26_08_00_-_Commissioning_of_Electrical_Equipment_Amend_0004_0004.pdf

Folsom Warehouse – Bridge Crane Replacement Amendment No. 0004 American River Division Solicitation No. 140R2026R0017 Folsom Unit - Central Valley Project, California Specifications No. 20-C0942

Commissioning of Electrical Equipment

Revised 26 08 00 - 1

SECTION 26 08 00

COMMISSIONING OF ELECTRICAL EQUIPMENT

PART 1 GENERAL

1.01 MEASUREMENT AND PAYMENT

A. Cost:

1. Include cost of commissioning of electrical equipment in prices offered in the Price

Schedule for other items of work.

1.02 SCOPE

A. Construction verification, field tests and functional performance testing as well as requirements for commissioning of the overall respective electrical systems, related subsystems and related equipment.

B. Division 25, Division 26, and Section 41 22 15 – Bridge Crane Electrical Components responsibilities and participation in the commissioning process.

1.03 DEFINITIONS

A. Construction Testing: Government Contract Quality Assurance, Contractor Quality Assurance / Quality Control, Contractor Field Quality Tests, and functional checkout at the equipment and device level. Refer to Section 01 46 00 – Quality Procedures.

B. Contractor Tests: Tests as required by other sections.

C. Factory Acceptance Test (FAT): Activity, including inspection and testing, to demonstrate that the system, subsystem, electrical equipment or component is in accordance with the specification and is typically conducted at the manufacturer’s facility.

D. I/O: Input/Output.

E. Operational Commissioning: Functional tests including verification of electrical and mechanical systems, electrical metering, instrumentation readings, motors, drives, automation control, network devices and protective relay functional tests.

F. PLC: Programmable Logic Controller.

G. Pre-Check Out Tests: Functional, static checkout at the system level performed prior to energizing the unit, the equipment, and the incoming line. Includes system verification of electrical and mechanical systems, systematic functional testing, and verification of completion of required Construction Testing. Refer to Section 26 05 90 – Wiring Checkout and Tests.

Revised 26 08 00 - 2

H. Site Acceptance Test (SAT): Activity, including inspection and testing, conducted at the site of the site of installation, to demonstrate that the installation of system, subsystem, electrical equipment or component is in accordance with the applicable standards, codes, specifications and installation instruction. Test is performed to demonstrate proper functionality after delivery and installation.

I. SPD: Surge Protective Device.

J. VFD: Variable-Frequency Drive Motor Controller.

1.04 REFERENCE STANDARDS

A. Bureau of Reclamation (Reclamation)

1. FIST 3-1-1991 Testing Solid Insulation of Electrical Equipment

2. FIST 3-3-1991 Electrical Connections for Power Circuits

3. FIST 3-8-2021 Operations, Maintenance, and Field Test Procedures for Protective Relays and Associated Circuits

4. FIST 4-13-2011 Thermal Analysis

B. Institute of Electrical and Electronic Engineers (IEEE)

1. IEEE 115 - 2019 Test Procedures for Synchronous Machines including

Acceptance and Performance Testing and Parameter Determination for Dynamic Analysis

2. IEEE 1248-2020 Guide for Commissioning of Electrical Systems in Hydroelectric Power Plants

3. IEEE C2-2023 National Electrical Safety Code

4. IEEE C62.34-2017 Test Methods and Performance of Low-Voltage Surge

Protective Devices Used on Secondary Distribution Systems

5. IEEE C62.62-2018 Recommended Practice on Surge Testing for Equipment Connected to Low Voltage AC Power Circuits

C. International Society of Automation (ISA)

1. ISA 62381-2011 Automation Systems in the Process Industry – Factory

Acceptance Test (FAT), Site Acceptance Test (SAT), and Site Integration Test (SIT)

