When is it acceptable to use Manufacturing Quality Control ...

When is it acceptable to use Manufacturing Quality Control Testing as Commissioning Acceptance Testing

Jaime Olivas – Page/ Olivas Consulting LLC.

AIA Quality Assurance

The Building Commissioning Association is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit(s) earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of the Completion for both AIA members and non-AIA members are available upon request.

This program is registered with AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.

Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

BCxA Conference – Chicagoland, IL – 2019 2

Learning Objectives

BCxA Annual Conference – Chicagoland, IL – September 2019 3

• How to select Electrical Equipment for Testing which is applicable to each project.

• Evaluate if Factory Testing is worth duplicating in Field or Site and Justify why some electrical field tests should be tested.

• How to determine effective Electrical Equipment testing results• Evaluate which field tests may be required to satisfy requirements

dictated by the Authority Having Jurisdiction (AHJ) and level of documentation required by the entity.

Six-Story Building In Malabo Equatorial Guinea - Issue


Equatorial Guinea Africa - Location


Fire Pump Issue (Malabo, Equatorial Guinea) (Africa)


• Fire Pump was tested by Manufacturer at Plant in the US• Fire Pump placard indicating pump starting method is provided with motor winding

connection diagram

Fire Pump Issue (Continued)


• Fire Pump Burned Up after being commissioned two weeks earlier.• Manufacturer stated they had wound and wired pump correctly, The

Installing Contractor sent connection pictures to manufacturers showing they had connected per their requirements.

Fire Pump Issue (Continued)


• It was determined by the manufacturer that the Fire Pump windings were must have been defective and they might have been affected by humidity

• Manufacturer stated they would cover Fire Pump under Warranty and would ship a new Fire Pump to Site

• Manufacturer found a Company in nearby in Cameroon to rewind motor for temporary use (3 months) until new fire Pump arrived, At owners expense.

Selecting Electrical Equipment For Testing


I have been involved in Electrical Commissioning since 2001, when It comes to Electrical Commissioning most projects call for electrical testing to be done per NETA Standards. Each Specification Section will have verbiage as to what NETA test are to be conducted.

How to Select Electrical Equipment Testing


• The typical project Electrical Specifications call for testing to be conducted per NETA Standards. Shown is a copy of a UPS specification Calling for NETA Tests

Electrical UnInterruptible Power Supply Specification

NETA TESTING


• NETA (interNational Electrical Testing Association) along with ANSI (American National Standards Institute) have published a standard, Acceptance Testing Specifications for Electrical Power Equipment and Systems (ATS), with the latest version published 2017

• The Electrical Commissioning Industry has adopted the NETA requirements for Electrical Testing as a Standard for Electrical Equipment Commissioning Acceptance requirements.

• Therefore when it comes to Electrical Commissioning of electrical power equipment, NETA testing requirements are conducted, documented and results are included in the final Commissioning Report.

Selecting Electrical Equipment to be Commissioned


• Owners rely on Commissioning Providers to be their experts to ensure components and systems work as designed. In some instances, they will look at saving costs and only require critical equipment to be tested.

• Typical Equipment Systems that should be electrically commissioned include: Power Distribution Systems; Switchgear/Switchboard, Transformers and Distribution

Panelboards Emergency Distribution Systems; Generators, Transfer Switches, Transformers and

Panelboards Lighting Control Systems and Fire Alarm Systems UPS Systems, Elevator Systems, Fire Pump Systems, Nurse Call Systems

Selecting Electrical Equipment to be CommissionedPower Distribution Systems


Switchgear/SwitchboardTransformers Distribution Panelboards

Selecting Electrical Equipment to be CommissionedEmergency Distribution Systems


Generators Transformers and PanelboardsTransfer Switches

Selecting Electrical Equipment to be CommissionedAdditional Systems


Systems Shown in previous slides and this slide are the Recommended Minimum Electrical Commissioning for New Facilities

Lighting Control Systems – IECC 2015 / LEED Fire Alarm Systems

Selecting Electrical Equipment to be CommissionedOther Systems


UPS Systems (Data Center and IT Facility Application) Associated Battery Systems

Selecting Electrical Equipment to be CommissionedOther Systems


Elevator Systems Fire Pump Systems

Questions


Now that we have covered Selecting Electrical Equipment to commission,This leads to the following questions:

• When is it acceptable to use the Manufacturing Quality Control Testing as Acceptance Testing?

• Can these QA/QC documents be used to satisfy specifications and NETA test requirements for commissioning?


Pentagon Unitized Switchboard Issue

Pentagon Renovation Team Project Project Phoenix Requirements



• 480V Panelboard with Stepdown Transformer and 208V Panelboard in one Enclosure

• Manufacturer stated they provided the equipment on site with all required documentation.

• Included the complete QA/QC documentation of all testing completed on equipment at manufacturing Plant. (QA/QC Process was extensive)

• Electrical Specifications Called for NETA Testing on this Equipment



• Contractor installed Conductors into 480 Volt Panel provided with Switchboard• Commissioning Provider stated NETA ATS called for separate Testing of 480V

Panelboard, Stepdown Transformer and 208V Panelboard. To be documented by NETA Testing Company.

