Commisionning Plan MTC ADIA Draft

COMMISSIONING PLAN

[DRAFT]

Project: ADIA Midfield TB

Main Contractor:TCA JV

Plan Approved:
Signature Title Date
 Commisionning Plan MTC ADIA Draft

TABLE OF CONTENTS
1. Overview
1.1. Purpose of the Commissioning Plan
1.2. Commissioning Scope
1.3. Commissioned Systems List
1.4. Forms
2. TCMO Organization Chart
3. Commissioning Parties
4. Roles and Responsibilities
4.1. Commissioning Parties
4.2. General Management Plan
4.3. General Descriptions of Roles
4.4. Scheduling
5. Commissioning Process
5.1. Commissioning Follow up Sheet
5.2. Commissioning Meetings and Progress Reporting
5.3. Off Site Tests and Inspections
5.4. Pre-commissioning Checkouts
5.5. Execution of Commissioning Test Procedures
5.6 Integration Tests Commissioning Strategy
5.7. O&M Manuals and Warranties
6. Summary
APPENDIX 1
 Commisionning Plan MTC ADIA Draft

1. Overview
1.1. Purpose of the Commissioning Plan
The Commissioning Plan provides direction for the commissioning tasks to demonstrate proper
performance of the critical systems before handing over. The plan clearly defines the responsible
parties, the commissioning organization of the main contractor, the information flow and the
reporting structure of the commissioning process.
1. Provide direction for the development of the commissioning procedures according to the MTC
Contract specification requirements and guidelines stated in: 01 33 00 Submittal Procedures , 01
45 00 Quality Control and Testing, 01 46 00 Factory Testing, 01 77 00 Project Close-out, 01 78
23 Operation and Maintenance Data , 01 78 36 Warranties , 01 78 43 Spare Parts, Tools, and
Extra Stock Material, 01 79 00 Demonstration and Training , 01 91 00 Commissioning, 01 92 00
Operational Support, 01 99 00 Operational Readiness.

2. Provide direction for the commissioning process, particularly defining the structure of the
subject systems and define & coordinate related commissioning activities in terms of reports,
procedures and responsible parties.
3. Define the dependencies of the activities via other Contract packages within ADIA and verify
relevant testing procedures are implemented correctly e.g. by embedding provisions for
interfaces and future tasks as necessary.
4. Outline rules providing the commissioning activities are reviewed ad scheduled in
accordance with the construction programme.
5. Keep track that inherent activities such as training, spare parts handovers are fulfilled.
This plan does not intend to provide detail of each procedure which depends on vendor
specific and industry wide practices but outline and wrap the activities to be executed. The
detailed testing requirements and procedures are to be submitted to the Consultant through
TCMO for review and comment.

1.2. Commissioning Scope

Commissioning is a systematic process of ensuring, through actual verification of performance,
that all building/infrastructure systems perform interactively according to the contract
requirements practically all the supervision and control by QA/QC during installations has to be
completed and NCRs affecting the subject system to be closed as a prerequisite.
The Commissioning process is intended to achieve the following specific objectives:
 Ensure that applicable equipment and systems are installed and inspected according to the
manufacturer’s recommendation and to industry-acceptable standards and that they are
checked-out by the installing contractors.
 Verify and document proper performance of equipment and systems (SAT) and the inter-
relationship between systems (SIT).
 Provide scheduling and coordination of training activities
 Follow up of the required Factory Inspections (FAT) are done in a timely manner.
 Ensure that complete O&M documentation and warranty certificates are delivered to the
Employer.

