MODULE #6 COMMISSIONING, VALIDATION, CERTIFICATIONS

Transcription

1 MODULE #6 COMMISSIONING, VALIDATION, CERTIFICATIONS MICHAEL WALSH PRINCIPAL, R.G. VANDERWEIL ENGINEERS, LLP 274 Summer Street, Boston, MA (T) (F)

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3 Module 6 Agenda 1. Cx Scope of Work 2. Roles & Responsibilities 3. Containment Testing 4. CDC, USDA and NIH Submission Requirements Commissioning 1

4 What is Commissioning? AIHA/ANSI Z9.14 Developed Specifically for BSL-3 Commissioning BSL-3 Experienced Cx & Design Team Help Define Failure Testing What is Commissioning? 2

5 Commissioning When should you begin working on the commissioning and turnover process for a building? Is it at this stage of the project? Commissioning Or at this stage of the project? 3

6 Commissioning Merrick & Company Commissioning - OPR To understand Owner requirements ASHRAE suggests Commissioning Agent (CxA) documents Owners Project Requirements As design progresses, CxA reviews design then construction to ensure OPR are met 4

7 Commissioning - Cx Plan Initial commissioning plan (CxPlan) developed as early in project as possible Understanding tests to be performed allows design team to address failure scenarios in design sequences rather than during testing and commissioning Commissioning Basis of Design Design team documents HOW OPR is met. CxA reviews BOD ensure design will meet owner requirements 5

8 Commissioning - Submittals In addition to the design team submittal review, CxA reviews actual equipment being provided to determine if manufacturers requirements will require adjustment to CxPlan Information gathered for subsequent tasks Commissioning O&M Manual Contractor prepares Operations and Maintenance Manuals for Design Team and CxA review 6

9 Commissioning Record Documents CxA reviews Record Documents to ensure matches adjustments made during commissioning Commissioning CxA prepares project training plan 7

10 Commissioning Systems Manual Cx Team compiles project systems manual Roles & Responsibilities 8

11 Commissioning Roles and Responsibilities Design Team Cx Responsibilities Cx TEAM MEMBER Design Architect and Engineers (AE) RESPONSIBILITY General: Develop and maintain the Basis of Design (BoD) document throughout the design and construction process Design Phase: Incorporate Cx specification sections prepared by the CxA in the total construction document package Review and incorporate Cx design review comments into the final contract documents Construction Phase: Review Cx Plan Attend the commissioning kickoff meeting and selected commissioning team meetings as needed. Review contractor submittals for compliance with contract documents. Support CM submittal review for commissioning issues Review, and approve the O&M manuals. Attend commissioning specific pre construction, planning, and coordination meetings as necessary. Provide construction punch lists. Review and comment on test and balance documentation. Review contractor's as built documents for completeness and accuracy. Provide clarifications on any design narrative and sequences documentation requested by the CxA. The designers shall assist (along with the contractors) in clarifying the operation and control of commissioned equipment in areas where the specifications, control drawings or equipment documentation is not sufficient for writing detailed testing procedures. Resolve Issue Log deficiencies associated with design items. Provide feedback and review of CVF s, ST s and IST documentation. Acceptance/Post Acceptance Phases: Witness testing of selected pieces of equipment and systems Commissioning Roles and Responsibilities Commissioning Authority Responsibilities Cx TEAM MEMBER RESPONSIBILITY Commissioning Authority General: (CxA) Coordinates and directs the commissioning activities in a logical, sequential and efficient manner. Develops and maintains/updates the Cx Plan throughout the design and construction process Design Phase: Review and comment on design documents to ensure commissioning activities are accommodated Review and comment on Basis of Design (BoD) and Owner s Project Requirements (OPR) documents to ensure that the design is meeting the intent of the OPR Develops Commissioning Specifications for bid and provide to AE for inclusion in the total design package Construction Phase: Develops Cx plan with design specific information and submit to OREP and AE for review Conducts initial Cx kick off meeting and co ordinates monthly/weekly/daily commissioning meetings thereafter. Shall make recommendations to CM for modification of the Construction Schedule to incorporate Cx activities. Obtains and reviews all applicable submittals for systems to be commissioned in order to develop CVs, STs and ISTs. Develops and submits CV, ST and IST test forms for review by CM, AE and OREP. Review and comment on Final Startup Reports Verifies completion of CV s by CM (or SUB). Reviews specific equipment tests, start up procedures, and systems submittals / shop drawings Reviews the CM integrated construction schedule to ensure commissioning tests periods and dates are accurate. Perform site visits to observe component and system installations. Report any discrepancies with the BoD and contract documents Review TAB plan and provide input in execution. Recommend approval of air and water systems balancing by reviewing completed reports and by selected site observation. Maintains Issues Log based on field and testing observations. Coordinates testing observation by client and submits suggestions to Owner for resolution of conflicts relating to Cx activities. Reviews O&M manual for completeness and ensures changes made during the course of the project Verifies O&M manuals are submitted to the owner per contract requirements. Verifies training is scheduled and completed by CM (or SUB) prior to facility turnover. Reviews results of third party testing agencies. Acceptance/Post Acceptance Phases: Directs and executes ST s and IST s with the support of CM (or SUB) Provides final commissioning report Carry out and document any required off season or deferred ST and ISTs Revise commissioning report after off season ST and ISTs as needed 9

