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Testing and Commissioning Procedure: 2017 EDITION
Testing and Commissioning Procedure: 2017 EDITION
FOR
IN
GOVERNMENT BUILDINGS
OF
2017 EDITION
This Testing and Commissioning (T&C) Procedure aims to lay down the minimum
testing and commissioning requirements to be carried out on Emergency Generator
Installation in Government Buildings of the Hong Kong Special Administrative Region
(HKSAR). Such requirements are applicable to both new installations upon completion and
existing ones after major alteration.
The present edition was developed from the 2012 edition by the Mechanical
Installation Specialist Support Group that was established under the Building Services
Branch Technical Information and Research & Development Committee of the
Architectural Services Department (ArchSD). This T&C Procedure has incorporated the
latest changes in the 2017 edition of the General Specification for Electrical Installation.
The ArchSD welcomes comments on this T&C Procedure at any time since the
updating of this T&C Procedure is a continuous process to tie in with technological
advances.
DISCLAIMER
This T&C Procedure is solely compiled for use on Emergency Generator Installation
carried out for or on behalf of the ArchSD in Government buildings of the HKSAR.
1. Introduction 1
Annex
Annex Page
Annex I Testing and Commissioning Progress Chart for Emergency 1-2
Generator Installation
Part 2 : Declaration
1. Introduction
The procedures stated in this Testing and Commissioning (T&C) Procedure cover the
activities in preliminary tests and inspections, functional performance tests and the
commissioning of newly completed Installations and existing ones after major
alteration. They are so compiled to facilitate the work of Project Building Services
Engineer (PBSE) / Project Electrical and Mechanical Engineer (PEME) and Project
Building Services Inspector (PBSI) / Project Electrical and Mechanical Inspector
(PEMI), who are appointed as the Supervising Officer’s Representatives, in the
following aspects with respect to testing and commissioning :
(a) to vet and approve the T&C procedures proposed and submitted by the
contractor for the Emergency Generator Installation (GE Contractor);
(b) to witness those T&C procedures as specified; and
(c) to accept the T&C certificates and other supporting data.
The GE Contractor shall carry out the T&C works as detailed in this T&C Procedure.
Supplementary T&C plans may be proposed by the GE Contractor as appropriate and
agreed by PBSE/PEME, e.g. for special equipment supplied and/or installed by the GE
Contractor.
The administrative requirements for T&C works are in general as specified in the
General Specification for Electrical Installation 2017 Edition and all current
corrigenda/amendments thereto published before the date of first tender invitation for
the Contract issued by the ArchSD (the General Specification).
All words and expressions shall have the meaning as assigned to them under the General
Specification unless otherwise specified herein.
GE_TCP
Page 1 of 4 2017 Edition
3. Scope of the Testing and Commissioning Works
The purpose of these tests is to ensure that all components and systems are in a
satisfactory and safe condition before start up. Preliminary adjustment and setting of
equipment at this stage shall also be carried out at the same time to pave way for the
coming functional performance tests.
Before carrying out any test, the GE Contractor shall ensure that the Installations
comply with all relevant statutory requirements and regulations. The T&C works shall
also comply with all site safety regulatory requirements currently in force. In particular,
the GE Contractor shall note the following:
The purpose of functional performance tests is to demonstrate that the Installations can
meet the functional and performance requirements as specified in the Specification.
Functional performance tests should proceed from the testing of individual components
to the testing of different systems in the Installations.
The GE Contractor may have to make temporary modifications as the tests proceed.
The specific tests required and the order of tests will vary depending on the type and size
of systems, number of systems, sequence of construction, interface with other
installations, relationship with the building elements and other specific requirements as
indicated in the Specification. The testing of systems may have to be carried out in
stages depending on the progress of work or as proposed by the GE Contractor.
Part of the tests may be required to be carried out in suppliers’ premises in accordance
with the provisions in the Specification.
GE_TCP
Page 2 of 4 2017 Edition
Any performance deficiencies revealed during the functional performance tests must be
evaluated to determine the cause. After completion of the necessary corrective
measures, the GE Contractor shall repeat the tests.