D. International Electrical Testing Association, Inc. (NETA)

1. NETA ATS-2021 Acceptance Testing Specifications

E. National Electrical Manufacturers Association (NEMA)

Revised 26 08 00 - 3

2. NEMA ICS 2.9-2002 AC Vacuum-Break Magnetic Controllers Rated 1500 Volts AC

F. National Fire Protection Association (NFPA)

1. NFPA 70-2023 National Electrical Code (NEC)

G. Underwriters Laboratories (UL)

1. UL 508-2018 Industrial Control Equipment

3. UL 60947-4-1 - 2022 Low-Voltage Switchgear and Controlgear – Part 4-1:

Contactors and Motor-Starters – Electromechanical Contactors and Motor-Starters

1.05 DESIGN REQUIREMENTS

A. Commissioning forms shall be filled in as work progresses by the individuals responsible for installation and are included in the respective submittals per the Submittal Table 01 33 00A.

1.06 SUBMITTALS

A. Submit the following in accordance with Section 01 33 00 - Submittals and Section 01 33 26 – Electrical Drawings and Data.

B. Reference the following specifications for submittal requirements and submit in accordance with Section 01 33 00 - Submittals and Section 01 33 26 – Electrical Drawings and Data:

1. Section 25 00 01 – Automation Control System.

2. Section 25 12 10 – Programmable Logic Controller.

3. Section 26 05 10 – Conductors and Cables.

4. Section 26 05 20 – Grounding and Bonding.

5. Section 26 05 33 – Raceways and Boxes.

6. Section 26 05 90 – Wiring Checkout and Tests.

7. Section 26 24 42 – Distribution Panelboards.

8. Section 26 43 13 – Surge Protection Devices for Electrical Circuits.

9. Section 41 22 15 – Bridge Crane Electrical Components.

Deleted

C. RSN 26 08 00-1, Schedule for Commissioning Tests:

1. See 1.08.A.6 for requirements.

Revised 26 08 00 - 4

1.07 PERFORMANCE REQUIREMENTS

A. Crane automation control systems are to be tested in their implementation to verify proper operation in accordance with contract specifications.

B. The SAT shall be performed after the delivery and installation of the system, equipment or components at the site.

C. Commissioning checks and tests are in addition to tests required by other sections.

D. Furnish materials, including test equipment, required for commissioning.

E. Replace defective equipment and make device setting adjustments as required for operation of electrical systems in accordance with Specifications and manufacturer’s instructions.

F. If required during testing, remove and replace wire connections.

G. Make wiring changes, wire tag revisions, and other repairs or revisions during testing session if a discrepancy is discovered.

H. Perform commissioning in presence of Government.

I. Work shall be performed during an outage in accordance with Section 01 14 30 – Interruption of Service.

J. While performing testing/commissioning, remove and replace wiring connections that may be required in processing of checkout; and make wiring changes, setting adjustments, equipment replacements, or other revisions which are necessary for proper functioning of installation.

K. Replace wiring, instruments, or equipment that is damaged during final testing/commissioning.

L. Provide spare parts and extra materials prior to the commissioning of the crane.

M. Provide a complete and thorough evaluation of the operation and performance of all components, systems and sub-systems.

N. The equipment provided and installed requires pre-check out tests and operational commissioning.

Government may require commissioning and survey of additional equipment.

O. System components which will not be functionally performance tested but will be included in the commissioning scope for conformance to the design documents, verification of installation, and Contractor testing shall include:

1. Crane electrical components.

2. Distribution panelboards.

3. Control enclosures.

4. Surge protective devices.

Revised 26 08 00 - 5

5. Conductors, cables, raceways, and boxes.

P. Grounding system. Commissioning of automation controls system:

1. Perform proper configuration and tuning of controllers, programmable logic controllers and network components to ensure requirements are met and facility personnel is well prepared for operation and maintenance.

2. Verify each control device is installed and connected according to approved drawings.

Each connection shall be verified and all safeties and sequences tested.