1.3. Commissioned Systems List

The following systems will be commissioned in this project. Brief information is given below.
[Indicative list only to be detailed upon all subcon /manufacturer Information Available]

SYSTEM Subcontactor Manufacturers Exp FAT Training O&M Spares

Startup Status
Date

HVAC System (AHU,

Chiller, FCU, Ducting,
MCC ,PCA)
Fire Protection (Fire Pumps,
Sprinklers, Fire Hydrants, Clean
Agents)
 Commisionning Plan MTC ADIA Draft
Plumbing
BMS and SCADA
Security Systems (CCTV, ACS)

Life Safety Systems (FADS Fire

alarm and detection)

MV Distribution (MV Cells,

Transformers)
LV Distribution (LV Panels)
Lighting and Small Power
Grounding and Lightning
Protection
Generators
UPS
Data and Telephone Network
(Structural cabling,)
SAS
(AODB,IB,RMS ,FIDS ,CYE);LAN
,SAN)
PBB
LET
HBS and X Rays
BHS

1.4. Forms
Forms used during commissioning overviewing & wrapping up subcontractors or manufacturers
SAT forms / Checklists are found in Appendix 1 of this plan.

2. TCMO Organization Chart

[Here a Matrix showing the Main Testing and Commissioning Organization members and
responsibilities, to be given.]

3. Commissioning Parties
[Here each member playing a role in the commissioning process has been identified and contact
information to be given]

4. Roles and Responsibilities

4.1. Commissioning Parties

Parties are indicated in section 3. For each system related MEP Department Mngs, Project
Manager of Subcontractor or Project Manager of Vendor where applicable, shall be
primarily responsible for the execution of the commissioning tasks.

4.2. General Management Plan

TCMO forms a workgroup consisting of related technical departments inclusive QA/QC and
Technical office of the main contractor to follow up and review execution of commissioning tasks.
In case of need subcontractors and manufacturers shall be involved in the workgroup. All
parties will work together to fulfill their contractual responsibilities and meet the objectives of
the Contract Documents.

4.3. General Descriptions of Roles

General descriptions of the commissioning roles are as follows:

 Commisionning Plan MTC ADIA Draft
TCMO (Testing and Commissioning Main Organization): Reviews the total process and
provides resources for seamless execution Coordinates the Commissioning process in periodical
meetings, oversees and checks documentation is done timely as scheduled by the relevant
executing party. Checks commissioning plan and monitors execution and provides
recommendations.
CO (Consultants): Approves procedures for the systems in scope, assists conceding parties in
commissioning process.
CA (Conceding Authorities/Employer) : Witness commissioning tests and signs-off on
Commissioning test forms clearing for handing over.
TO (Technical Office): Integrates commissioning activities into the construction process and
schedule follows up and reports the execution on periodical reports.
QM (QA/QC Manager): Ensures the documentation is done properly, follows up and assists in
pre-commissioning activities and completion of punch list.
DC (Department Mngs): Ensures items such as Fat, Warranties, commissioning, and training
are implemented in the contracts PO s with vendors and subcontractors. Coordinates execution
of commissioning activities within his scope ensures that Subcontractors and Manufacturers
perform their responsibilities, collects, prepares and submits documentations to TCMO.
Subs (Subcontractors): Demonstrate proper system performance
Mfr (Equipment manufacturers and suppliers): provide documentation to facilitate the
commissioning work and perform contracted startup where applicable.
DCC (Document Control): Keeps all record and technical documentations in hard and soft
format and defines an indexing system to follow up documentation easily.

4.4. Scheduling

The Main Contractor will integrate all commissioning activities within its project schedule via TO
and monitor the progress on the project schedule.
During the construction progress, in necessary cases schedules related to the Commissio ning are
to be revised and relevant parties shall be informed timely.

5. Commissioning Process
The objective of Commissioning is to demonstrate that each system is operating according to the
documented design intent and Contract Documents. Commissioning testing facilitates bringing
the systems from a state of substantial completion to full dynamic and integrated operation
where Interfaces and sequencing & scoping of the works to be clearly described , from an
Integrated Commisioning perspective.. Additionally, during the testing process, areas of deficient
performance are identified and corrected, improving the operation and functioning of the
systems. In general each system should be operated through all modes of operation. Inter-
system integration performance shall further be tested and checked within management level
systems. The DC in coordination with TCMO oversees and coordinates the development
test procedures in a sequential written form; and coordinates, directs and documents the
actual testing, which will be performed by the installing subcontractor or vendor.
 Commisionning Plan MTC ADIA Draft

Sample Flow chart illustrates the Integrated commissioning principles .

