Tu r n Ov er Pac k ag es , FA T an d Commissioning San Francisco Bay Area Chapter Commuter Conference May 13th 2008 Misha Anissimov, Genentech Mike Britting, Hathaway Dinwiddie Leo Santini, Hathaway Dinwiddie
FAT FA T need a Fa Factor ct ory y Acc A cce epta pt ance nc e Test? st ? • Why do we nee Benefits,, who are the sta st akeholde kehold ers? rs ? • Who Benefits s hould d be in charge charge,, who shoul s hould d go? • Who shoul wo rth the t he cost? cos t? • Is it worth
FAT FA T need a Fa Factor ct ory y Acc A cce epta pt ance nc e Test? st ? • Why do we nee Benefits,, who are the sta st akeholde kehold ers? rs ? • Who Benefits s hould d be in charge charge,, who shoul s hould d go? • Who shoul wo rth the t he cost? cos t? • Is it worth
Basi Basic c FAT FAT • E stablis ablish h what needs eeds to be be tes testted • E stablish ablish wh who need needs s to att attend end • E stabli ablis sh the sched schedu ule • E stablish ablish wh who will will be be res resp pons onsib ible le for for reporting and recording
Commissioning Basics for the Owner Misha Anissimov, P.E.
M.E. 101, Inc.
What is Commissioning? • ASHRAE defines it as “ A quality-focused process for enhancing the delivery of a proj ect. The process focuses on verifying and documenting that the facility and all of its systems and assemblies are planned, designed, installed, tested, operated and maintained to meet the Owner’s Project Requirements . • TRANSLATION: The process of testing and challenging your building systems in such a way as to find all of the problems and mistakes before Building Turnover. Each problem found during Commissioning = One less problem found by the User. ”
Establish the Team – (the Cx agent’s support network) •
The Owner’s Representative : sho uld h ave a solid wo rki ng kn owledge of Mechanical Systems design and func tion, and provide unbiased infor mation to upper management.
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Commissioning Agent : Reviews Contr ols, Writes FPT’s, executes FPT’s
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Mechanical Engineer of Record : Own’s the system design and Sequence of Operation .
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General Contractor’ s MEP Coordi nator : Will act as the “ enforcer” in helping resolve issues between subcont ractors.
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Mechanic al Contractor Proj ect Manager and Field Start Up Technician
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Controls Contractor Proj ect Manager, Design Engineer and FIELD PROGRAMMER.
Step 1 : Establish Scope
. A detailed Commissioning (Cx) specification is needed to define systems/parameters to be tested, trends to be run, documentation that is required. Spend time achieving clarity in yo ur ow n mi nd of exactly what you want to accomplis h.
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If you are using a generic specification, supplement th is wit h you r own build ing-specific attachment. What are some uniqu e tests you want to inclu de? 72 hour trends of all buil ding zones? A 5-day “ quality of li fe” check? A Cx agent Overview class for Facilit ies? Unusual systems which may require special attention? 100% vs. 10% point to poi nt? Get Facilit ies Involved. All f acilit ies engineers have pet peeves. Maybe they hate variable pri mary chilled water systems. Include specific t ests in the scope to specifically address Facilit ies and User concerns.
Step 2: Choosing a Commissioning Agent -
As always, word-of-mouth recommendations of Agents are a great starting p oint. This is 100% Labor….less cost m eans less Cx activi ty.
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PROPOSALS: Ask for sample Issues logs (what kind of problems did they unco ver in past jo bs?), Ask for s ample Functi onal Perform ance Tests-FPT’s (how are the tests writt en? Do the documents in clude generous amoun ts of h ard data like pressure/temperatures/flows , or do the tests look too simplified “ pass/fail” with no d ata recorded). Test data acquir ed in the field is useful l ater in tro ubleshooti ng.
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INTERVIEW: Meet the lead Cx Manager who would be assigned to your project. Be sure you are getting an “ A” list person, not a “ B” list person . Is he or she an effective leader? Do they take charge? Ask them about a system you have had problems wit h in the past and how they would test it.
Step 3: Preparation Preparation Preparation -
THIRD PARTY OVERSIGHT: Be sure the con tract and channels of commu nication are establish ed s o th at the Owner always gets the “ real deal” information from the Cx Agent. He is your person in the trenches making sure everything wor ks.
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PLANNING: I like to start with dedicated Cx meetings early..right after 95% CD Documents are iss ued. That means d edicated Comm issioning Meetings once a week, starting wi th a thoro ugh document design review pr ocess
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75% of Commissio ning Problems are controls related. Start wi th a detailed Controls Sequence of Operation Review by the Cx Agent, Mechanical Engineer, and FACILITY’S rep. You are build ing a Cx TEAM.
- After SOO , Get the Con tr ols Pr ogrammers i nvolved. Ask fo r L ogic Diagrams to und erstand how the system will be programmed.
