer:
Model No:
EAT/LAT:
Manufacturer:
Cooling Capacity:
Fluid Flow:
Motor HP:
Heating Data
Heat Capacity:
ITEM
Observations
YES
NO
COMMENTS
General
1
Unit housing undamaged
2
Permanent labels affixed
3
Flexible duct intact
4
Hydronic hose insulated & sufficient length
5
Fixed walkway vent connections
6
Supply hose adequately supported
7
Power circuit installed
8
PCA rail mounting hung from under bridge
9
Smoke detectors installed and wired
10
Automated dampers installed and open
11
Latches installed and secured
12
NTP plugs provided on discharge nozzle
13
Filters installed & clean
14
Auto-defrost installed on coils
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
43
Commissioning Plan
Bid Phase
Issued July 29, 2014
ITEM
Observations
YES
15
Bridge connection installed
16
Unit startup performed
17
Motor vibration isolator installed
18
Motor and blower removable from PCA housing
19
Blower installed: permanently lubricated motor
bearings where bearings are not accessible
20
Hydronic coil installed and undamaged
21
Sliding tube assembly: Outer duct section,
middle section, inner section of decreasing
diameters
22
Rotunda/ C-Tunnel mounted units: devices
installed to transport the glycol supply/return
lines, PCA electrical supply and condensate
return across the bridge
23
Coils mounted on coil casing with the same end
connections accessible for service
24
Plenum is insulated
25
Hydronic coil hose connections complete
NO
COMMENTS
Sliding tube insulated throughout
the entire length
Telescoping
26
Laminate segments with wiper seals
27
Exterior paint finish clean and undamaged
28
Tube insulation installed and undamaged
Condensate System (if applicable)
29
Condensate pump installed & operational
30
Internal float switch installed
31
Drain pan installed under cooling coil section
and properly sloped
32
Insulated condensate hose installed
Controls
33
Controls complete
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
44
Commissioning Plan
Bid Phase
Issued July 29, 2014
ITEM
Observations
YES
34
Fan control sequence identified
35
PCA operation warning light installed in bridge
panel
36
Hydronic coil control valve installed
37
Smoke detector circuit operational
38
Heating control sequence verified
39
Temperature sensors calibrated
NO
COMMENTS
Heating Components
40
Electric heat wired and operational
41
Heater performance (kW) identified
Cooling Coil
42
Entering and leaving gauge ports
43
Balancing devices installed and set
44
Isolation valves installed
45
2 way/ 3 way valve installed
46
Pipe insulation undamaged
47
Fin and tubes intact
Notes
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
45
Commissioning Plan
Bid Phase
Issued July 29, 2014
PFC-203 PRE-FUNCTIONAL CHECKLIST - CONDENSATE / SUMP PUMP
Project Information
Terminal B High Gates Electrification
PROJECT:
PROJECT NUMBER: 9500540
UNIT DESIGNATION:
The above equipment and systems integral to them are complete and ready for functional testing. The checklist items
are complete and have been checked off only by parties having direct knowledge of the event, as marked below,
respective to each responsible contractor. This pre-functional checklist is submitted for approval and is subject to an
attached list of outstanding items yet to be completed. A Statement of Corrections (SOC) will be submitted for any
outstanding items to be completed prior to functional testing. None of the outstanding items preclude safe and reliable
operation of the unit(s) being tested. _____ SOC list attached.
Sign-off
TEST DATE:
COMPANY
START TIME:
NAME
CONTACT INFORMATION
Mechanical Contractor
Electrical Contractor
Controls Contractor
Certified Start-up Technician
Other
CMAR
• Pre-functional checklist is to be completed as part of startup & initial checkout, preparatory to functional
testing.
• Checklist does not take the place of the Manufacturer's recommended checkout and startup procedures or
report.
•
Items that do not apply shall be noted with the reasons on this form (N/A - not applicable, BO - by others).
• Contractor shall be responsible to see that checklist items by their subcontractors are completed and checked
off.