 Commisionning Plan ADIA Draft

Upon complete installation of any individual equipment component or complete system a series of
precedent actions need to be undertaken before actual system commissioning takes place. These are
generally divided into the following categories:

 Equipment & System Inspections

 Individual component/equipment tests
 Sub-System Functional Tests
 Segmental System tests
 Laboratory Tests
 Zone Testing
 Individual Integration/Interface tests
 Full system commissioning
 Final Acceptance Tests

5.1. Commissioning Follow up Sheet

A sheet indicating the main systems to be commissioned and brief highlighting the equipment is
given in the attachment Annex 1. The procedures shall be prepared based per system by the
relevant party and submitted to consultant through TCMO. Subcontractors/Manufacturers forms
and reports shall be filled out as per system and per location.
The training, Fat, O&M manuals shall also be prepared and filed based per system.
This sheet will be the main guiding chart to follow up all of the commissioning activities and shall
be kept updated by the end of each week by DC or Subs and sent to TCMO & TO as progress
report.
The procedures including checklists and forms shall be prepared or collected from subcontractor
or manufacturers by DC and submitted DC->TCMO->DCC->CO or DC->TCMO->DCC->CA
at least a month ahead from the commissioning activities starting.
Also during execution of the works completed and filled out forms shall be submitted to TCMO for
tracking and records.

5.2. Commissioning Meetings and Progress Reporting

Tentatively each week TCMO calls for a short commissioning meeting to update parties involved
in commissioning. These meetings will cover coordination, deficiency resolution and planning
issues. The frequency of such meetings will be fitted to the construction progress, until the final
6 months of the construction when they will be held as frequently as one per week. Minutes of
such meetings will be submitted to all parties for information and action.
The Employer/Consultant can call meetings if and when he considers such meetings are
required.

5.3. Off Site Tests and Inspections

Factory Acceptance Tests / Source Inspections: Factory Acceptance Tests and Source
Inspections will be planned and scheduled by each DC, , according to the Contract Specifications
and preceding requirements of the CA. Factory Acceptance Tests witnessing and source
inspections shall participated by representatives of CO or CA . The DC will coordinate the tests
and inspections with the Manufacturer(s). The tests will be performed by the Manufacturer. The
test results will be received by DC and submitted to QM & TCMO trough DCC for the records.
Manufacturers’ Tests and Certificates: For the Manufacturers’ tests which witnessing or
inspection is not necessary according to the Contract Specifications, the tests will be performed
by the manufacturer. Certificates of compliances to industry standards and conventions will be
submitted to TCMO & QM trough DCC.

5.4. Pre-commissioning Checkouts

Pre-commissioning is important to ensure that the equipment and systems are operational and
that commissioning testing may proceed without unnecessary delays. The pre-commissioning
activities for a given system must be successfully completed prior to formal commissioning also
providing time to remedy any malfunctions. In case needed a sampling strategy may be used.
 Commisionning Plan ADIA Draft
The pre-commissioning test reports shall be signed off by QM & TCMO supervisors and punch
lists to be followed up.

