Methodology

The Contractor Shall pay Special attention to and take responsibility for: 

·       Staffing

·       Procurement 

·       Coordination

·       Scheduling 

·       Engineering / Design

·       Shop drawing production

·       Timely preparation of submittals

·       Method statements and other technical work

·       Inspection and Testing

·       Commissioning

·       Turnover and closeout

A: Staffing of the Master System Integration section of the Contractors Team is the cornerstone for enabling a successful fully integrated airport facility. In this regard the Contractor Shall build a team of highly skilled and experienced engineers so that complete control of the works can be done with the highest visibility within the Owner / Engineers Senior Management. The team Shall be lead by an experienced Airport Systems Integrator having completed several major airport systems integration projects on airports of similar size and scope.

General Tasks for the MSI

MSI Functional Organization Chart

 

B: Procurement: of the Special Airport Systems will have many interfaces to other systems.

The MSI Team will promote the application of procurement methods that make certain that all equipment, materials, and services are obtained in a timely manner, efficiently, and economically while adhering to requirements of the Owner / Employer, principles of good public policy, practices and sound business judgment. These methods use proven procurement schemes and policies as guidelines.

  • The procurement process will be regulated by the Procurement and Delivery Procedure, which the Contractor will submit to the Owner / Engineer within agreed time form the Commencement Date.

Milestones proposed as recognition of procurement progress:

  • Purchase Order
  • Shipment of Materials
  • Reception of Materials on Site
  • Completion of System FAT
  • Completion of iFAT

The main procurement organization Shall be situated within the Contractor project office. This procurement team will be assisted by the MSI Team.

The procurement office Shall operate mainly from the same offices where the project design and engineering will be carried out, to ensure full coordination between the Engineering and Procurement departments.

The procurement team shall perform the following activities:

  • Finalization of bidder list and submission to Company.
  • Preparation of request for quotation for all equipment and material.
  • Responses to Tenderer’s and bidders queries
  • Issue of bid bulletins as appropriate
  • Clarifications and / or clarification meetings with Vendors
  • Preparation of Purchase Orders and variations/amendments
  • Desk and Field expediting (including expediting of Vendor drawings and data).
  • Co-ordination for Inspection, including mechanical and performance test witnessing in Vendor premises (FAT) where applicable.
  • Management and co-ordination of freight forwarding
  • Material receipt at site
  • Follow-up of OSD reports
  • Administration of invoices, performance bonds, insurance, warranties, etc.
  • Subcontract and management of Inspection Agencies, if required,
  • Expediting and collating of Vendor final documentation, QA/QC documentation, maintenance manuals, recommended spare parts, etc.
  • Closeout of the purchase order and hand over warranties to Employer, if any.

Furthermore, the Procurement team will take advantage of the Contractor’s international network of affiliate companies, associated companies or overseas branches that will act as relays on their domestic or neighboring markets for purchasing assistance, expediting and inspection activities.

C: Coordination:  is a key element of the Master Systems Integration Team duties. This not only includes the Special Airport Systems elements but also the complete work scope which includes all the necessary trade and building coordination works. A key element of the coordination works is also with the stakeholders, customs, immigration, police, airlines, and external services to name a few. A key tool we will use is the interface schedule which will drive the development of the Detailed Design Documents / Interface Control Documents.

Interface Coordination

The SAS MSI identifies and resolves all interfaces under its responsibility, which contribute to the attainment of the overall System performance requirements or other Main Contract requirements.

For each of the interfaces identified, the SAS MSI shall, at an early stage of the design and procurement processes, investigate the interaction between interfacing elements, to verify that the design characteristics of the individual elements have been correctly specified. Interfaces will be identified and classified. A proper Interface Matrix will be created and maintained.

The high level of Interface Development Path is shown in the below diagram. (will be included in the PDF Version)

Typical Interface Development Path

Interface Definition Documents and Interface Requirements Specifications will describe exhaustively all the interfaces including physical, functional and non-functional aspects. Input / Output registers are created, when requested, to pass the interface information.

Coordination meetings with all the relevant stakeholders and Contractors will be organized in order to align the interface definition process. Precise responsibility of a single interface must be assigned to a particular Contractor. The other involved parts will contribute to the interface definition and will help the responsible Contractor to finalize the relevant Interface documents.

The need for Enabling Systems or simulators from the different Contractors must be highlighted during the Integration process and properly addressed to facilitate the test and the final integration of the different interfaces.