3. Controllers and PLCs shall be verified for the following:

a. Steady-state errors minimized for set points.

b. Responds with appropriate timing to disturbances.

c. Remains stable under all operating conditions.

4. Proportional, PI and PID controller tuning parameters shall be verified using ultimate oscillation or first-order-plus-dead-time.

1.08 ROLES AND RESPONSIBILITIES

A. Contractor

1. Ensure cooperation and participation of specialty sub-contractors.

2. Ensure participation of major equipment manufacturers in appropriate training and testing activities.

3. Attend Construction Phase coordination meetings.

4. Complete Commissioning Forms for all equipment.

5. Remedy any deficiencies identified in Commissioning Tests and notify COR in writing that deficiencies have been addressed.

6. Prepare preliminary schedule for inspection, SAT, Commissioning Tests, and update schedule as appropriate throughout the construction phase.

7. Provide a complete set of Final As-Built drawings to the COR.

PART 2 PRODUCTS

2.01 TEST EQUIPMENT

A. The Contractor(s) shall furnish all special tools and equipment required for testing and commissioning process. A list of all tools and equipment to be used during commissioning shall be submitted to the COR for approval. Government will furnish necessary utilities for the commissioning process.

B. Proprietary Test Equipment and software required by any equipment manufacturer for programming and/or start-up, whether specified or not, shall be provided by the manufacturer of the

Revised 26 08 00 - 6 equipment. Manufacturer shall provide the test equipment, demonstrate its use, and assist in the commissioning process as needed.

PART 3 EXECUTION

3.01 METHOD AND ACCEPTANCE

A. Provide skilled technicians to start-up and debug all systems. These same technicians shall be made available to assist the Government in completing the tests. Work schedules, time required for testing, etc., shall be requested by the Contractor. Ensure that the qualified technician(s) are available and present during the agreed upon schedules and of sufficient duration to complete the necessary tests, adjustments, and/or problem resolutions.

B. Provide templates of copies of each commissioning form that will be used to perform tests to the Government 7 days prior to construction progress meetings.

C. Commissioning forms shall be completed for each installation phase and each electrical equipment, system and subsystem in accordance with contract specifications.

1. Provide a description of the work completed since the last entry.

2. Provide the percentage of the total work completed for each electrical system and finalization.

3. Circle “YES” or “NO” for each commissioning form item. Should the information requested for a device or component not apply to the phase of installation for the system, list it as “N/A”.

4. Provide explanation for all discrepancies, critical responses or “N/A” responses.

5. Upon one hundred percent completion of each installation is finalized and responses are filled out, document the following:

a. Complete.

b. Initials.

c. Date timestamp.

D. Conform to FIST 3-1, FIST 3-3, FIST 3-8, NFPA 70, NETA ATS, IEEE C2, and IEEE 1248.

E. Government approval of commissioning dates is required prior to scheduling commissioning activities.

1. Notify COR in writing 28 days in advance of first commissioning activity.

2. Notify COR in writing 14 days in advance of each commissioning session.

F. Contractor shall have the following onsite at time tests and commissioning are performed:

Revised 26 08 00 - 7

1. Two sets of the Contractor’s Record Drawings full-size (ANSI D) electrical schematic and wiring diagrams with field markups for equipment being tested. Sets to be maintained by Contractor and used to produce final as-built drawings.

2. Operation and maintenance instruction books and test reports for equipment being tested.

3. Field copy of approved Commissioning Test Plan and Procedures.

G. Perform wiring checkout and operational and function testing in accordance with Section 26 05 90

– Wiring Checkout and Tests prior to commissioning.

H. Government may verify any tests or retest.

I. Government may perform additional tests prior to energizing equipment, including be not limited to:

1. Crane Motors commissioning tests.

2. Bridge Crane Electrical Components tests.

3. Distribution Panelboards tests

4. Automation Control System function testing.

5. PLC and HMI testing.

6. Operational testing of any furnished equipment.

J. Document changes and update Final and As-Built drawings in accordance with Section 01 78 30 – Project Record Documents.