If any test cannot be completed because of circumstances that are beyond the control of
the GE Contractor, it shall be properly documented and reported to the PBSE/PEME,
who shall then liaise with the relevant parties to resolve the situation. The GE
Contractor shall resume his testing work immediately upon the attainment of a suitable
testing environment.
The GE Contractor shall carry out tests for the Installations to meet statutory requirements
as specified in the Specification. After the proper testing and commissioning of the
Installations, the GE Contractor shall notify the appropriate authority as specified in the
Specification, through the PBSE/PEME of the completion of the Installations and its
readiness for inspection and testing. The GE Contractor shall arrange for the necessary
inspections and tests as required by the Authority.
The GE Contractor shall submit his proposed T&C procedures together with the Testing
and Commissioning Progress Chart shown in Annex I to PBSE/PEME for approval.
All inspection and T&C results shall be recorded by the GE Contractor in the
appropriate test record forms . A complete set of these forms can be found in Annex II.
Data recorded in other formats may also be acceptable subject to prior approval of the
PBSE/PEME. Upon completion of all the required T&C works, the GE Contractor shall
complete and sign a testing and commissioning certificate as shown Annex II to the
effect that the agreed T&C works have been duly carried out.
A functional performance test report covering all measured data, data sheets, and a
comprehensive summary describing the operation of the system at the time of the
functional performance tests shall be prepared and submitted to the PBSE/PEME.
Deviations in performance from the Specification or the design intent should be
recorded, with a description and analysis included.
Where required in the Specification, the GE Contractor shall conduct a final evaluation
of the performance of the Installations, the results of which shall be included in the
commissioning report.
GE_TCP
Page 3 of 4 2017 Edition
3.5.2 Tests for Specific Facilities or Devices
Tests for specific facilities or devices that are installed in the Installations, such
as Catalytic Converter.
GE_TCP
Page 4 of 4 2017 Edition
Annex I
Contract Title :
Name of GE Contractor/Sub-contractor :
Testing and Commissioning Progress Chart for Emergency Generator Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)
Activities Reference S A S A S A S A S A S A S A S A
to
Annex II
3.1,
1. Visual Inspections
3.2&3.3
U/G Fuel Oil Tank
Services Tank
Pipeworks
Generator Set
Battery
Cooling System
Exhaust System
Submission of
Record of Test
2. Pre-commissioning 3.4
Inspection
Submission of
Record of Test
3. Insulation 3.5 & 4.1.3
Resistance Test
Submission of
Record of Test
4. Control Functional 3.5 & 4.1.4
Test
Submission of
Record of Test
Annex I GE_TCP
Page 1 of 2 2017 Edition
Annex I
Testing and Commissioning Progress Chart for Emergency Generator Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)
Activities Reference S A S A S A S A S A S A S A S A
to
Annex II
3.5 &
5. Dummy Load Test
4.1.5
Submission of
Record of Test
Earth Protection 3.5 &
6.
Test 4.1.6
Submission of
Record of Test
Submission of T&C
7.
Certificate
Notes
* Delete if not applicable
(1) Insert revision no.
(2) Insert additional columns as necessary
S - schedule % completion
A - actual % completion
Annex I GE_TCP
Page 2 of 2 2017 Edition
Annex II
Testing and Commissioning Certificate on
Emergency Generator Installation
Part 1: Details of Project
Part 2: Declaration
2.2 I also certify that site tests have been performed in accordance with the
requirements set in this T&C Procedure and that the results are satisfactory. A
record of the tests has been prepared and submitted to the PBSE/PEME.
_____________________________________ __________________________________________
_____________________________________ __________________________________________
_____________________________________ __________________________________________
Notes:
1. T&C Procedure refers to the Testing and Commissioning Procedure for Emergency Generator Installation.
2. The GE Contractor’s Representative signing this Certificate must be a person or representative authorised by
the GE Contractor.
* Delete if not applicable
Annex II GE_TCP
Page 1 of 14 2017 Edition
Annex II
Part 3: Items Inspected and Tested
Item tested/ Items witnessed
checked by by PBSE/PEME/
GE Contractor PBSI/PEMI
3.1.1 The welding has been examined and the effectiveness of the welding *Yes/No *Yes/No
and standard of workmanship is satisfactory.