Approvals
CX APPROVAL DATE:
COMPANY
OAR APPROVAL DATE:
NAME
CONTACT INFORMATION
Commissioning Agent
Owner's Authorized Representative
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
46
Commissioning Plan
Bid Phase
Issued July 29, 2014
PFC-203 PRE-FUNCTIONAL CHECKLIST - CONDENSATE / SUMP PUMP
Project Data
Project:
Name:
System:
Date:
Terminal B High Gates Electrification
9500540
Building Equipment Identification
Type:
Identification:
Manufacturer:
Condensate / Sump Pump
Unit Data
Model No:
Serial No:
Input Power:
Voltage/Phase:
RLA:
FLA:
Motor HP:
Motor Eff.:
Motor RPM:
GPM:
ITEM
Observations
YES
NO
COMMENTS
General
1
Contract required identification complete
2
Vibration isolation devices installed and functional
3
Pipe fittings complete and pipes properly supported
4
Check valve installed in discharge piping
5
6
Operating and alarm floats installed and adjusted
based on contract requirements.
Sump pit is cleaned of any debris before pump is
installed in sump pit
7
Factory sump pump inlet strainer in place and clean
8
Factory supplied or contract required pump removal
device installed
Electrical and Controls
9
All electric connections verified tight
10
Proper grounding installed
11
Power wiring tested based on contract requirements
(Report Attached)
12
Motor safeties in place and operable
13
Local control panel to operating and alarm float wiring
complete
14
Local control panel to operating and alarm float wiring
point to point verification complete. (Point to point
report attached)
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
47
Commissioning Plan
Bid Phase
Issued July 29, 2014
ITEM
Observations
YES
NO
COMMENTS
Operational Checks (This is not the functional performance test)
15
Sump pit was cleaned of any debris before pump was
started
16
Pump rotation verified correct
17
During pump operation no unusual noise or vibration
was seen
18
No leaking apparent in piping and around fittings
19
Record full load running amps for each pump
_______ rated FL amps x _______ service factor =
_______ Max Amps
Running less than Max?
20
Specified sequences of operation and operating
schedules have been implemented with all variations
documented
21
Specified point-to-point checks have been completed
and documentation record submitted for this system
22
All recommended factory start-up procedures were
followed during start-up (Start-up report is attached
Notes
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
48
Commissioning Plan
Bid Phase
Issued July 29, 2014
Appendix 3
Sample Functional Performance Testing
Forms
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
49
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-201 FUNCTIONAL PERFORMANCE TEST- GROUND POWER UNIT
Project Information
PROJECT:
Terminal B High Gates Electrification
PROJECT NUMBER: 9500540
UNIT DESIGNATION:
TEST INFORMATION
TEST DATE:
COMPANY
START TIME:
PARTICIPANTS:
NAME
CONTACT INFORMATION
Directions:
The following pages are to be filled out by a representative of the commissioning firm who will observe the testing
described herein.
Remarks:
Existing movement capabilities shall be recorded and verified to be in acceptance with DFW Airport passenger
boarding bridge movement requirements.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
50
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-201 FUNCTIONAL PERFORMANCE TEST- GROUND POWER UNITS
Observations
REQUIRED ACTION
ACTION
1. Operate the hoist selector switch
1. The reel assembly travels in both
located at the PBB wheel bogie in the directions and automatically stops in
up and down position.
either direction when at their travel
limits.
Y
N
REMARKS
2. Rotate the hoist switch clockwise to 1. The hoist cable lowers the 400 Hz
the "Lower" position.
cable in a smooth controlled manner
to a ground handling position.
2. The cable hoist limit switch
interrupts the control power to the
motor contactor when the travel limit
"lower" has been reached.
3. Unhook nylon strap connected to
hoist cable mounting frame.
1. Cable is released and has sufficient
length to reach aircraft connection
point.
4. Go to the gate being tested and turn 1. The gate box will be energized.
the main power disconnect lever to the
"ON" or "UP" position. The main
power disconnect is located on the
PBB rotunda column next to the PCM.
Go to gate box to be tested and turn
the gate box disconnects lever or
switch to the "ON" or "UP" position.
5. If there is a RED fault light, press
the "RESET" or "OFF" pushbutton.
1. After RESET the four red fault lights
will come on in sequence, and then
turn off.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
51
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-201 FUNCTIONAL PERFORMANCE TEST- GROUND POWER UNITS
Observations
REQUIRED ACTION
ACTION
1.
Operate
the
hoistcable
selector
switch
1. The reel
assembly
travels
in both
6. Insert an aircraft
power
remote
mounted
on 400
Hz
source analyzer into the end of the
Control station turns on.
aircraft cable assembly. Press the ON
pushbutton on the remote mounted
400 Hz control station.
7. Check the phase rotation indicator
on the phase checker.