Civil works interface represents a complex and critical process in order to finalize the design and to reduce any kind of reworking during the equipment installation phases. Civil works drawings are the basis for the detailed design completion. The space requirements (for equipment and cables) and the position of peripheral equipment (i.e. cameras, displays, and telephones) must be exchanged between the SAS MSI and other Main contractors to expedite the finalization of the work.

All the interfaces are under Configuration Management and Requirement Management strict control.

D: Scheduling will be given a very high priority so that the individual systems can be driven to completion in time to perform system integration testing which is a major prerequisite for beginning ORAT activities. As part of this responsibility, the MSI Team will be responsible for also managing the design, installation, testing and commissioning of the various Special Airport Systems packages.

E: Engineering / Design will be an initial primary focus by the MSI Team so that all Interface Control Documents can be finalized with sufficient time to allow the various systems providers to develop/code the interface messages necessary for the Information Broker and be compatible with the Airport Operational Database schema. Detailed Single Line Drawings will be developed showing all physical interfaces and well as the associated protocols using the interfaces.

SAS MSI Team will be intensively involved in verification and co-ordination of the Design and Engineering of SAS during the Airport development. The main purpose is to verify whether the existing base design reflects the requirements of the Stakeholders and to follow up that the solutions and detailed design produced by the systems vendors comply with those requirements and the ICT Master Plan.  

The scope of this document is to provide an outline for the typical process and the methodologies that will be applied in the framework of the design development of the systems under the Scope of Work. In particular, the different stages composing the entire design are addressed, while the specific portion of Design that is under the direct responsibility of the MSI SAS is detailed in the Responsibility Matrix.

For each one of these stages inputs, activities performed and produced deliverables are illustrated; these deliverables will be submitted to the Owner / Engineer for review and approval.

This document provides a sufficient level of detail in order to make visible how the project shall handle the design development challenges and satisfy the requirements listed in the Tender documents.

During the Contract implementation, the contents outlined in this document will be amended and Shall evolve along the project development to ensure that every member of the engineering team in the SAS MSI Staff understands the task to be performed, knows the process, the methodologies and the tools to be used during the system design.

Moreover, this document is the foundation document for the planning and management of all SAS engineering and design activities carried out in relation to the Contract.

The processes, procedures, and plans introduced within this document form the basis of an integrated engineering effort to be applied by the SAS MSI.

The SAS MSI use the System Engineering (SE) process based on experience and proven approach encompassing the entire set of scientific, technical, and managerial efforts needed to provide a set of life-cycle balanced system solutions that satisfy customer needs with capabilities to be provided while taking into consideration costs, schedule and risk.

The SE process is an iterative, disciplined method that includes requirements analysis, requirements allocation, design synthesis, and technical management processes.  This process takes place over the entire life cycle of a Project and may be applied to all levels of acquisition from Systems of Systems to individual platforms, systems, subsystems, and components.

System success is dependent on the extent to which these systems satisfy their Stakeholders’ needs, are affordable, are acquired on time and work with other systems in a coherent family of systems.

Stakeholders consist of all individuals and organizations within the airport community whose mission success is enabled by the capabilities embodied in the systems, organizations with a direct interest, involvement and /or investment in the facilities who dictate the requirements for the Airport development.

Systems engineering is thus a disciplined acquisition approach that requires identifying Stakeholder requirements to a level of detail sufficient to design and build the system, to make trade-off decisions between alternative means of satisfying these requirements, to select the alternatives that balance performance, cost, schedule, risk, and the potential for evolutionary growth, and to identify the interfaces (both internal and external) necessary so that the system or family of systems can be integrated to exchange data among all systems in the airports.

This document mainly addresses the system design phase, however, it is important to emphasize that the System Engineering approach is shared with the whole project development and it is part of a wider process and methodology providing a coordinated and integrated solution.

Integration Test Laboratory

In line with the Contract requirements, the MSI Team shall be in charge of the “Integration Laboratory Environment” (ILE), up to 250 square meters of space, provided by the Employer.

The MSI Team shall develop requirements for the systems subsets to be delivered by suppliers in the ILE. The ILE shall be maintained throughout the life of the project and shall be available for the Employer’s use after the project. The MSI Team shall develop installation and workmanship standards, apply MSI-developed Integration Control Documents (ICD), develop and conduct system and integration test scenarios.

The ILE Shall be designed and constructed to the highest standards and will utilize modern technology in terms of maximum reliability, ease of maintenance, personnel safety, and high availability for operational use. The ILE will support the installation, testing, and validation of the SAS systems and subsystems.

