Testing and Commissioning of Building Management System (BMS)

Description

This procedure describes the Testing and Commissioning of Building Management System (BMS) in accordance with the standards and requirements of project specifications.

Introduction

This covers the MEP activities related to the Testing & Commissioning of Building Management System (BMS).

Definitions

T & C – Testing and Commissioning
INR – Inspection Request
MEP – Mechanical, Electrical & Plumbing
QA/QC – Quality Assurance/Quality Control
BMS – Building Management System
ITP – Inspection and Test Plan
MST – Method Statement
PQP – Project Quality Plan
STARRT – Safety Task Analysis Risk Reduction Talk
DDCP – Direct Digital Controller Panel

References

Health Safety & Environment
Building Management System
Project Specification
Health and Safety Plan
Construction and Environmental Management Plan
Approved Shop Drawings & Installation Details
Approved Material Submittal
Approved Method of Statement

Responsibilities

Project Manager

Responsible for accomplishing the stated project objectives which include creating clear and attainable project objectives, building the project requirements, and managing the constraints of the project management triangle, which are cost, time, scope, and quality.

Commissioning Manager

Responsible for day-to-day commissioning activities during all phases of the project in coordination with the T & C Manager. Execute commissioning procedures directing a commissioning team consisting of the project manager, commissioning engineer, foreman, technicians, operations personnel, other contractors personnel support system handover and acceptance from the construction team and operation team; including discipline walk downs and punch list generation.

Report to the project manager on issues regarding commissioning, startup schedule, and progress. Interface with client management regarding the commission and startup.

QA/QC Manager

Responsible for supporting the project MEP team in implementing and maintaining Quality Management System for the project through PQP, ITP, MST, and procedures in compliance with project specifications, codes, and standards.

Site Engineer

Supervise operations in accordance with the approved Method Statement, shop drawings, specifications, material submittal, and schedules to achieve the acceptance of the project deliverables.

Project Commissioning Engineer

Responsible for carrying out Testing and Commissioning of BMS with respect to the submitted checklist, approved sequence of operation, and test report.

Site Supervisor

Supervise closely, the activities designated to them and ensure that all instructions and safety procedures are followed and strictly adhered to.

T & C Engineer

Responsible for all the Testing and Commissioning of BMS.

Site Foreman

Liaise with the site engineer and supervisor for the work execution.

QA/QC Engineer

Ensure the proper implementation of the quality system and monitor the overall quality of the work is maintained. Conduct inspection and monitor tests.
Determine and report any non-conformance and recommended corrective actions. Ensure that all personnel is aware of the quality requirement.
Training of relevant personnel.
Conduct surveillance and inspection duties at various stages to ensure compliance with QA/QC plan.
Responsible for conducting inspections.
Arrange inspection for installation and testing by the consultant. Assures corresponding check sheet/s are addressed & followed, perform internal inspection & approval prior to issuance of Inspection Request (INR). He will be responsible for getting the work inspected/approved by the consultant.

HSE Manager

Health, safety, and environmental (HSE) managers generally plan, coordinate and implement issues and directives within the organization. He ensures safe environmental working conditions for all employees.

HSE Officer

Ensure enforcement of safety procedures in accordance with the approved HSE Plan.
Closely monitor the site engineer’s strict implementation of the method statement for BMS, testing & commissioning BMS, and Risk Assessment.
The use of proper tools and equipment to maintain safety, certifications of equipment and their adherence to safety regulations, reporting of any unsafe work, or stopping work that does not comply with HSE procedures.
Advise health & safety requirements and monitor the hazard controls implemented on site as per the procedure, method statement, and risk assessment.
All safety violations and on-conformance of the HSE plan shall be registered and immediate action shall be done in coordination with the site engineer.

Site Foreman

Liaise with the site Engineer and supervisor for the work execution.

Interfacing with other Operations

Other mechanical, electrical, plumbing works and architectural, civil, and structural requirements.

Duration, Phasing with the Subcontractors

All works associated with construction work referred to in this procedure shall be completed as per the project schedule.

The work shall be done by the contractor and the duration of the work shall be indeterminate and will not critically affect the progress of the project.