3.1.2 The metal surface has been properly prepared in accordance with the *Yes/No *Yes/No
specification.
3.1.3 The manufacturer’s application procedure for the primer has been *Yes/No *Yes/No
followed and the type of primer, the number of coatings is in
accordance with the specification.
The underground tank has been subjected to hydraulic test to a *Yes/No *Yes/No
3.1.4 pressure as specified and the results are satisfactory.
3.1.5 The size and structure are correct in accordance with the approved *Yes/No *Yes/No
plans.
3.1.6 The fuel tank has been mounted securely to the concrete plinth in *Yes/No *Yes/No
accordance with the approved plans.
3.1.7 The pipework from the fuel pump to the underground tank is of *Yes/No *Yes/No
proper fall to prevent airlock.
3.1.8 Vent pipe is of proper size and arranged at proper location in *Yes/No *Yes/No
accordance with the approved drawing.
.
3.1.9 Underground fuel tank chamber is water proofed and back filled with *Yes/No *Yes/No
dry sand.
3.1.10 Underground and buried fuel pipes are protected with proper coatings *Yes/No *Yes/No
in accordance with the specifications against corrosion.
3.1.11 Fuel filling point is of proper arrangement in accordance with the *Yes/No *Yes/No
approved drawing.
3.1.12 Man-holes and hand-holes for the underground fuel tank are properly *Yes/No *Yes/No
arranged to allow maintenance access and water tight with double
sealed covers
3.1.13 Proper types of filters and water separators are provided in the fuel *Yes/No *Yes/No
supply lines to the daily fuel tanks.
Annex II GE_TCP
Page 2 of 14 2017 Edition
Annex II
Item tested/ Items witnessed
checked by by PBSE/PEME/
GE Contractor PBSI/PEMI
3.2.1 The daily service fuel tank has been fabricated and welded in *Yes/No *Yes/No
accordance with the specifications and drawings.
3.2.2 The pipework & socket connections (for filling, overflow, supply,, *Yes/No *Yes/No
drainage, return and vent) have been properly installed at the fuel tank
in accordance with the specifications and drawings.
3.2.3 One quick closing valve has been installed properly with all *Yes/No *Yes/No
necessary linkage for operation from outside the building.
3.2.4 The fuel tank has been fitted with an approved content gauge unit and *Yes/No *Yes/No
level sensing equipment.
3.2.5 The fuel tank has been subjected to hydraulic test to a pressure as *Yes/No *Yes/No
specified and the results are satisfactory.
3.2.6 The metal surface has been properly prepared and coated in *Yes/No *Yes/No
accordance with the specifications.
3.2.7 The tank has been mounted properly in accordance with the *Yes/No *Yes/No
specifications..
3.2.8 The metal supporting frame is of proper structure and material used is *Yes/No *Yes/No
of proper size in accordance with the standard guide drawings.
3.2.9 Proper types of filters and water separators are provided in the fuel *Yes/No *Yes/No
supply lines to the generator sets.
3.2.10 Rotary hand pump with check-valve, strainers, proper flexible inlet *Yes/No *Yes/No
hose and drip tray shall be provided.
Annex II GE_TCP
Page 3 of 14 2017 Edition
Annex II
Item tested/ Items witnessed
checked by by PBSE/PEME/
GE Contractor PBSI/PEMI
3.3 Visual inspection
3.3.1 The Generating Set has been properly fixed on a common steel *Yes/No *Yes/No
section base frame and fixed at the positon in accordance with the
approved drawings.
3.3.2 Protection screen has been provided on all moving parts. *Yes/No *Yes/No
3.3.3 Protection guard has been provided on hot exhaust. *Yes/No *Yes/No
3.3.4 The fresh-water-cooled radiator has been properly fixed and there is *Yes/No *Yes/No
no water leakage and with proper maintenance access.
3.3.5 The radiator cooling fins and water tank are in good condition and *Yes/No *Yes/No
properly fixed.
3.3.6 The water circulation pump with thermostatically controlled *Yes/No *Yes/No
temperature regulator has been properly fixed.