The Test Facility will be functionally divided into zones which will be marked for the different pre-designated activities. The respective zones are as planned by the responsible test engineers and the presently identified ones are:

  • Pre-assembly and Installation Zone
  • Integration and Interfaces Test Zone
  • Configuration Dock
  • Utilities and Server Area

The floor plan layout design shall provide the operators with a clear line-of-sight for monitoring the systems and sufficient workspace for a comfortable working environment.  In ILE there are the necessary common utilities installed: Heating, Ventilation, Air Conditioning (HVAC) power, lighting, communications, easy access to the water closet and break rest facilities, etc.

There are numerous benefits derived from establishing and utilizing an ILE prior to installing systems on-site. These include the rapid assessment of alternative solutions for Hardware and Software issues, rapid assessment of user interfaces, testing to assess characteristics of subsystems test results, such as “Network Performance” and synchronization, and traffic loading, etc. The client will realize the benefits gained from the Laboratory long after the Permanent Test and Training Facility and have been installed and commissioned.

Main tasks of the Lab Test and Staging platform are:

  • Assembly of equipment, racks, cabinets, and products off-site in order to minimize on-site labor-intensive activities
  • Configuration of systems prior to delivery to site
  • Collection of data for system database population
  • Set up and proving of the fully integrated systems function and performance in order to de-risk on-site testing and commissioning
  • Testing system physical, functional and information interfaces between SAS systems and other systems in order to de-risk on-site testing and commissioning
  • Testing system physical, functional and information interfaces between SAS components and systems and other components and systems in order to de-risk on-site testing and commissioning

For testing carried out with other components and systems the SAS MSI shall be coordinating the activity.

F: Shop Drawing Production is critical to the timely coordination of the Special Airport Systems with the Civil, Structural and Builders works and very critical to the coordination with the Mechanical, Electrical, and Plumbing trades. In particular, the Electrical works will be providing containment and power (normal and essential) to the Special Airport Systems and as such, detailed drawings need to be done early so that these requirements can be incorporated into the MEP Coordinated Services Drawings necessary for the construction works.

G: Timely preparation of submittals – To ensure that all Contract Requirements will be full-filled, the Contractor Shall use a Verification Cross Reference Matrix which will detail all the Quality Documents that need to be submitted from Subcontractor / Material approvals, Installation, Testing, Commissioning, Operation and Maintenance Manuals, Training and Site System Integration Testing.

H: Method statements and other technical work Shall be provided well in advance of their use date, documented in a Submittals Program and agreed by the Owner / Engineer. This will allow sufficient time for all parties to be fully conversant in the methods we will use to implement the systems. We expect the method statements to be completed in a systematic and professional way using ‘best practice’ methods and in accordance with the Contract Stated Standards and Codes. The Contractor Shall expect that a significant amount of ‘technical work’ will be required to finalize the Design. The main schedules and tools that will be utilized include; Verification Cross Reference Matrix, Compliance Matrix, Interface Control Documents, Interface Activity Schedules, Detailed Design Documents, Interface Schedule, Interface Matrix, Single Line Drawings, and System Integration Single Line Drawings, and others. 

K: Inspection and Testing will be done in accordance with the approved method statements. The inspections will follow Fix 1 though Fix 4 standards. Testing will be done on a system by system basis. System Integration Testing will start when at least two interfacing systems are ready in addition to the Structured Cabling Network / Computer Network Equipment being declared ‘Network Ready for Use (NFRU)’ by the Owner / Engineer. A key element is the provision of an Integration Test Laboratory where System Integration Testing can begin. The Contractor Shall implement the Integration Test Laboratory within 6 months of the contract award. Testing of the various systems will be in accordance with the Owner / Engineer Approved Interface Control Documents. Should anomalies be found in the Integration Test Laboratory they will be corrected in the Interface Control Document and then re-tested. After a system has passed all Laboratory Test Environment Tests the system will be released to the site.

L: Commissioning will be done in accordance with the approved method statements. Careful attention will be given to subcontractors completing their internal tests prior to advising the Owner / Engineer that the commissioning test will begin. At this phase, we would expect all drawings to be approved for construction, draft operations and maintenance manuals available, and all major snag items resolved.

The SAS MSI Team will be supporting the Contractor for testing and commissioning of SAS systems with their respective suppliers. The scope of activities will follow the relevant procedure produced earlier during design. Operationally the related activities on site will be integrated into the overall T&C frame.

During the course of the design process, the T&C management will participate in all design phases of the project. The T&C manager will participate in Interim design to assure that the test requirements have been captured and analyzed early in the project. The T&C manager will participate in all stakeholders and subsystem meetings to assure that the user requirements can be validated and test requirements have been incorporated in the appropriate design documents. These requirements will be reviewed again during the detail design and clarification and modification to the requirements will be added accordingly to assure that all requirements are testable and validation can be incorporated in the design documents during the design phase. 