Y
N
REMARKS
1. It should be "A", "B", "C"
2. If the phase rotation is in the wrong
direction change any two (2) phase
leads on the service side of the 575V
disconnect switch at the gate box or at
the load side of the new 200 amp
circuit breaker located at the base of
the PBB rotunda.
8. Operate ON/OFF switches at the
400 Hz control station, located on the
PBB bogie wheel.
1. This can be determined as the
lights for all three phases on the
phase checker will be illuminated
when the gate box contractor is
closed.
9. Operate the ON pushbutton closing 1. The contactor should close.
the gate box contactor.
10. Toggle the E&F switch to the
NEUTRAL position.
1. The contactor should open.
11. Toggle the E&F switch in the
phase checker to the F position and
press the ON pushbutton.
1. The contactor should close.
12. Toggle the E&F switch to the OFF 1. The contactor should open.
position, or Neutral position.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
52
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-201 FUNCTIONAL PERFORMANCE TEST- GROUND POWER UNITS
ACTION
1.
Operate
the
hoist selector
switch
13. Close the contactor
with the
E&F
switch in either the E or F position.
Then, pull the phase checker out of
the end of the cable.
Observations
REQUIRED ACTION
Y
N
REMARKS
1. The reel
assembly
travels
contactor
should
open.in both
14. Press the "Reset" button on the
gate box.
Simulate an overload scenarion on the
gate box.
1. The lights on the panel should
reset.
2. The overload light on the exterior of
the gate box cabinet should illuminate.
15. Press the "Reset" button on the
gate box.
Simulate an under voltage scenarion
on the gate box.
1. The lights on the panel should
reset.
2. The under voltage light on the
exterior of the gate box cabinet should
illuminate.
16. Press the "Reset" button on the
gate box.
Simulate an over voltage scenario on
the gate box.
1. The lights on the panel should
reset.
2. The over voltage light on the
exterior of the gate box cabinet should
illuminate.
17. The manufacturer/seller shall now conduct load bank test as follows:
18. Connect the gate box aircraft
output cables to each of the 60KVA
load banks.
1. At each of the two (2) output cable
connector head assemblies measure
and record the Line to Neutral (L-N)
voltage for each phase.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
53
Actual Load Voltage:
A-N: ____
V
B-N: ____
V
C-N: _________
V
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-201 FUNCTIONAL PERFORMANCE TEST- GROUND POWER UNITS
ACTION
1.
Operate
the
hoist
selector
switch
19. Apply 54 Kvar
reactive
load
to
each of the load banks.
20. Add 72KW to the existing 54Kvar
load (60kva at 0.8 PF) to each of the
load banks
21. Test 28V DC power supply
Observations
REQUIRED ACTION
1. At
The
reelof
assembly
travels
in both
each
the two (2)
output
cable
connector head assemblies measure
and record the Line to Neutral (L-N)
voltage for each phase.
1. At each of the two (2) output cable
connector head assemblies mesure
and record the Line to Neutral (L-N)
voltage for each phase.
1. With load bank connected, energize
the 28v DC power supply verifiy and
record the indicated voltage.
Y
N
REMARKS
Actual Load Voltage:
A-N: ____
V
B-N: ____
V
C-N: _________
V
Actual Load Voltage:
A-N: ____
V
B-N: ____
V
C-N: _________
V
Actual Load Voltage:
________________V
22. Reconnect the nylon strap back to 1. The hoist cable raises the 400 Hz
the hoist cable mounting frame.
cable in a smooth controlled manner
Rotate the hoist panel switch counter back to the stowed position.
clockwise to the raised position.
2. The cable hoist limit switch
interrupts the control power to the
motor contractor when the travel limit
"raise" has been reached.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
54
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-201 FUNCTIONAL PERFORMANCE TEST- GROUND POWER UNITS
ACTION
1. Operate the hoist selector switch
Observations
REQUIRED ACTION
Y
N
REMARKS
1. The reel assembly travels
Notes in both
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
55
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-202 FUNCTIONAL PERFORMANCE TEST- PRE-CONDITIONED AIR UNIT
Project Information
PROJECT:
Terminal B High Gate Electrification
PROJECT NUMBER: 9500540
UNIT DESIGNATION:
TEST INFORMATION
TEST DATE:
COMPANY
START TIME:
PARTICIPANTS:
NAME
CONTACT INFORMATION
Directions:
The following pages are to be filled out by a representative of the commissioning firm who will observe the testing
described herein.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
56
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-202 FUNCTIONAL PERFORMANCE TEST- PRE-CONDITIONED AIR UNIT
Observations
REQUIRED ACTION
Y
Aircraft Hydronic Cooling Mode
ACTION
1. Activate the PCA in aircraft
cooling mode of operation by
setting the DDC.