3.02 SITE ACCEPTANCE TEST

A. The SAT shall be performed after the delivery and installation of equipment, system, and sub-systems at the site. The SAT is performed to demonstrate the proper functionality.

B. Pre-SAT Activities:

1. Prior to conducting the SAT the relevant hardware or software components shall be delivered to the site and properly installed. The following items shall be completed during the installation of the automation system/subsystem/components before the SAT can be carried out:

a. Hardware installation: all system components.

b. Grounding system installed for the relevant equipment or device being tested.

c. Review of software revisions, updates or modifications from FAT to date.

d. System or equipment energization.

e. Correct software or firmware installation.

C. Test Plan:

Revised 26 08 00 - 8

1. A written test plan and specification, developed and agreed to by owner and vendor in advance of testing, documenting:

a. The tests to be conducted to ensure the relevant systems meet technical, operational, and performance requirements,

b. The applicable acceptance criteria to be used for each test,

c. Safety instructions,

d. Necessary facilities/tools/hardware/software,

e. Necessary manpower and support personnel,

f. Who (owner or the vendor) is to perform each test.

2. The test plan shall address all of the following areas applicable to the specific project:

a. Overall scope of the tests, including hardware, software, configuration/programming and documentation.

b. Hardware, including installation, Check Prints, wiring/cabling, terminations.

c. Software, including the loaded custom configuration, programs and graphics.

d. FAT functional tests to be re-performed after installation.

e. Security of the plant SCADA network.

f. Tests to be performed after loop checks, such as interlock checks, complex functionality checks and sequence or batch checks.

D. Site Test Notification:

1. Government reserves the right to witness SAT. Notify Government at least 60 days in advance when tests are to be performed.

E. SAT Punch List

1. Reference to specification or SAT test plan requirement.

2. Description of the issue.

3. Person(s) responsible for resolution.

4. Description of the resolution and date completed.

5. Sign-off area for owner and the vendor for acceptance, if not recorded otherwise.

F. SAT Reports

1. Attendees.

2. Tests performed.

3. Results of all testing.

4. Open issues and agreements for resolution.

5. Acceptance as approved by COR.

Revised 26 08 00 - 9

6. Provided to Government within 21 days.

G. SAT Documentation

1. Copies of test plans.

2. Punch List with updated status of each item.

3. Documentation of hardware and software, including versions, tested.

4. Documentation of configurable parameters used.

5. Final complete system and application software.

3.03 COMMISSIONING

A. Work shall include, but not be limited to:

1. Crane motors, drives, automation control system, power distribution system, and control enclosures.

2. Operating breakers locally and remotely, confirming operation of protective relays, monitoring and alarm signals for proper operation, operating crane motors, variable frequency drives, operating switches and automation components to establish various crane configurations and operation of crane automation control system.

3. Date: After completion of Commissioning, and during a period of time agreed to by Contractor and COR.

a. During each test of electrical system and equipment, the contractor’s manufacturer’s expert will be onsite and complete the commissioning tests.

4. Furnish all materials, including test instruments beyond those furnished under these specifications that are required for commissioning tests.

5. Use electrical schematic and wiring diagrams from the Record Documents for that particular electrical system, to perform any additional internal wiring check of equipment and of external cabling.

6. Ensure there are no discrepancies in drawings, equipment or wiring.

7. When necessary, make final wiring changes, final adjustment settings, make equipment replacements, etc., required for proper functioning of installation to conform to requirements of specifications.

8. Re-examine and check all protective devices and sequence of operation of all controls for all electrical equipment for proper functioning and settings.

9. Provide drawings from the Record Documents (for that particular electrical system or sub-system) for use by Reclamation that show final electrical installation at time of examination;

and instruction books, test reports, coordination curves, and manufacturer’s data for electrical equipment installed.