A Few Words about FPT’s • Actively Review Functional Performance Tests – especially key tests. Focus on the “ Objectives” and the “ Results” you would like to see. • Beware of Boiler Plate FPT’s. Are the tests custom tailored to your systems? • FPT’s are common sense and are the “ battle plan” of Commissioning.
Step 4: Execution • The SOO’s have been scr ubbed, you k now h ow th e Contro l Systems will be programmed, the Functional perfor mance tests have been cr eated and reviewed by the Owner, you have adequate staffi ng fo r all trades-contracto rs, and yo u have PGE power to all systems! You are ready to start Cx activi ties! • Embrace “ PROBLEMS” : The more you find no w, the better. • Keep FACILITIES Involved: Witnessin g t ests i s great facili ties traini ng….and establishes a comfor t level before turnover. • Cx is a coordinated team effort – and delays WILL occur. Avoid the temptation t o accelerate Cx activi ties—this w ill result in error s. Cx agents are not painters /sheetroc kers, etc. Start with a REALISTIC schedule and then ADD SOME EXTRA.
A Few Words About Scheduling • Substantial Completion – Certificate of Occupancy does not mean the Building is ready for User Move-In. • Ideal Move – In Date should lag 4 – 8 weeks or so behind substantial completion • Cx activity issues TAKE TIME to resolve. Simple Issues are quick. Design Issues can take weeks. • Case Study: A simple Lab Building with a top notch team, with Mechanical Engineering Owner oversight, and a thorough review process is pr ojected to have the Cx Issues resolved 3 – 4 weeks after substantial completion. THIS IS NORMAL.
Turn Over Packages • What is the Turn Over Package (TOP)? • Why is the TOP essential for successful Project completion? • What is needed for a TOP?
The Owner’s Perspective • Establish the requirements for contractor turnover packages • Assign defined roles & responsibilities and incorporate into the Contract Documents • Establish ongoing TOP meetings • Manage and support the turnover plan/schedule throughout the Project
Case Study: Genentech TI Project Leo Santini, MEP Coordinator
Hathaway Dinwiddie
Summary: The Contractor’s Perspective • • • • •
Know your contract and specifications Define and/or clarify all questionable items Formalize the complete organization of the TOP Team members buy-in Provide a means of signing off and tracking documents as the Project progresses • Develop an outline/schedule for key turn over items • Follow through and execution - maintain visibility and communication among all team members
Key Items in Turnover Package • • • • • • • •
O&M’s delivered to Facilities for SOP’s Seismic calcs, inspection & approval letters Start-up data BAS AT box programming data VFD parameters data Accurate BAS as-builts and control sequences EH&S Binder Sound consultant calculations, and reports
Other Turnover Items & Activities • Training & Coordination – Equipment is
running. Coordinate days and times with Facilities • Final Punch List – Final punch walks occur weeks before substantial completion. Final punch completion and Owner backcheck completed by substantial completion date. • As Builts – Architectural backgrounds freeze 30 days before substantial completion • Final Building Turnover – Checklist signature and date by Owner Project Engineering, Facilities and Contractor
Building Turnover Checklist
MEP System Turn Over Checklists
TOP Manuals: Table of Contents GENERAL DOCUMENTATION Volume I:
SUBMITTALS Volume II:
PROJECT SPECIFICATIONS Volume III:
SYSTEMS DOCUMENTATION Volu me IV:
Volu me VII:
A. Project Directory B. TOP Matrix C. As-Builts Record Set CD D. Master Punchlist E. Warranty Letters F. RFI Log w/Responses G. O & M Manuals
