TESTING

Field Quality Control

All costs for performing operational demonstrations and system validation tests shall be included in the Contract Rates, and no extra payment will be made to the Contractor on account of overtime, weekend, or holiday labour costs required to perform and complete the demonstrations and validation tests. Requirements specified in this Section are in addition to the demonstration and test requirements specified under other Sections of the Specification.


Operational Demonstrations and Systems Validation Testing

Testing shall be performed by the Contractor in accordance with the approved procedure plans to demonstrate to the Engineers satisfaction that:

All components of the process systems defined herein, the complete systems, and the new plant systems are fully completed and operatable.

All units, components, systems, and the entire plant systems operate with the efficiency, repeatability, and accuracy indicated and specified; and

All components, systems, and the entire plant conform to the Contract Documents and the approved Shop/ Construction Drawings, samples, construction manuals, material lists, and other approved submittals.

Scope of Operational Demonstrations and Systems Validation Testing

System validation tests are required for all mechanical and electrical equipment, and systems specified including all associated and related electrical systems and control devices specified and instrumentation and control systems specified except the Building Plumbing shall be tested as specified in the relevant Sections.

Works to be operationally demonstrated are defined as individual equipment items such as pumps, aerators, scrapers, mixer, etc. and all similar equipment items. Demonstrations shall be performed simultaneously on groups of identical equipment items and groups of items supplied by one manufacturer to the extent feasible.

Systems to be validation tested are defined as complete systems that perform a discrete process function of the plant such as primary clarification system, secondary clarification system, sludge recycling system, pumping systems, emergency power system, and similar systems. Each system shall include associated structures, tanks, piping, utilities, instrumentation and controls, and like related items. Two or more separate systems shall be validation tested simultaneously when necessary to validate an entire discrete plant function.

Operational demonstrations and validation testing shall not commence for any equipment item or system until all related structures, piping, electrical, instrumentation, control, and like work have been installed, tested and connected in compliance with the pertaining requirements specified elsewhere in the Specification.

Fresh potable water shall be used to fill tanks, wells, piping, and systems that contain water or sludge for normal operation. The specified chemicals shall be used for chemical systems but do not exceed in service concentrations. All temporary facilities, storage, and similar facilities shall be furnished. Use procedures that conserve testing materials and avoid wastage, especially with respect to large quantities of fresh water and electrical power.

Operational demonstrations and system validation testing shall be performed under continuous inspection by the Engineer. Technical representatives of the various equipment manufacturers shall be present at the start of the operational demonstration, shall examine their equipment at least twice near the beginning and end of the validation tests, shall supervise the start-up and adjustment procedures, and shall perform all other services necessary for the manufacturer's certified reports required herein.

All defects and malfunctions disclosed by demonstrations and validation tests shall be immediately corrected using approved methods and new materials for repairs as required. Interruption time necessary for corrective work shall be added to the specified total demonstration and validation test periods.

Satisfactory completion and approval of required operational demonstrations and system validation testing is one of the conditions precedents to the Engineer's acceptance of the work and does not constitute final acceptance.

Operational Demonstrations

The performance of installed equipment shall be demonstrated that it complies with all requirements indicated and specified. Equipment items shall be operated through entire no-load to full-load range in accordance with the approved procedure plan for not less than 24 consecutive hours, unless a longer period is specified under other Sections.

Commissioning and System Validation Tests

Plant shall be commissioned with potable water and the Contractor shall supervise the working of the Plant for system validation tests and shall during that period provide all necessary engineering and technical supervision continuously to effect any adjustment that may be necessary. Perform validation testing in accordance with the approved procedure plan.

Each system shall be tested, including standby systems, by continuous operation in “in-service” condition for not less than 168 consecutive hours, with no interruptions except for normal maintenance or corrective work. Where the “in-service” condition is an automatically controlled repeat cycle with on/off intervals, it shall be so operated.

Systems shall be operated continuously 24 hours a day under constant inspection of trained operators. System operation shall be cycled from full load to light load and back to full load each 24 hours. Variable speed equipment shall cycle through the applicable speed range at a steady rate of change. Simulated alarm and distressed operating conditions shall be induced and test controls and protective devices tested for correct operation in adjusting system functions or causing system shutdown.

Subject to Contractor's request and Engineer’s approval in each case, Contractor may simulate certain operating conditions relating to flow rates, water levels, and malfunctions. Permission for simulations will be granted only where it is unwise or impossible to obtain the conditions covered by the capability of ranges or equipment. The simulation methods shall reflect reasonable anticipated operating conditions.

When the whole of the Works has been run under the supervision of the Contractor for validation tests to the complete satisfaction of the Engineer without interruption (for 3 months) and the Engineer shall have so certified in writing then the Contractor may apply for PAC of the Works in accordance with the Conditions of Contract.

Ranges for Testing

Flow metering systems shall be tested at not less than 3 values corresponding approximately to minimum, average and maximum capacity, respectively.

Variable speed equipment shall demonstrate accurate response to speed controlling devices and controls within the required operating ranges. Actual output shaft speeds of manually adjustable speed equipment shall be validated by measurement of shaft speeds versus speeds shown by equipment instruments.

Automatic Response of Equipment

Response of equipment to appropriate manual or automatic controls, or combinations of both automatic and manual controls, shall be demonstrated to be correct and accurate. Where applicable, all components shall be tested for both manual and automatic operation. Where a component performs more than one function shall be validated.

Pumping equipment shall respond accurately and reliably to liquid level and flow rate signals from appurtenant basins, sumps, or wet wells. Automatic alteration and backup pump functions shall also be validated.

Chemical feed systems where so designed shall respond accurately to flow signals and feed proportionally over the ranges of process flows to be validated.

Ventilation systems and air compressors shall respond accurately, smoothly and reliably to control signals, where applicable.

Recording of Data

Neat and comprehensive records of each operational demonstration and system validation test shall be maintained by the Contractor. Each portion of the demonstration or validation procedure shall be described with all components itemized. Records shall be prepared on forms in a step-by-step fashion paralleling the approved procedure plans. Forms shall list for the following:

a) Step taken;
b) Result anticipated;
c) Result obtained;
d) If incorrect, corrective action taken; and
e) Retest result;
f) Steps (d) and (c) shall be repeated until all systems operate as required.

Instruments, gauges, and other sensors and display devices forming a part of the various systems shall be employed for data acquisition to the extent applicable. Contractor shall furnish all other instruments, gauges, recorders, and test devices as required of the types conforming to the approved procedure plans.

All applicable data such as, but not limited to water and other liquid levels, flows, pressure, head differentials, duration of runs, instrument readings, chemical feed rates, voltage settings, drive speeds, motor running currents, voltages, pressure, clarity and related information, as applicable, and in accordance with the approved procedure plans, shall be recorded at the start and finish of each operational demonstration and at maximum 8 hours intervals during system validation tests, unless shorter intervals are specified elsewhere.
When a repeat of the same demonstration or validation test is required to verify the results, the repeat procedure shall be indicated on the recorded data by numerical indication, date, and time