List of Contractors / Subcontractors

Subcontractors for MEP
Supplier
Brand: Honeywell Alerton-USA

Resources

Plant and Equipment

Not Applicable

Workforce

Project Manager
Project Engineer
Site Engineer
Supervisor/ Foreman
QA QC Manager
Electrician
Installers
Helpers/Laborers
Safety Officer
First Aider
QA/QC Engineer

Light Tools

The following are the types of tools identified for work:
Standard electrical tool kits
Wire cutter
Insulation tape
Wrench tools
Spirit level
True RMS multimeter
Noise level meter
Electrical tools (plier, screwdriver set and etc.)
Stopwatch

Note:
All testing equipment and measuring tools to be used shall have valid calibration certificates prior to usage.

Materials
BMS Field Devices
DDCP Control panel
Workstation PC
BMS Client Graphics

Site Planning

The duration of work shall be indeterminate but will not critically affect the progress of the project.

Preparation

Permits from the concerned authority shall be obtained prior to starting work at the site.
The contractor shall ensure that all gate passes, permits, tools, materials for safety precautions, manpower, and equipment are available before the commencement of work.
The site team shall make sure that access roads are always clear from any obstruction and site is always accessible.
Provision of access and egress such as ladders, steps, ramps, or other safe means of egress and be within a reasonable distance.

Site Clearance

Before commencing the work, the area shall be cleared of all debris, materials, or other obstructions.

Traffic Management

The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials movement through the site following the direction and road signs displayed on site. The required diversion routes shall be marked on drawings including the required traffic signs.

The Work Permits and Operator Certificates shall be compiled for the reference of authorized personnel.

Pre-construction Safety Meetings

The meeting shall be scheduled prior to the beginning of the work and before any subcontractor starts on the project.
General contractual safety, health, and environmental requirements.
Traffic safety will be discussed to emphasize these meetings.
Roles of the contractor, subcontractors, authorized representatives, and all project workers.
Accident reporting requirements.
Specific details of the work to be performed along with the use of personal protective equipment.

Methodology

Pre-Commissioning Procedure for BMS

Prior to the commencement of any T & C works, the area and access will be inspected to confirm that they are in a suitable condition to commence the work. Secure a working permit (if any) clearance from the designated safety officer to start the work.

All relevant documentation (approved shop drawing, Installation drawing, procedure, approved method
statement approved ITP, checklist, and approved material inspection request) applicable to a particular section of work will be checked before the commencement of work.

The site engineer will instruct the in-charge supervisor about the work scope, who in return will relay to the tradesmen regarding the execution of the work and will distribute all necessary approved construction shop drawings and coordinated layout plans.

The site engineer/supervisor should also check the tools and equipment available which should be compliant with the contract requirement, and in good and safe working condition.

Ensure that all workers are aware of the T & C procedure to ensure the best quality of workmanship.

Toolbox meetings shall be conducted by the supervisor for training and special needs for installation as required.

Ensure to make available also copies of the necessarily approved manufacturers drawings and
manufacturer’s instruction manuals (if any) for use at the site.

Provide all necessary work permits indicating all the activities performed before starting to work.

After satisfactory completion of the above steps, works may then commence in the respective areas.

Testing and Commissioning Procedure

1. Visual Inspection And Mechanical Checks

Shall be thorough and systematic and the methods to be employed shall include visual inspection, physical measurements, and mechanical operation.

The result of the visual inspection/ mechanical operation will help to decide whether other commissioning tests should immediately follow or not.

A typical application routine shall cover the following steps:

• Check nameplate details, labels, inscription details, etc. – To establish conformity with the contract
  documents.
• Check sufficiency and completeness – To establish that each piece of equipment is complete in every
  respect and that all relevant information, tools, and aids for safe operation/ maintenance have been provided.
• Check physical soundness – To establish that the equipment is free from damage and defects.
• Check installation details – To establish that the installation has been installed as intended and as required under good engineering practice and is free from visible defects which may cause
  operational hazards.
• Check cleanliness- To establish that each equipment/system component is (externally and internally) free from accumulation of dust, dirt, debris, etc.
• Check accessibility/ maintainability – To establish that each equipment/ relevant component is easily accessible for operation and maintenance.
• Check satisfactory adherence to safety – To ensure that the installation or any part thereof will not pose any safety problem and that all visible aspects of various safety regulations have been rigidly followed.
• Visual Inspection procedures and checklists are illustrated in Appendix “C” – Visual Inspection and Mechanical Operations Checklist.