10. While performing testing/commissioning, remove and replace wiring connections that may be required in processing of checkout; and make wiring changes, setting adjustments, Revised 26 08 00 - 10 equipment replacements, or other revisions which are necessary for proper functioning of installation.

11. Operational and Functional Testing:

a. If required, adjust and calibrate protective devices in accordance with specifications, and manufacturer’s instructions and recommendations.

b. Check electrical systems and controls for proper sequence of operation, correct adjustments and settings, and agreement with schematic diagram.

c. Testing, calibrating and programming shall be in conjunction with Government.

d. Deleted

12. Replace wiring, instruments, or equipment that is damaged during final testing/commissioning.

B. Complete all phases of work so the systems can be started, tested, balanced, and commissioning procedures undertaken. This includes the complete installation of all equipment, materials, conduits, duct, wire, insulation, controls, etc., per the contract specifications and related directives, clarifications, and change orders.

C. A Commissioning Plan shall be developed. The Contractor shall provide all necessary information pertaining to the actual equipment and installation. If contractor-initiated system changes have been made that alter the commissioning process, notify the COR.

D. Perform hot-phasing verification at various locations and stages of the process to verify proper operation and configuration of the system.

E. Document commissioning results on Government approved, Contractor supplied checklists and data logs.

F. Document changes and update operation and maintenance manuals to reflect final as-built conditions after commissioning.

G. Document changes to as-built schematic and wiring diagram drawings. If discrepancies are found in wire or cable tags, modify in accordance with Section 26 05 10 – Conductors and Cables and with approval from COR.

H. Contractor Lead Test Engineer:

1. Provide checklists and data logs for verification of test performed and passed.

2. Provide overall checklist and data log document.

3. Provide written procedures for testing and commissioning of Contractor provided equipment. Incorporate Manufacturer’s recommended tests into the procedures.

Government may dictate the order of the tests performed on equipment and systems.

4. Direct Contractor’s personnel to perform tasks as outlined in the commissioning procedures.

Revised 26 08 00 - 11

5. Communicate directly with the COR designated Lead Test Engineer during onsite commissioning.

I. Complete, as determined by the Government, all required Construction Testing prior to Pre- Checkout Tests.

J. Notify Government, of time for each SAT/commissioning for each system, sub-system, electrical equipment and components. This will allow Government to get the appropriate personnel onsite to witness each test.

K. Use electrical schematic and wiring diagrams from the Record Documents for that particular electrical system, to perform any additional internal wiring check of equipment and of external cabling.

L. Insure there are no discrepancies in drawings, equipment, or wiring.

M. When necessary, make final wiring changes, final adjustment settings, make equipment replacements, etc., required for proper functioning of installation to conform to requirements of specifications.

N. Assist Government with commissioning and operational commissioning.

1. Pre-Checkout Tests: Testing responsibilities for the Contractor shall be assigned in accordance with approved Test Plan and Procedure report.

2. Operational Commissioning: Offline and online testing responsibilities for the Government and the Contractor will be assigned in accordance with approved Test Plan and Procedure report.

O. Contractor shall perform test activities as required by the Government to verify proper operation after corrections have been made.

1. Any changes made including, but not limited to programming changes shall require re-testing of all impacted control logic functions, devices, components and associated equipment.

P. Performance:

1. Commissioning tests shall ensure that interconnected systems function together to demonstrate the crane control philosophy and contract specification requirements.

2. Verification of the communication and interaction between subsystems or with other systems to ensure desired functional performance.

3.04 BRIDGE CRANE ELECTRICAL COMPONENTS

A. Site Acceptance Testing

1. Perform SAT for control panel, including a functional test of all equipment and affiliated

I/O interfaced to the Automation Control System.