N
REMARKS
1. Blower motor activates in
cooling mode of operation.
2. Cooling coil valve opens.
3.VFD slowly accelerates preset
cooling speed by aircraft selection.
4. Cooling coil valve modulates to
maintain outlet air setpoint.
6. Electric heat remains disabled.
2. Verify actual fan speed and
airflow cooling mode.
1. Record actual RPM and airflow
in remarks
Actual Speed:
_____________RPM
Actual Airflow:
_____________CFM
3. Measure the leaving air DB
temp. At the leaving air temp.
sensor. Observe the LAT at the
DDC control readout.
1. The temperature should be
within specified tolerance.
Sensor Air Temp:
______________F
Actual Air Temp:
______________F
4. Using a voltmeter, measure the
actual motor voltages.
1. The actual measured voltages
should coincide with the motor
nameplate voltages.
Nameplate Volts:
______________V
Actual Volts:
______________V
5. Using an ammeter, measure the 1. The actual measured
amperages should be less than
actual motor amperage.
the motor nameplate amperages
and below the motor service factor
allowance.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
57
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-202 FUNCTIONAL PERFORMANCE TEST- PRE-CONDITIONED AIR UNIT
ACTION
6. Push STOP button on Remote
Station.
7. While PCA is running, activate
the ventilation mode by setting the
DDC controls to simulate an
ambient temperature setpoint from
>45 F to <55 F.
Observations
REQUIRED ACTION
Y
Aircraft
Hydronic Cooling Mode
1. Blower
stops.
2. Coil Valve Closes.
3. Electric heat remains off.
4. Condensate pump remains
disabled (if applicable).
1. Blower motor activates in
cooling mode of operation.
2. Cooling coil valve opens.
3. VFD slowly accelerates preset
cooling speed by aircraft selection.
4. Cooling coil valve modulates to
maintain outlet air setpoint.
5. Condensate pump is automatic
(If applicable).
N
REMARKS
Note: Blower may not be
re-started for a set
period of recycle time, if
applicable.
Outside Air Setpoint:
________________F
________________Hz
6. Electric heat remains disabled.
8. Verify actual fan speed and
airflow ventilation mode.
1. Record actual RPM and airflow
in remarks.
Actual Speed:
______________RPM
Actual Airflow:
______________CFM
9. Measure the entering and
leaving air DB temperature at the
unit.
1. No observable air temperature
difference is measured entering
and leaving the unit.
10. Using a voltmeter, measure
actual motor voltages.
1. The actual measured voltages
should coincide with the motor
nameplate voltages.
Nameplate Volts:
________________V
Actual Volts:
________________V
11. Using an ammeter, measure
the actual motor amperage.
1. The actual measured
amperages should be less than
the motor nameplate amperages
and below the motor service factor
allowance.
12. Push STOP button on Remote 1. Blower stops.
Station.
2. Coil Valve Closes.
3. Electric heat remains off.
4. Condensate pump remains
disabled (if applicable).
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
58
Note: Blower may not be
re-started for a set
period of recycle time, if
applicable.
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-202 FUNCTIONAL PERFORMANCE TEST- PRE-CONDITIONED AIR UNIT
Observations
ACTION
REQUIRED ACTION
Y
Aircraft
Hydronic
Mode
13. While PCA is running, activate 1. Blower
motor
activates Cooling
in
the electric heat mode by setting
cooling mode of operation.
the DDC controls to simulate an
2. Cooling coil valve opens.
ambient temperature setpoint from
3.VFD slowly accelerates preset
>45 F.
cooling speed by aircraft selection.
N
REMARKS
Outside Air Setpoint:
_______________F
VFD Setting:
_______________Hz
4. Cooling coil valve modulates to
maintain outlet air setpoint.