3.3.7 The engine mounted instrument panel has been fixed properly and *Yes/No *Yes/No
c/w lubrication oil temp. and cooling temp. gauges, tachometer and
hour meter.
3.3.8 The lubrication oil system with replaceable element types filter has *Yes/No *Yes/No
been properly fixed.
3.3.9 The fuel oil system c/w filter, fuel transfer pumps has been properly *Yes/No *Yes/No
installed.
3.3.10 The fuel control solenoid c/w emergency shut off valve has been *Yes/No *Yes/No
provided and properly installed.
3.3.11 The tubular exhaust silencer has been properly installed. *Yes/No *Yes/No
3.3.12 For remote radiator, if applicable, c/w break tank booster pump, heat *Yes/No *Yes/No
exchanger and proper maintenance access etc.. has been properly
installed.
3.3.13 The enclosure to the alternator satisfy IP21 or as specified. *Yes/No *Yes/No
3.3.14 Anti-condensate heater for the alternator has been provided and *Yes/No *Yes/No
proper fixed.
3.3.15 Starting batteries of proper type have been provided and properly *Yes/No *Yes/No
installed. Battery connection bars are protected with corrosion
resistant petroleum jelly.
3.3.16 The air silencers have been properly installed with bird screens at the *Yes/No *Yes/No
air-intakes. Sharp edges shall be properly shrouded.
Annex II GE_TCP
Page 4 of 14 2017 Edition
Annex II
Item tested/ Items witnessed
checked by by PBSE/PEME/
GE Contractor PBSI/PEMI
3.3.17 Proper lifting appliances and gears are in place to suit the *Yes/No *Yes/No
maintenance requirements.
3.3.18 A suitable double pole switch for each generator set to isolate the *Yes/No *Yes/No
starter unit from the battery is provided. Indication light on the
control panel to show its status if it was being put to “OFF” position.
3.3.19 Framed schematic diagram of proper size is mounted in place. *Yes/No *Yes/No
3.3.20 Durable warning signs needed and in accordance with the *Yes/No *Yes/No
requirements for the installations are properly mounted.
3.3.21 Adequate illumination level inside the generator room (minimum of *Yes/No *Yes/No
200 lux as measured at floor level and at the components that required
access during normal operation.
3.3.22 Enough working spaces and provision of proper maintenance access *Yes/No *Yes/No
to the components that required regular maintenance.
3.3.23 Proper hydraulic platform trolley is provided for the maintenance of *Yes/No *Yes/No
the draw out type ACB if any.
3.3.25 Proper identification labels are provided for the major components of *Yes/No *Yes/No
the generator sets.
3.3.26 Proper clearance is provided around the generator sets to allow for *Yes/No *Yes/No
maintenance access,
Annex II GE_TCP
Page 5 of 14 2017 Edition
Annex II
Item tested/ Items witnessed
checked by by PBSE/PEME/
GE Contractor PBSI/PEMI
3.4 Pre-commissioning inspection
3.4.1.2 Lubrication oil is at right level and with replaceable filter. *Yes/No *Yes/No
3.4.1.3 The engine exhaust has been properly fixed and covered with *Yes/No *Yes/No
asbestos-free insulation, anti-vibrations and aluminum cladding.
3.4.1.5 Proper replaceable air filter has been installed. *Yes/No *Yes/No
3.4.1.6 Effective and adequate earth bonding have been provided for the *Yes/No *Yes/No
engine and alternator.
3.4.1.7 The exposed portion of the exhaust pipe outside the generator room is *Yes/No *Yes/No
in stainless steel 316.
3.4.1.8 Proper water draining points and devices are installed in the engine *Yes/No *Yes/No
exhaust system.
3.4.2 Alternator
3.4.2.3 The alternator output terminal is at correct phase sequence. *Yes/No *Yes/No
3.4.2.4 All main power cable terminals are properly identified with *Yes/No *Yes/No
non-ferrous metallic labels.
3.4.2.5 Independent earthing system is provided and properly connected for *Yes/No *Yes/No
neutral connection.