Revised 26 08 00 - 12

2. Full system test verifying functionality as outlined in Section 25 12 10 – Programmable Logic Controller.

3. Site acceptance testing in accordance with NETA ATS.

4. Site acceptance testing of unit shall be conducted after complete installation of equipment.

5. Site Test Procedures:

a. Following completion of Government inspection, a performance test shall be satisfactorily performed for each crane control system. One copy of all final crane drawings and a preliminary operation and maintenance manual shall be made available at the test site.

b. Verify that voltages at VFD locations are within 10 percent of motor nameplate rated voltages. If outside this range for any motor, notify the Government before starting the motors.

c. Test each motor for proper phase rotation.

d. Perform each electrical test and visual and mechanical inspection stated in NETA

ATS.

e. Perform the following infrared (thermographic) scan tests and prepare reports:

1) Perform infrared scan of each VFD. Remove front panels so joints and connections are accessible to scanner.

2) Instruments and Equipment: Use an infrared scanning device designed to measure temperature to detect significant deviations from normal values.

f. Test and adjust controls, monitoring and safeties. Replace damaged and malfunctioning controls and equipment.

g. Where applicable, test VFD operation with Hoist Motor under lightly loaded conditions, low-speed operation and high-impact load testing.

h. Test procedures shall define the tests required to ensure that the system meets technical, operational, and performance requirements.

i. Support personnel provided during testing shall be familiar with the project and be capable of fixing problems identified during testing.

j. Perform Site Acceptance Testing for PLCs and VFDs in accordance with requirements in ISA 62381.

k. Perform 100 percent I/O checkout.

l. Verify all validated software and hardware updates and patches are installed prior to start of functional testing.

m. Test procedures shall define location of tests, milestones for the tests, and identify simulation programs, equipment, personnel, and supplies required.

1) Any simulation programs, equipment, personnel, and supplies required shall be provided by the Contractor.

Revised 26 08 00 - 13

n. Provide test procedures for testing all process control system capabilities and functions specified.

o. Test Procedures shall cover actual equipment and sequences to be used for the specified project and include detailed instructions for test setup, execution, and evaluation of test results.

6. Conduct testing for acceptance after the erection work has completed.

7. Allow inspection of all parts of the crane containing electrical parts or moving mechanical parts.

8. Site Acceptance Test Reports:

a. With test results, include final calibrated engineering unit values and corresponding amperage for each endpoint of calibrated analog devices.

9. Perform field wiring checkout and test in accordance with Section 26 05 90 – Wiring Checkout and Tests.

10. Motor controllers and VFD shall be tested in accordance with IEEE 115, UL 508 and UL 60947-4-1:

a. Vacuum-break controllers:

1) Temperature-rise limits.

2) Dielectric properties tests.

3) Rated making and breaking capacity.

4) Endurance performance test.

5) Performance under short-circuit conditions.

6) Terminal performance test.

7) Short-time operating capability

8) Operation and operating limit tests.

9) Tests to be performed in accordance with NEMA ICS 2.9.

11. Acceptance Testing Preparation:

a. Test insulation resistance for each VFD element, bus, component, supply, feeder and control circuit.

b. Test continuity of each circuit.

12. Contractor’s Self-Test:

a. The Contractor, at the Contractor’s facility prior to Government witnessed factory acceptance test, shall test each major component. Testing and inspection shall include motors, motor controls, brakes, lights, speeds, limit switches, interlocks and wiring. Operationally test all drives. Once tests are completed, the Contractor shall notify the COR to schedule the Government representative witnessed factory acceptance test.

Revised 26 08 00 - 14

b. Test insulation resistance for each VFD element, component, motor supply and control circuits.

13. Inspections:

a. All test deficient items shall be resolved prior to shipment of the crane. The government reserves the right to inspect all equipment and Contractor’s corrective actions performed.

b. The Contractor shall perform an inspection and complete no load operational tests.

The Contractor shall ensure the crane controls meets this specification and systems are properly adjusted, operational and can be safely load tested.

c. Inspect VFD, wiring, components, connections and equipment installation. Test and adjust controllers, devices and equipment.

d. The Failure of the crane to pass any of the inspections shall be cause for rejection.