5. Condensate pump is automatic
(If applicable).
6. Electric heat is enabled.
14. Verify actual fan speed and
airflow ventilation mode.
1. Record actual RPM and airflow
in remarks
Actual Speed:
______________RPM
Actual Airflow:
______________CFM
15. Measure the entering and
leaving air DB temperature at the
unit.
1. The temperature difference
indicates heating occurs.
Entering Air Temp:
________________F
Leaving Air Temp:
________________F
16. Using a voltmeter, measure
actual motor voltages.
1. The actual measured voltages
should coincide with the motor
nameplate voltages.
Nameplate Volts:
________________V
Actual Volts:
________________V
17. Using an ammeter, measure
the actual motor amperage.
1. The actual measured
amperages should be less than
the motor nameplate amperages
and below the motor service factor
allowance.
Nameplate Amps:
________________A
Actual Amps:
________________A
18. Push STOP button on Remote 1. Blower stops.
Station.
2. Coil Valve Closes.
3. Electric heat turns off.
4. Condensate pump remains
disabled. (if applicable)
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
59
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-202 FUNCTIONAL PERFORMANCE TEST- PRE-CONDITIONED AIR UNIT
Observations
REQUIRED ACTION
Y
Aircraft
Hydronic
Cooling
Smoke
Detection
TestMode
ACTION
19. Simulate condition that
activates the smoke detector
system / PCA safety interlock.
1. The smoke detector interlock
shuts down the PCA unit.
N
REMARKS
Note: Reset the PCA
after completion of this
test.
Emergency Stop
20. Press the emergency stop
pushbutton while the PCA is
running.
1. The PCA shuts down.
21. Verify condensate line section
at building is heat traced properly.
1. Minimum of >10 ft of
condensate line is heat traced
prior to entering building.
Note: Reset the PCA
after completion of this
test.
Condensate Heat Trace
Notes
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
60
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-203 FUNCTIONAL PERFORMANCE TEST- CONDENSATE / SUMP PUMP
Project Information
PROJECT:
Terminal B High Gates Electrification
PROJECT NUMBER:
9500540
UNIT DESIGNATION:
TEST INFORMATION
TEST DATE:
COMPANY
START TIME:
PARTICIPANTS:
NAME
CONTACT INFORMATION
Directions:
The following pages are to be filled out by a representative of the commissioning firm who will observe the testing
described herein.
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
61
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-203 FUNCTIONAL PERFORMANCE TEST- CONDENSATE / SUMP PUMP
Observations
REQUIRED ACTION
Initial Check
ACTION
1. Set the power switch to the
"on" position.
1. The pump energizes.
2. Set the power switch to the
"off" position.
1. The pump de-energizes.
3. Simulate a demand for pump
operation by filling sump with
fluid (water) until float switch is
activated.
1. The pump energizes and the
fluid is evacuated.
4. Test pump for correct rotation,
alignment and connection.
1. Pump operates quietly in the
correct rotation with no
significant vibration.
5. Using a voltmeter, measure
the actual motor voltages.
1. The actual measured
voltages should coincide with the
actual nameplate voltages.
Y
N
REMARKS
Automatic Operation
Nameplate Volts:
_____________
Actual Volts:
_____________
6. Using an ammeter, measure
the actual motor amperage.
1. The actual measured
amperages should be less than
the motor nameplate amperage
and below the motor service
factor allowance.
Nameplate Amps:
_____________
Actual Amps:
_____________
High-Level Alarm Test
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
62
Commissioning Plan
Bid Phase
Issued July 29, 2014
FPT-203 FUNCTIONAL PERFORMANCE TEST- CONDENSATE / SUMP PUMP
ACTION
7. Simulate a High-level Alarm
condition for pump by disabling pump
and filling sump with fluid (water) until
high level float switch is activated,
then enable pump.
Observations
REQUIRED ACTION
Initial and
Check
1. The pump energizes
the
Y
N
REMARKS
high-level alarm is activated and
pump does NOT start.
2. Verify audible and visual alarm.
3. Verify that the remote alarm
contact closed to allow for future
remote monitoring.
4. Enable pump to normal operation
and verify that fluid is evacuated.
Notes
DFW International Airport
Project No: 9500540
Terminal B High Gates Electrification
63
Commissioning Plan
Bid Phase
Issued July 29, 2014