• Manufacturer stated that if Enclosure was removed and anyone touched the inside of the equipment the warranty would be voided



• This caused and issue for Cx Provider, Specifications called for NETA testing and documentation

• If Cx Provider were to accept Manufacturers Documentation as substitute for NETA requirements this would mean accepting that nothing happened to equipment during transportation from Plant to Site

• Owners representative was advise by Cx Provider that it would be a decision of the Owner to accept documentation but Cx provider recommended testing on site


Pentagon Unitized Switchboard Issue - Resolution• Owner’s Rep. pushed back on the manufacturer to stand by their warranty as NETA

testing was a requirement of the specifications• If your QA/QC process is so great they should not have any issue proving their results• If they didn’t accept this field testing requirement, He would send their equipment back

(60 Units ordered)• The manufacturer relented and equipment was allowed to be field tested on site


Pentagon Network Transformer Issue - Resolution• Network Transformer were on Site for 6 months before being energized • Cx Provider felt Transformer Oil may be compromised or may have too much water from

condensation due to location where transformers had been stored before being installed• Manufacturer stated they had provided Transformer documentation of factory testing• Manufacturer assured Owner they would honor any warranties if transformers were

defective in any way• Cx Provider used Manufacturer provided documentation for Transformer Testing


Common Factory Testing Duplicated on Site

• Usually Provided with detailed Factory QA/QC Documentation • Also Provided with On Site Installation Testing • Many specifications include Factory Acceptance Testing (FAT) which can be witnessed by the Cx

Provider and/or Engineer.

Generators


Common Factory Testing Duplicated on Site

• Single Unit Generators load bank testing on site can be a great way to take advantage of Cx cost Savings by having Cx Provider witness and document Installing Contractor Load Bank testing

• Parallel Generator systems may also offer some cost savings if Cx Provider can witness load sharing functions and if there is no requirement to use building load for such testing

Generators


Common Factory Testing Duplicated On Site

• Enclosure Sound Rating Testing – At Manufacturing Plant• Enclosure Installation Site Testing• FAT Testing should replicate site installations as much as possible

Generators



• Generators are usually tested thoroughly at the Factory as a requirement of the specifications. • FAT Test results take on a big role in satisfying specifications requirements and proving the system

provided meets are requirements. FAT testing should be coordinated with final design

Generators



• The Generator installer has a typical Generator Installation Checklist that is completed and included with documentation

• Generator Checklist can be included into Generator Functional Test Scripts.



• Usually Provided with detailed Factory QA/QC Documentation• Usually Provided with On Site Installation Testing (Check Specification)

UnInterruptible Power Supplies (UPS)



• Usually require Load banks to test how Step Loads affect UPS in regards to Harmonic Distortion (THD)• Usually require capturing in Waveform any transients or excursions from rated values




• Manufacturer usually provides documentation of specific test required by specifications• Manufacturer uses Load banks to conduct any Step load testing requirements• UPS Installer provides on site Load bank testing (Only if specified in specifications)



Uninterruptible Power Supplies (Power Quality Meter)

• Specification test requirements for UPS usually involve capturing waveforms down to the millisecond level to identify any transients introduced during step loading of the UPS

• Theses test require the use of Power Quality Meters (PQM), they are critical in capturing transients and Harmonic distortion as a requirement of the specifications

Fluke 435 Dranetz PX5

• Waveform Capture of UPS under No Load (Part of Start Up Documentation)BCxA Annual Conference – Chicagoland, IL – September 2019 34

Waveform Capture (Information)

UPS Manufacturer Start-Up

• Waveform Capture of UPS at Full Load - Block Load (Field Testing Documentation)BCxA Annual Conference – Chicagoland, IL – September 2019 35

Waveform Capture (Information)

Field Cx Testing No effect on voltage


Effective Test Results

• Testing Results are the most important documents when commissioning Electrical Equipment• Properly documented Electrical Equipment Test results are vital documents for creation of Final Cx

Report• These Tests will be used to establish a baseline for developing a Maintenance Program for

Facilities


Effective Test Results

Reports Required Recommended

List of Typical Electrical Documents included in a Final Electrical Commissioning Report:

Conductor Megger Test Report XCircuit Breaker Test Report Above 200 AmpsTransformer Test Report XPanelboard Test Report XSwitchgear/Switchboard Test Report XTransfer Switch Test Report NFPAGenerator Test Report

Uninterruptible Power Supply Test Report XNFPA

Fire Alarm Test Report NFPASecurity System Test Report XNurse Call System Test Report (Hospitals) FGIReceptacle Test Report (Hospitals) NFPA 99 6.3.3.2Elevator Test Report AHJFire Pump Test Report NFPA

NFPASmoke Pressurization Test Report

• Typical Tests that involve an (AHJ) include equipment such as Elevator/Escalator Testing, Fire Alarm Testing and Smoke Pressurization Testing

• Usually require that the Cx Provider document the test results while the AHJ physically conducts the functional testing.


Field Reports for Authority Having Jurisdiction (AHJ)

• One of the biggest issues in commissioning these systems is that the Cx Provider must coordinate with the AHJ to make sure that the functional tests include all items required by the AHJ.

• Elevator Installer use Elevator Inspection Checklist to document activities conducted during installation of elevatorBCxA Annual Conference – Chicagoland, IL – September 2019 39




• Four areas of Elevator testing that are usually separated by AHJ• Hoist Way Checks – Elevator Pits, Hoistway Safety Stops• Lobby Checks – Elevator Recall Functions• Cab Load Checks – Weight Verifications• Equipment Room Checks – Fire Detection and Elevator Shunt Trip



• Functional Test Scripts can be draft versions up until the actual testing occurs• Additional tests not included in the Functional Test Scripts must be added to Final test script for

inclusion into the final Commissioning Report• These same scripts can be conducted by AHJ and Maintenance Staff in subsequent years

Jaime Olivas [email protected](651) 783-2688

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Thank You for Your Time and Attention

Any Questions?

When is it acceptable to use Manufacturing Quality Control ...

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