B. Commissioning

1. Program microprocessors and variable frequency drives for required operational sequences, status indications, alarms, event recording and display features. Clear events memory after final acceptance testing and commissioning tests.

2. Set field-adjustable switches, auxiliary relays, time-delay relays, timers, and overload-relay pickup and trip ranges.

3. Adjust the trip settings of thermal-magnetic circuit breakers with adjustable, instantaneous trip elements. Initially adjust to six times the motor nameplate full-load amperes and attempt to start motors several times, allowing for motor cool-down between starts. If tripping occurs on motor inrush, adjust settings in increments until motors start without tripping. Do not exceed eight times the motor full-load amperes. Where these maximum settings do not allow for starting of a motor, notify Government.

4. Performance Test with Characteristic Curve:

a. Test with 110 percent of the hoist capacity load.

b. Submit certificate of load test and compliance with OSHA requirements.

5. No Load Free Run Test.

6. Static and Dynamic Balancing Test.

7. Contractor is responsible for utilizing the ECF verification checklists supplied under Section

26 08 00 – Commissioning of Electrical Equipment in accordance with the procedures defined.

8. Government will review Contractor’s test reports and if found acceptable will respond accordingly. Refer to Section 01 46 00 – Quality Procedures.

3.05 DISTRIBUTION PANELBOARDS

A. Site Acceptance Testing

Revised 26 08 00 - 15

1. Perform panelboards continuity and insulation tests after installation and before the panelboard is energized.

a. Continuity tests using a DC device with buzzer.

b. Insulation test using a 500-volt minimum insulation-resistance test set.

1) Record readings after 1 minute and until readings are constant for 15 seconds.

2) Resistance between phase conductors and between phase conductors and ground shall be not less than 25 megohms.

c. Record test data. Include identification of panelboard and megohms readings verses time.

B. Commissioning

1. Adjust the trip settings of thermal-magnetic circuit breakers with adjustable, instantaneous trip elements. Initially adjust to six times the motor nameplate full-load amperes and attempt to start motors several times, allowing for motor cool-down between starts. If tripping occurs on motor inrush, adjust settings in increments until motors start without tripping. Do not exceed eight times the motor full-load amperes. Where these maximum settings do not allow for starting of a motor, notify Government.

3.06 SURGE PROTECTION DEVICES FOR ELECTRICAL CIRCUITS

A. Site Acceptance Testing

1. Contractor shall not perform insulation resistance tests with SPDs connected. Disconnect

SPDs before conducting test, and reconnect immediately after tests are complete.

2. General:

a. Perform SAT in accordance with manufacturer’s recommendations. In addition, include the following:

1) Visual Inspection and Tests:

a) Compare equipment nameplate data with specifications and approved drawings.

b) Verify that disconnecting means and feeder size and maximum length to SPD corresponds to approved drawings.

c) Verify tightness of accessible bolted electrical connections via calibrated torque-wrench.

d) Vacuum-clean enclosure interior.

e) Verify the correct operation of all sensing devices, alarm outputs and status indicators.

b. Wiring checkout and tests in accordance with Section 26 05 90 – Wiring Checkout and Tests.

Revised 26 08 00 - 16

c. Site acceptance testing in accordance with IEEE C62.34 and IEEE C62.62.

d. Site acceptance testing of unit shall be conducted after complete installation of equipment.

3.07 RACEWAYS AND BOXES

A. Site Acceptance Testing

1. After delivery, with Contracting Officer witness:

a. Inspect physical and mechanical condition.

b. Verify conduit types, sizes and quantities match approved data.

2. Acceptance at discretion of Contracting Officer.

3.08 CONDUCTORS AND CABLES

A. Commissioning:

1. Demonstrate continuity and proper function of field devices and systems impacted by the removal and installation of cables and conductors.