There are different stages for the Test and commissioning in this project:

  • Factory Acceptance Test; where subsystems will be tested in a controlled environment, at the Subcontractors’ premises or at the SAS MSI temporary test facility. During this stage, all stand-alone functions and capabilities of the system and criteria to start integration testing are meet will be examined according to test plan and procedure.
  • Integration Testing; This activity will be conducted at Test Platform where all testing activities are conducted in a controlled and integrated manner, in particular interfaces and integrated functions among systems will be tested.
  • Pre-Commissioning and Commissioning & Test phase where the systems will be moved from the temporary test facility and install in the production site. During this phase of the project, the following test will be conducted.
  • Pre-commissioning test, where the systems will go under power-up test carrying out localized testing of discrete elements of the systems in their production environment.
  • Commissioning test where the systems will be fully configured and loaded with production applications accordingly. During this step, the systems will be tested for integration between the systems. Other tests such as demonstrating system resilience through failover and recovery mechanisms will be conducted.
  • Performance Testing; this step will demonstrate the satisfaction of performance requirements, some tests may be performed simulating the increasing of the systems load.
  • Takeover Tests; a trial demonstrating the integrity of the production systems will be performed to achieve the state’s business functions – leading to the Substantial Completion Take-over Certificate form the Employer to the General Contractor.
  • Test after completion – NOTP (Non-Operational Trial Period) program, where staff will support the system vendors’ additional series of tests, which may be impossible to perform during the normal test environment. 

A Test and Commissioning Manager will be appointed within SAS MSI. He will carry out his duties in coordination with the Test & Commissioning Manager to be appointed by Contract. He will also have the role to interface with the other Contractors’ reference persons.

Processes and Procedures for T&C

The T & C Commissioning Manager according to the SAS MSI test processes will develop all test procedures, and test scripts prior to any test stage activities. These test producers and test scripts will be submitted as the main deliverable for the given stage to Engineer for review and comments.

In the Work Programme, the testing phases will be indicated and properly scheduled.

Then, upon acceptance of the test procedures and test scripts, the T&C manager will review, validate and manage a more detailed test schedule and will assign a test conductor who will manage the test activities according to the plan.

This detailed test schedule will include therefore clear planning of all the tests to be performed within the testing phase presented in the Work Programme.

The test conductor will coordinate with appropriate stakeholders and manage the test activities. Any discrepancies will be recorded on the test report.

Test & Commissioning Coordination Roles and Deliverables

The T&C coordination responsibility of SAS MSI T&C Manager is as follows:

  • Work with the Integration Architect and to develop the overall test plans and review detailed test documentation that includes but is not limited to the following:
  • Test plans
  • Test procedures
  • Test scripts
  • Test Readiness Report format
  • Test discrepancy report format
  • Regression test procedure and report format
  • Develop test policy and regulations
  • Review test schedules
  • Attend tests
  • Coordinate with all stakeholders’ attendance as applicable.
  • Develop weekly reports on test activities.

Turnover and closeout will be done in accordance with the contract requirements. 

The SAS MSI shall coordinate the Tests on Completion before on the completed Works as specified in the Contract or as agreed with the Engineer. The Tests shall demonstrate that the Works have been completed in compliance with the Contract. The Tests shall also demonstrate that the Plant, Materials, and Systems function and perform as specified. The Contractor may carry out the Tests in sections as agreed with the Engineer.

The system vendors shall provide all necessary labor, materials and test equipment

At least 6 months before the start of the Tests on Completion the SAS MSI shall issue to the Owner / Engineer for the Owner / Engineer’s review and/or approval a method statement with a schedule of the proposed Tests on Completion. The Contractor shall include in the method statement the proposed pro forma and other forms for recording the results of the tests that the Contractor proposes to carry out.

Notice of the date after which they will be ready to carry out each of the Tests on Completion will be given according to Contractual requirements and details shall be provided, which shall include but not be limited to the following:

  1. Time of Tests on Completion.
  2. Location of Tests on Completion.
  3. Parties to attend Tests on Completion.
  4. Tests specification and criterion.

Tests on Completion shall be carried out within 14 days after this date, on such day or days as the Engineer shall instruct.

Taking-Over at Substantial Completion

The purpose of the handover stage is for the SAS MSI to verify the readiness of the Works for safe and effective operation and maintenance to the satisfaction of the Engineer prior to Taking-Over.