2. Cable Continuity Test

Continuity check:

• Cable labeling on both sides (field and DDCP sides).
• Checking of cable termination at the DDCP side.
• Checking of cable termination on the field level side.
• Cable Continuity Test checklists are illustrated in Appendix “C”- DOC Panel Checklist.

3. Checking of field devices/points (per DDCP)

Checking that the field devices’ part numbers are correct according to drawings and bill of material.

Checking the proper installation of the field device.

Checking the tagging of each device (if required).

Point-to-point checking from the DDCP to the BMS field points. Use the multimeter to verify the cable continuity and make sure that the field device is terminated at the correct DDCP terminals.

4. DOC Panel power on test

The DDC panel (DDCP) power-on test must be carried out after the completion of procedures (1-3) of the related DDCP. The power test procedure consists of:

• Check for the ground cable at the DDCP.
• Open the 24VAC fuse of each controller on the concerned DDCP.
• Request the contractors in charge to power on the DB.
• Checking the main power 230VAC on the supply of the DDCP using a multimeter.
• Checking the low voltage side, 24VAC supply from the panel transformers using the multi-meter.
• Closing all 24 VAC fuses of the panel
• Checking the low current 24VAC supply to each DDC controller and IO module.

DOC Panel power on test checklists is illustrated in Appendix “C”- DOC PANEL CHECKLIST.

5. Field devices/points tests

This part consists of testing the correct functioning of each field device/point and testing the correct interpretation of its signal at the DDCP. This procedure takes place after downloading the program to the DDC controller and opening the commissioning software.

Refer to the list below, to find the proper way of commissioning each kind of field device/point.

i. Binary or Digital Input

• Select the digital point to be tested,
• Simulate that point and confirm the change of state at the programming PC.
• Check on the commissioning screen of the laptop for the value change.
• If yes, check the point tag name in the configuration coincides with the field point.
• If the point indication does not change, they can be checked by simulating manually (this is done in general for all faults and alarms) and the same steps (3 & 4) are continued
• Note the input point that has been verified, and check against the device on the appropriate commissioning documentation.

ii. Binary Output

• Verify proper interfacing device is installed and connected properly. (e.g. Relay)
• With power OFF at controlled devices, ensure the interfacing device responds to a Software /Overridden command. The software command can be initiated at the commissioning software whereas the manual command can be initiated by jumping the coil of the relay.
• Note that the device has been verified by making a check against the device on the appropriate commissioning documentation.

iii. Analogue Input

• Measure the actual input variable.
• Check the value read on the commissioning tool, and verify that it corresponds to the measured one.
• Check that the unit on the commissioning software point is matching the parameter we are checking.
• Check the input reading has a logical sense and does not fall out of the normal working range.
• Note that the input has been verified by making a check against the sensor on the appropriate commissioning documentation (Appendix “C”- Commissioning Tests (Post-Energizing) Sequence and Requirements).

iv. Analogue Output

• Check the units (0-10VDC, 4-20ma, etc) on the commissioning software point are matching the
• parameter to be tested.
• Send multiple different outputs.
• Verify that the connected device is physically responding according to each output sent
• Calibrate the device if needed (in our case usually, the valves and actuators are preassembled, tested, and factory-calibrated prior to the delivery).
• If the device has feedback, then verify the feedback of the device corresponds with the different values of output sent.

N.B. Before checking the analog input and output, make sure the device is already factory calibrated. If not refer to the MFR calibration procedure and datasheets.

6. Testing

The testing shall be thorough, systematic, and sequential (where appropriate). The methods employed shall generally include electrical tests, which can be broadly classified into:

• Pre – energizing tests – To establish that the equipment or system can be safely energized and that all system components have been properly installed in Line with the manufacturer
  recommendations. Manufacturer installation details are illustrated in Appendix “C” Commissioning Tests (Pre -Energizing) Sequence and Requirements.
• Post-Energizing tests – To establish that the equipment or system can be safely operated as intended, all safety features are operative and performance objectives are attainable.