5.5. Execution of Commissioning Test Procedures

5.5.1. Coordination and Scheduling

The executing parties will provide sufficient notice to the CO /CA regarding their completion
schedule for the commissioning of the equipment and systems. The DC will schedule
Commissioning tests through the TCMO, and the related subcontractors. The TCMO in
coordination with DC will direct, witness, and document the commissioning of related equipment
and systems and make sure eventually the Forms are signed and comments are noted & being
followed by DC to be completed/corrected. The subcontractors will execute the tests as per
previously submitted procedures.
Tests will be executed under strict safety requirements.
5.5.2. Documentation, Non-Conformance and Test Approval
Documentation: The documents signed off shall be collected by DC in complete and submitted to
TCMO through DCC to be used for handing over and completion certificate issues.
Non-Conformance:
•The DC will record the results of the test on the commissioning test form. All major
deficiencies or non-conformance issues will be noted and recorded on the form attaching snag
list as necessary and shall be followed up until the snag list cleared and signed off by CO or CA
.
•The part of the test shall be rescheduled to a date decided upon negotiation via the executing
party and upon rectification result to be noted on the form.
•Corrections of minor deficiencies identified, may be made during the tests at the discretion
of the CO or CA.
Approval of Tests: Each test of satisfactory result shall be signed off upon completion on the
relevant form by CO & CA and executing parties. .

5.6 Integration Tests Commissioning Strategy

Integration tests to be done with in the management system level to demonstrate interfaces
are working and achieving the required performance. Also other packages interfaces defined on
the interface matrix shall be considered in the integration tests for future balancing and
adjustments.
A Schedule similar to the following shall be prepared by MSI team to monitor the progress of the
integration testing activities.
 Commisionning Plan ADIA Draft

5.6.1. Systems Integration and Testing

Prior to integration testing the functionality of individual systems will be tested to
demonstrate they meet the contractual technical specifications using the approved
hardware and software implementations partially under coordination of the airport
wide MSI.
The purpose of Integration Testing is to:
5.6.1.1. Test the interfaces between pairs of systems comprising MTC to demonstrate
that their interaction and exchange of data meets the contractual technical
 Commisionning Plan ADIA Draft
specifications using the approved hardware and software.
5.6.1.2. Test the interfaces between pairs of systems within MTC and other contractors
systems being delivered to MTC to demonstrate that their interaction and
exchange of data meets the contractual technical specifications using the
approved hardware and software elements.
5.6.1.3. Test the interfaces between pairs of systems within MTC and other systems which
already exist at Abu Dhabi International Airport to demonstrate that their
interaction and exchange of data meets the contractual technical specifications
using the approved hardware and software.
5.6.1.4. Prove the connectivity and interworking from the systems within MTC to existing
Terminal and facilities as applicable

5.6.1.5. Demonstrate that the complete integrated configuration of systems internal and
external to MTC meets the contractual technical specifications using the
approved hardware and software.

Factory Acceptance Test (FAT)

MAIN TESTS

Laboratory Acceptance Test (LAT)

Functional test

Integration Acceptance Test

Site Acceptance Test (SAT)

Airport wide Integrated

Acceptance Test (AAT) and Final
Acceptance

5.6.2. System Integrations to be tested within MTC

(Here a list within MTC to be added indicating system name, Supplier/Subcon and expected
duration of the tests)
5.6.3. New systems to be provided by other contracts external to MTC
(Here a list of others to be added indicating system name, Supplier/Subcon, Scope descriptions,
corresponding system of MTC and expected duration of the tests)
5.6.4. Existing systems ow ne d by ADAC, Airlines and Others
(Here a list of ADAC -& Airlines owned systems to be added indicating system name,
Supplier/Subcon ,Scope descriptions , corresponding system of MTC and expected duration of the
tests ,clients input needed for the clause)
5.6.5. Testing Methodology
5.6.5.1. Test plans will be produced in accordance with the relevant ICD’s to
describe how testing is to be carried out for all the systems provided.
5.6.5.2. Test specifications will be written by the suppliers/SC to describe the actual
tests to be performed reviewed by MSI to be approved by Engineer.
5.6.5.3. Test scripts shall be produced to describe the precise actions to be taken
 Commisionning Plan ADIA Draft
during the tests, the data values to be used and the expected results of
successful tests which will demonstrate that the functionality and performance
of the systems meet the contractual specifications.
5.6.5.4. These test plans, specifications and scripts will be reviewed by MSI team and
signed off to indicate their agreement that successful completion of the tests
shows compliance with the specifications.
5.6.5.5. Testing shall be carried out by the supplier of the system in the presence of MSI
& related disciplines , ADAC and The Engineer according to the Testing, and the
actual results recorded against the test. If the actual result is as expected the
test will be considered as passed. If the test result is not as expected this shall
be considered as a defect and the supplier/SC shall correct the defect within an
agreed time period and resubmit for re-testing.
5.6.5.6. In the event that some system components repeatedly fail the tests in
coordination with the Engineer it will be decided to continue or not with these
defects whether they do not materially prevent moving to the next stage of
testing .In such circumstances the supplier shall correct the defects in
accordance with the terms and conditions of the contract.