The Test & Commissioning Manager will oversee all handover activities. 

Taking-Over after NOTP

For some systems and configuration of the Works, there will be 3 months long Non-Operational Trial Period After Substantial Completion. This program will run in parallel to ORAT and within the frame of Defects Liability Period for the Project. The main objective will be proving the operational reliability on a per-system basis mostly involving responsibility and contribution from vendors of systems subject to NOTP.  

At that time the MSI SAS Team will attend to ORAT in order to support General Contractor MSI and may support the NOTP to a limited extent. 

Deliverables required for Handover

During the period of handover the SAS MSI shall consolidate with system suppliers and verify the following for submittal by the MSI to the Owner / Engineer for approval in a format and structure to be reviewed and/or approved in advance by the Engineer:

  1. As-built documentation, drawings, diagrams and schedules
  2. Inspection, test and commissioning certificates
  3. Quality assurance records and certification
  4. Operations and maintenance manuals
  5. Training manuals
  6. Training and familiarization plans
  7. Software and operating system licenses
  8. Backup of captured data for systems configuration and population
  9. Warranty and guarantee certificates
  10. Asset Schedule
  11. Schedule of Tests on Completion

There will be also other deliverables according to requirements specific to each system in preparation for handover for operational use – e.g. The transfer of data collected and generated during design, configuration and testing as required for support of functioning of the systems, wherever applicable.

The documentation, drawings, diagrams, and schedules produced during the design stage shall be revised to as-built unless otherwise approved by the Engineer.

The format, structure and sample content of the O&M and training manuals shall be submitted for preliminary reviewed and/or approval by the Engineer and used as a benchmark for the final submissions.

Upon acceptance, the SAS MSI shall submit all paperwork in two hard copies bound in volumes and four electronic copies on DVDs in a format and structure to be agreed with the Engineer.

During the handover period, the Contractor shall verify with the Engineer that the installed equipment and materials are in good condition and in doing so shall conduct site visits and inspections.

The SAS MSI shall facilitate the handover of all equipment and tools necessary to safely and effectively operate and maintain the systems and assets including but not limited to:

  1. Spares
  2. Test equipment with all associated certification
  3. Calibration and configuration tools with all associated certification
  4. Rack, cabinet and enclosure keys

Contractor Experience

The Contractor must have a long and proven track record for performing works of similar size and scope on several of the world’s new airports.

Or Equivalent – The proposed head of MSI is Professor David R. Langholff who has over 20 years of executive management of Special Airport Systems / Extra Low Voltage Systems and Master Systems Integration. Notable airports include Hong Kong International Airport, Inchon International Airport, Kuala Lumpur International Airport, Thailand International Airport and Dubai Terminal 3 / Concourse 2 International Airport. 

Commissioning of the complete Airport Systems Integration will be provided in stages, starting with the preliminary Laboratory Testing, Functional System to System Testing on-site; Operational Testing based on Test Scenarios (like a Flight Departure or Gate Reassignment); Cross-Functional Operational Testing; Failure Mode Testing; Recovery Mode Testing; and Full Site System Integration Testing. These will all be developed and approved by way of Quality Documents such as Method Statements and Integration Test Plans and Procedures.

The MSI Team will use methods and procedures that were previously utilized on similar Airport Integration Projects which include; Interface Control Documents (ICD); Interface Activity Schedules (IAS); Verification Cross Reference Matrix’s (VCRM); Integration Test Laboratory (ITL); all of which will be under the control of the Interface Control Working Group managed by the MSI Team Director.

Qualifications:

Project Organization

  1. The Master Systems Integration team will be headed by an MSI Project Director who will have several Design Managers reporting to this position as per the chart below.
  2. The team will be primarily comprised of staff that will be directly hired by the Contractor
  3. The Contractor intends to retain some specialist consultants from world-renowned organizations to assist in the preparation of the Concept of Operations (CONOPS) and ORAT management documents.
  4. The MSI Team will see the entire project through, from project start to the final site commissioning. The senior members of the Team will continue on throughout the ORAT phase of the works.

 

Airport Experience

  • The Contractor to provide.

List of Attached Master Systems Integration Appendices

  • System Integration High Level
  • System Integration Interface Schedule
  • Previous System Integration High Level
  • Previous System Integration Medium Level
  • Previous System Integration Single Line Drawing
  • Previous System Integration Tracking Matrix
  • Interface Control Document
  • Interface Activity Schedule
  • Detailed Interface Document
  • Verification Cross Reference Matrix
  • Integration Test Script
  • Concept of Operations – Outline Table of Contents