3.09 AUTOMATION CONTROL SYSTEM

A. Site Acceptance Testing:

1. Government will witness test. Notify COR in writing at least 28 days prior to test.

2. SAT shall be completed concurrently and in accordance with requirements outlined in

Section 41 22 15 – Bridge Crane Electrical Components, Section 25 12 10 – Programmable Logic Controller and as specified herein.

3. Demonstrate the functionality, performance and stability of the hardware and software before turning over the system.

4. A witnessed Site Acceptance Test shall be performed on the completed Automation Control System.

a. The System Integrator standard test forms shall be submitted for review by the

Government, including complete test procedure and forms.

b. Each feature and function of the control system shall be documented on the test forms and shall be tested and demonstrated to the satisfaction of the Government.

All revisions made to the crane control system operation shall be approved by the Government prior to final acceptance.

c. The testing program shall be conducted in accordance with the prior approved procedures and shall be witnessed and signed off by both the System Integrator and COR upon satisfactory completion.

5. All special testing materials and equipment required to demonstrate compliance with the specification shall be provided under the scope of this Section. Where it is not practical to

Revised 26 08 00 - 17 test with real process variables, provide suitable means of simulation. These simulation techniques shall be subject to the approval of the COR.

6. Coordinate all testing with other associated suppliers and subcontractors.

7. The Government will furnish a discrepancy list to the Contractor 45 days after the test.

8. Contractor shall resolve discrepancy, deliver required documentation and complete other contract requirements associated with the equipment.

9. Perform bench and throughput testing of all installed systems and equipment.

10. Perform field wiring checkout and functional test in accordance with Section 26 05 90 –

Wiring Checkout and Tests.

11. Communication Links:

a. Verify communication links between devices.

B. Commissioning:

1. Commissioning tests shall be completed concurrently and in accordance with requirements outlined in Section 41 22 15 – Bridge Crane Electrical Components, Section 25 12 10 – Programmable Logic Controller and as specified herein.

2. Commissioning testing shall be a joint effort between the Contractor and Government personnel.

a. Contractor to verify that commissioning tests are sufficient to safely and adequately test the new panels and automation controls.

b. Contractor to suggest modifications to test routines or additional test routines based on contractor’s experience.

c. Provide field service engineer for testing; and to make programming adjustments and modifications, wiring changes, and equipment or device replacements required for successful commissioning of new equipment.

d. Provide 30 days notice prior to beginning commissioning tests.

e. Commissioning test duration will not exceed 28 calendar days for the first crane and

14 calendar days for the subsequent units.

f. Government will provide Job Hazard Analysis.

g. Contractor will provide commissioning test procedure.

3. Contractor to demonstrate that the system was fully tested during assembly and installation and is a functioning, integrated and reliable control system.

4. Provide crane operators with initial system training.

a. Purpose: Instruct operators in the basic knowledge needed to operate the equipment during the time period following commissioning and before the formal training session takes place.

b. Demonstrate operational sequences and answer questions about the new equipment.

Revised 26 08 00 - 18

c. Ensure operators are familiar and comfortable with standard operational sequences.

d. Provide written operations checklists and or procedures as necessary.

e. Verify completion of this testing with the COR.

5. Document changes and update Government copies of operation and maintenance manuals and software to reflect final as-left conditions after commissioning.

6. Submit completed, signed and approved Electrical Commissioning Forms to the COR and Reclamation.

7. The Government and COR will provide written acceptance after commissioning testing, Electrical Commissioning Forms submitted, and all discrepancies have been resolved.

8. Provide labor for adjustments and modifications during commissioning tests.

9. Demonstrate continuity and proper function of field devices and systems impacted.

10. Demonstrate operation of graphic displays and HMIs.

11. Check process timing sequences and make adjustments where necessary to improve systems operation.

12. Adjust logic, settings, and HMIs.

13. Verify logic and operation of the system.

END OF SECTION