5.6.6. Integration Testing

Integration testing shall be carried out in a three-stage process.

5.6.6.1. Stage 1 – Peer to Peer testing

5.6.6.1.1 All peers of systems which need to exchange data will be tested in
accordance with an Interface Control Document (ICD) which defines the data
to be exchanged and the behavior of the systems when they receive the data
described.
5.6.6.1.2. Each ICD must have been agreed between the parties of the two systems
and signed off by them prior to commencement of any interface testing
preferably during design Phase and may be further developed/verified
during Test Lab , FAT etc .Phases .
5.6.6.1.3. The peers of systems which are to be tested in this way have to be described
Integration Documentation during design Phase.
5.6.6.1.4. First multiples of systems within MTC shall be integrated.
5.6.6.1.5. Then multiples of systems between MTC and external systems supplied by
others to be tested.
5.6.6.1.6. Finally multiples of systems external to MTC (ADAC existing Airlines etc) shall
be tested.

5.6.6.2. Stage 2 - Incremental integration of all systems

5.6.6.2.1. Following successful pair wise testing of the various system components, in
accordance with the approved Test Plans to be supplied by the respective
subcontractor, system components shall be added and tested incrementally to
demonstrate that the successive addition of each system does not impact either its own
functionality or that of the systems already integrated. In this way a smaller but growing
version of the entire integrated airport systems can be shown to meet the technical
specifications.

5.6.6.3. Stage 3 – End to End Testing of selected Operational Scenarios

5.6.6.3.1. End to end testing of the fully-integrated systems shall be carried out
using the appropriate test scripts with specified, agreed selected scenarios to
demonstrate that the end systems function as specified. These tests shall be
witnessed and signed off by MSI and other related parties.
 Commisionning Plan ADIA Draft

5.7. O&M Manuals and Warranties

The DC reviews the O&M manuals, documentation before submitting. The DC also reviews each
equipment warranty and verifies that all requirements to keep the warranty valid are clearly
stated and submit them to TCMO ÆDCCÆ CA and/or CO

6. Summary

The work flow of the commissioning process is summarized in the table below:
Description
İtem Created By Received By Reviewed
/Approved By
Commissioning TCMO Commissioning Plan All Commissioning CO (A)
Plan (Wrap parties
Procedure)
Commissioning DC ,Subs Defines subject systems , TCMO QM TO TCMO
Follow up Sheets ,Mfg constituents as per location
or just system
Commissioning DC ,TO Defines timing of activities TCMO TCMO TO
Schedules
Commisoning DC Defining the execution of TCMO TCMO CO(A)
Test Procedures ,Subs,Mfgs specific test per system
Precommisioning DC Filled out checklists TCMO TCMO
Checklists ,Subs,Mfgs
Commissioning TCMO Record / track of all activities All CO
Progress Meeting mainly in form of MoM
Filled out & signed Subs/Mfg DC Recorded documentation of TCMO CO CA (A)
Commisoning Test the test on the form
forms

O&M manuals Subs / Mfg Documentation for CO CA

warranty DC equipments, training etc.
certificates
,training logs

APPENDIX 1

1- Commissioning Follow up Sheet to be given

2- Wrap up Commissioning Forms to be given

The following forms are to be provided electronically.

Form Number Description

Form – 01 Pre-commissioning Test Form
Form – 02 Commissioning Test Form