The Post-energizing tests shall be mainly based on the approved sequence of operation for all monitored and controlled equipment as indicated in Appendix C- Commissioning Tests (Post-energizing) Sequence and Requirements.

Post-energizing tests shall not be generally undertaken unless pre-energizing tests have yielded favorable results.
Pre and post-energizing tests are illustrated in Appendix C.

7. Functional Test

The sequence of operation tests will be performed after all the equipment’s/unit are commissioned.

Ensure that electricity and chilled water are available.

Ensure access to all the related areas is available.

Ensure that all the related equipment is approved.

Ensure that the HVAC engineers/technicians, and the fireman (or an authorized person) is available at the site to carry out the joint operation test.

Ensure that the water and air are fully balanced and the report is approved by the client
representative. The area is clean.

All the discipline have completed their work 100% no final tuning, patchwork, or any kind of activities that may affect the sequence testing.

Before carrying out any test, ensure that the installations comply with the statutory requirements and regulations, particularly on the safety and protection requirements.

The pre-commissioning testing and commissioning of these hardwired points are done through the checklists presented in Appendix C.

8. Commissioning of DOC Controller Software along with the relevant system sequence of operation.

Consequently, as BMS specialists, the sequence of operation adequate to the electro-mechanical units and systems of this project is as per the design documents. Actual sequence by relying on all the BMS design documents, specs, drawings, electro-mechanical equipment locations, and air & water flow drawings throughout the building.

All detailed sequences of operation will be checked/documented in their corresponding commissioning form Appendix-F, which corresponds to the approved design system sequence of operation.

9. Interface Test

The interface procedure is the step during which the data of the field devices is presented in the web browser of the BMS workstation.

This procedure for the project is divided into two parts.
• The DOC controllers
• The MOD bus objects

In order to proceed to the interfacing of MOD bus and IP objects, we need to set up the workstation PC and initialize the network supervisory/IP controllers.

BACnet interface-Field devices and points

• The BACnet/IP controllers of this project shall monitor and/or control most of the MEP equipment and systems. The interface points of each system are hardwired to the different Data Gathering Panels (DGP) spread in strategic locations across the whole project.
• The input/ output points of one system are different from another. Please find the IO point list including all types of systems with their respective input/ output points going to and from the building management system.
• The pre-commissioning testing and commissioning of these hardwired points are done through the checklists already presented in Appendix C.
• BACnet/IP integration: Once the testing and commissioning are completed, the controllers are said to be in standalone mode. This means that no network is connecting them to a supervisory system.
  In order to have the complete input/ output list shown on the workstation and in order to be able to send and receive commands and values, we need a supervisory system. Consequently in order to monitor and control the field points from the BMS workstation; we need to complete the IP integration of the controllers with the supervisor.
• In addition, the input/output points of these controllers must be mapped into the supervisory BMS system.
• The riser diagram in Appendix-“BMS Network Riser Diagram Layout” shows the BMS cable layout. Each of the connections from the Panel with the IP controller is connected to the BMS workstation in the BMS control from with supervisor through BACnet/IP. The IP integration of the systems/equipment is done through the supervisor.

10. Demonstration Procedures

After the interface part is completed we can see the field data represented on a user-friendly graphical interface and we can say that the BMS workstation is ready to operate. A simplified demonstration procedure can begin in the main BMS control room.

The client representative or consultant can attend in the control room and check the BMS and the accomplished work:

a. Quantity check

The quantity check confirms to the client that the BMS system is complete.
Provide the client representative with a list of all systems that have to be interfaced with the BMS.
The client representative checks that each system from the list provided can be viewed on the BMS workstation

b. Point-to-point check

The point-to-point check confirms that each piece of equipment has been integrated into the BMS system in the proper way.

The client representative can check that:
Each kind of equipment can be accessed on the BMS workstation.
Each kind of equipment has all the required BMS points.
The readings of all points are a correct reflection of the site parameters.

c. The sequence of operation check

The sequence of operation check is the final part that confirms the good operation of each kind of mechanical or electrical equipment.

The client representative can reproduce, from the operator workstation, each step of the form “sequence of operation”.

The client representative can check at the same time that the sequence performed on the screen of the workstation is exactly what is happening actually on site.

d. Fine-tuning the sequence

The software supervisor software has been designed specifically to meet the need of the building owners and managers to efficiently monitor and control all the mechanical and electrical systems in a typical building.
The different features of the software provide a guarantee to the client that the system is performing as it requires.