Annex II GE_TCP
Page 6 of 14 2017 Edition
Annex II
Item tested/ Items witnessed
checked by by PBSE/PEME/
GE Contractor PBSI/PEMI
3.4.3 Control cubicle
3.4.3.1 Permanent Chinese/English labels have been provided for all *Yes/No *Yes/No
accessories.
3.4.3.2 All control wirings are fitted with yellow ferrules marked in black. *Yes/No *Yes/No
(i) Automatic 2 rate battery charging equipment c/w charging rate *Yes/No *Yes/No
ammeter
Annex II GE_TCP
Page 7 of 14 2017 Edition
Annex II
Item tested/ Items witnessed
checked by by PBSE/PEME/
GE Contractor PBSI/PEMI
3.4.3.5 Indication lamp for:
3.4.3.6 Generator output under voltage & over voltage protection devices *Yes/No *Yes/No
3.4.3.7 Approved type 4-pole withdrawable air circuit breaker or 4 pole *Yes/No *Yes/No
MCCB c/w overload & short cot. Protection
3.4.3.8 Mechanically & electrically interlocked 4-pole contactor for *Yes/No *Yes/No
automatic load transfer & 4-pole manual by-pass
3.4.3.9 All indication lamps shall be operated at a voltage not greater than *Yes/No *Yes/No
50V
3.4.3.10 Control cubicle shall be installed for each diesel generator set. *Yes/No *Yes/No
3.4.3.11 Control cubicle shall be equipped with thermostatically controlled *Yes/No *Yes/No
anti-condensation heater.
3.4.3.12 Rubber mat of ribbed surface to IEC 61111:2009 in proper size are *Yes/No *Yes/No
laid in front of the main control cubicle.
Annex II GE_TCP
Page 8 of 14 2017 Edition
Annex II
3.6 Control Interlock test of the ventilation exhaust fans for the generator *Yes/No *Yes/No
rooms
(b) Generator fails to start to fire control main panel *Yes/No *Yes/No
(d) Generator engine fault to fire control main panel *Yes/No *Yes/No
(f) Essential Power Supply ON/OFF to Lift Machine Room *Yes/No *Yes/No
(g) Essential Power Supply Normal/Trip to fire control main panel *Yes/No *Yes/No
3.8 Comment
Annex II GE_TCP
Page 9 of 14 2017 Edition
Annex II
Part 4: Test Record attached to the Test Certificate
4.1 Emergency Generator Installation
(i) Manufacturer
(ii) Model
(i) Make
(ii) Model
(vi) Governor
(c) Alternator
(i) Make
(ii) Model
(i) Manufacturer
Annex II GE_TCP
Page 10 of 14 2017 Edition
Annex II
(ii) Make/Model No.
(i) Manufacturer
Annex II GE_TCP
Page 11 of 14 2017 Edition
Annex II
4.1.4 Control Function Test
Annex II GE_TCP
Page 12 of 14 2017 Edition
Annex II
4.1.5 Dummy Load Test
(Parameters to be recorded at 15 min interval during the whole dummy load test period)
Model __________________
Function Test
Serial No. __________________
Annex II GE_TCP
Page 13 of 14 2017 Edition
Annex II
4.1.7 Noise Level Measurement
Background
4.1.8 Comment
Annex II GE_TCP
Page 14 of 14 2017 Edition
Annex III
List of Calibrated Equipment/Instruments
Necessary for the Testing and Commissioning Works
Unless otherwise specified, the equipment/instruments used shall meet the requirements shown
in the table below.
Maximum period
Performance Specification Accuracy between calibrations
Tachometer 30-5000 rpm +1% 1 year
Multi-tester (AVO) 0-1000V +1% 1 year
0-10A
0-1MΩ
Clamp on ammeter 0-1000A +1% 1 year
Insulation tester 500V-1000V +1% 1 year
Pressure Gauge 0-100kPa +2% 1 year
0-1000kPa
Sound meter 0-120 dBA +2% 1 year
Other necessary testing equipment +2% 1 year
Notes: Apart from the testing equipment/instruments above, the GE Contractor shall provide
additional calibrated equipment/instruments in accordance to the recommendations by the
manufacturers to facilitate the inspection, testing and commissioning of Emergency Generator.