A. B.
Submittal Log Approved Submittals
A. B. C.
Specification Listing Record Specifications Record Basis of Design (BOD)
DRY-SIDE HVAC Central Air Handling Economizer Return Air Fan General Lab Exhaust "H" Area Exhaust Fans Radioisotope Exhaust Fans Air Terminal Zones IDF/MDF Backup AC Units Mechanical Room, Boiler Room Exhaust Fans Refrigeration Room Ventilation, Refigerant Leak Detection, Purge & EPO Bag In / Bag Out Filtration System
LABORATORY SUPPORT EQUIPMENT D.I. Pointof Use Polishers Chemical Fume Hoods Radioisotope Hoods Bio Safety Cabinets
Volume VIII:
"DIRTY" PROCESS UTILITIES Laboratory Vacuum
Volume IX: Volume X: Volume XI:
"CL EAN" PROCESS UTILITIES RO/DI Water System Carbon Dioxide Laboratory Compressed Dry Air
Volume XII: Volume XIII: Volume XIV: Volume XV: Volume XVI:
BUILDING UTILITIES Domestic HW/CW Natural Gas Sanitary Waste & Vent Lab Waste & Vent Storm/Roof Drainage
Volume XVII: Volume XVIII: Volume XIX: Volume XX:
FIRE/LIFE SAFETY SYST EMS Fire Alarm & HVAC Interface Elevator Recall and Safety Sequences Fire Sprinkler Flammable Vapor Detection (LE L)
Volu me V:
WET-SIDE HVAC Preheat/Reheat - Boilers, P umps Condenser Water - Towers, Pumps Refrigerated Water - C hillers, P umps
Volume XXII: Volume XXIII: Volume XXIV: Volume XXV: Volume XXVI:
ELECTRICAL & SPECIALTY SYSTEMS Normal Power Service & Distribution Emergency/Standby Distribution Grounding Lighting & Lighting Control Generator & ATS UPS, Batteries Security Including CC TV FMS - Facility Management System
Volu me VI:
CONTROLS SYSTEMS BAS - Building Automation System
Volume XXVII:
ENVIRONMENTAL HEALTH & SAFETY EH&S - E nvironmental Health & Safety
Volu me VII:
LABORATORY SUPPORT EQUIPMENT D.I. P oint of Use P olishers Chemical Fume Hoods Radioisotope Hoods Bio Safety Cabinets
Volume XXI:
APPENDICES App end ix A : App end ix B: App end ix C:
Seismic Bracing Drawings, Calcs and Inspection Sign-off - Mechanical/Plumbing Eqpt & Overhead Balance Report - Air & Water Commissioning Plan and Report
System Docs: TOP Matrix N O I B T A C T E S
SYSTEM DOCUMENTATION
N G I S G N I R E F E F O N I G N E E N G
F F O N G I S S E I T I L I C A F E N G
R O T C A F R F T O N N O G I C S L P A E R E M N E G
G N I L D N A H R I A L A R T N E C
SECTION 3 - EQUIPMENT T ESTING/INSTALL ATION VERIFICATION SECTION 3a - PIPING A B
SECTION 1-GENERAL A
B
Syst em Overview
i.
Equipment List
x
ii.
BOD - Basis of Design
x
D raw in gs
i.
Construction Drawings and/or P&IDs
x
ii.
Vendor Furnished Drawings
x
iii.
As-Built Drawings
x
C
Punchlists/Mechanical Comple tion Letter
x
D
B al an c e Re po r t
x
i.
Commissioning P lan
x
ii.
Final Commissioning Report
x
War ran ty
G Owner Training Documentation
A
x
C
Syst em Docum entation
i.
B
Installation Guide and O&M Manuals
x
ii.
Contractor/Vendor Supplied EquipmentSubmittals/Drawings
x
iii.
EquipmentPrefunction Checklist
x
iv.
HEPA Filter Certification
v.
Seismic and/or Structural Calculations
x
vi.
Labeling Document
x
vii.
Recommended Spare Parts List
x
i.
FAT Test Results
ii.
Field Test Results
x
iii.
Contractor/Vendor Startup Reports
x
iv.
Hood Certifications (GNE)
SECTION 3a - PIPING Piping Sp ecificat ions
i.
Piping Submittal
ii.
Valving Submittals
iii.
SpecialtyPiping / Plumbing Fixture Submittals
iv.
Seismic Details and Stamped Drawings
v.
Weld Procedure(s)
vi.
Welder Certification
vii.
Pipe Brazing/Soldering Procedure(s)
Installation Documentation/Field Verification
i.
Pressure Test Report
ii.
Flushing Report
iii.
Cleaning and/or Passivation Report
iv.
Sanitization Plan and Report
v.
Field QC Reports/Particulate Report
Duc two rk Spec ificat ion s
x
D u ct w or k D o cu m en t at io n
i.
Ductwork Submittal
x
ii.
Insulation Submittal
x
iii.
Shop Drawings
iv.
Seismic Details and Stamped Drawings
x
v.
Specialty Ductwork
x
Installa tion Documentation
i.
Ductwork Leak Tests
x
ii.
Seismic Inspection reports & Sign-off
x
SECTION 4 - ELECTRICAL A
Electr ical Spec ificati ons
B
Single Line Diagrams
C
Electrical Documentation
D
T es t R ep o rt s
SECTION 3 - EQUIPMENT TEST ING/INSTALL ATION VERIFICATION
A
A
x
SECTION 2 - EQUIPMENT
P ip i ng D o cu m en t at io n
SECTION 3b - DUCT WORK
B
E Startup/Commissioning Test Plan
F
C
Pipin g Spec ificat ions
i.
Electrical Commodities Submittal
ii.
Seismic Details, Stamped Drawings and Inspection Reports/Sign-off
Electrical Equipment Checkout
i.
Ground SystemTesting
ii.
Transformer Testing/Reports a. Tilt-Meter Testing b. Insulation Resistance Test Report
iii.
Megger Testing a. Switchgear/Switchboards