The “Alarm and Event messages” sent by the supervisor and stored on the BMS operator workstation can be viewed at any time to trace the history of alarms and events on the site.

The “trending of any monitored value” at user-defined periods ranging from a few seconds to one week is useful for analyzing the performance of building control systems and locating the source of system problems.

The “scheduling feature” allows the user to define building occupancy periods and the start and stop times for mechanical or electrical equipment. Operating parameters such as temperature set points and power consumption limits can be set according to the time of day.

Multiple features of the Building Management System will be closely recording all the responses of different systems. An unwanted response (slow, illogical, alarm, the system did not start … ) or an unwanted value (temperature too high, pressure too low … ) will be taken care of by the project engineer that will proceed with the fine-tuning of the sequences, control modules, conversions … that will lead to a satisfying workable system.

Inspection and Test Plan

The engineer should verify that the supervisor/foreman with construction responsibilities for installation is familiar with this method statement and is issued with copies of the inspection checklists and test plans.

The engineer should satisfy the procedures provided by QA/QC inspections to ensure the T & C of BMS meets the specified engineering requirements and approved drawings.

As part of the assessment, the QA/QC Inspection procedures must ensure quantitative or qualitative acceptance criteria for determining the prescribed activities have been accomplished satisfactorily.

The QC inspection personnel in coordination with the site engineer and supervisor should verify that the quality of the installation activities is within the prescribed criteria.

The quality control engineer along with the project engineer and site supervisor will monitor that all components are installed as per contract specifications and approved submittals.

Inspection Request (INR) shall be submitted by QA/QC Engineer for verification and inspections.

Readable stamped approved drawing to be available during installation and inspection.

Risk Assessment

Please refer to Appendix A.

Permit Requirement

Vehicle permit for equipment.
Working Permit
Night Work (if required)
Driving permit

Drawings, Diagrams, Maps and Survey Data

Refer to approved shop drawings.

Pre-Start Safety Briefing Arrangements

Refer to Risk Assessment in Appendix A.

a. Protective and Safety Equipment

All workers involved shall be equipped with adequate PPE’as stated below:
a. Safety helmet with company logo
b. Safety boots
c. High visibility vest
d. Safety goggles
e. Hand gloves
f. Coveralls

b. Information to personnel

a. Safety induction
b. Job training
c. Superintendents notices/memos
d. Toolbox talks
e. STARRT card

c. Special Safety Requirements

a. All necessary personal/protective equipment (PPE), as well as harness, be provided.
b. The equipment operators shall possess the required licenses and certificates.
c. Generated dust shall be controlled by periodic water spraying.
d. The project safety officer is responsible along with the project zone site engineer for ensuring that all operations are carried out with due regard to the safety of all project personnel & property.
e. All working activity shall comply with the client safety procedure.
f. First aid material.
g. General management of protection/operation hazards is to be observed.
h. In case of working at night, refer to the method statement for night works

Environment and Quality Issues

a. Precautionary measure

All precautionary measures shall be briefed to all workers prior to commencing the activity.

b. Disposal requirements

All waste shall be disposed of as per the Construction and Environmental Management Plan and as per Government approved disposal areas.

c. Inspection, test, and sampling

Request for Inspection and Testing will be submitted prior to and after execution of works.

d. Quality assurance requirements

Ensure that work is executed as per the approved shop drawing, procedure, and method statement and that records are generated referring to approved ITP.

Best management practices shall also be considered which may be stated by product manufacturers or suppliers.

Authority requirements will take precedence over all requirements in case authority approval is to be secured. For non-authority approval activities, approved latest project specifications will take precedence.

It is to be ensured that regular toolbox training related to work quality is conducted and records are maintained.

List of Appendices

Appendix A: Risk Assessment

Appendix B: Inspection and Test Plan (ITP)

Appendix C: Visual Inspection and Mechanical Operations Checklist
Commissioning Tests Pre -Energizing Sequence and Requirements
Commissioning Tests Post-Energizing Sequence and Requirements
Test Forms
Commissioning Checklist

Appendix D: Approved Method of Statement for Installation of BMS