12 Commissioning Roles and Responsibilities Contractor/CM Responsibilities Cx TEAM MEMBER RESPONSIBILITY Construction Manager (CM) General: Coordinates subcontractors in support of commissioning activities. Designates representatives for all critical sub contractors associated with the commissioning process. This shall include representatives from Mechanical, Electrical, Plumbing, TAB, Controls/BMS, and manufacturer/vendor subcontractors. These team members shall be identified in the Cx Plan. Ensure that all subcontractors and vendors execute their commissioning responsibilities according to the contract documents. Update/maintain project schedule to accommodate commissioning activities Provide access means (lifts, ladders, etc.) to support commissioning activities Construction Phase: Attend the commissioning kickoff meeting and all commissioning team meetings. Coordinate attendance of SUBs. Integrates Cx activities into construction schedule. Provides CxA with submittals pertinent to the development and execution of CVs, STs and ISTs. Develops start up plans and incorporates into construction schedule, keeping CxA informed of any changes. Performs and documents equipment start ups. Rectifies any system or equipment deficiencies found during system start up. Submits completed, signed, and dated start up reports to CxA. Review and sign off on Final Start up Reports Reviews the final CVs, STs, and ISTs for safety concerns, equipment and warranty protection, and general comments prior to their execution. Submits review comments to CxA. Responsible for all subcontractors completing CVFs prior to the execution of ST and ISTs. Coordinates TAB agency in completion and documentation of test and balance work. Submits TAB report to CxA for review Clearly identifies any outstanding issues with associated piece of equipment or system prior to scheduling ST s or IST s. Support the CxA in resolution of issues recorded in the Issues Log. Submit training plan and coordinate the SUBs to provide the training of owner personnel as required by the contract documents Coordinate the submission of the O&M manuals, according to the contract documents, including clarifying and updating the original sequences of operation to as built/as tested conditions. Produce final as built drawings and specifications Acceptance/Post Acceptance Phases: Coordinates SUBs in execution of and witnesses ST and ISTs. Provide utilities and testing equipment necessary to complete associated STs and ISTs. Carry out / coordinate O&M staff training for effective, ongoing operations and maintenance of all systems. Commissioning Roles and Responsibilities Owner Representative Responsibilities Cx TEAM MEMBER Owner s Representative (OREP) RESPONSIBILITY General: Facilitate the coordination of the commissioning work by the CxA, and, with the CM and CxA, ensure that commissioning activities are being incorporated into the master schedule. Develop and maintain the Owner s Project Requirement (OPR) document throughout the design and construction process Assign operation and maintenance personnel and schedule them to participate in commissioning team activities. Review and approve the final Cx Plan. Design Phase: Provide the OPR documentation to the CxA and Contractor for information and use. Provide the BoD document, prepared by the AE and approved by owner, to the CxA for use in developing the commissioning plan, CVs, STs, and ISTs. Coordinate the resolution of non compliance and design deficiencies identified in all phases of commissioning. Construction Phase: Attend Cx meetings and approve/reject results of Cx efforts as required to ensure optimal performance of systems as per Owner s requirements and contract documents. Perform the normal review of contractor submittals. Reviews initial and final CVs, STs and ISTs. Provides approval and direction to move forward with Cx activities. Support the CxA in resolution of issues recorded in the Issues Log Engage owner s personnel in witnessing of installation verification, system and integrated system testing. The owner s personnel shall be designated by the OREP for the specific Cx activities as deemed necessary. They shall include but not be limited to representatives from Facilities Maintenance Staff, Environmental Health and Safety Staff, BioSafety Staff, etc.. Acceptance/Post Acceptance Phases: Assist the CM in coordinating the training of owner personnel. Provide final acceptance of CVs, STs and ISTs. Provide final acceptance of equipment, systems and ultimately the project. Assist the CxA as necessary in the seasonal or deferred testing and deficiency corrections required by the specifications. 10

13 Testing & Certification Testing and Certification Identify Required Testing Standard Testing & Balancing Air Systems Water Systems Containment System Testing Duct Integrity Standard Leakage Test Pressure Decay Testing Helium Leak Testing Room Integrity 11

14 Testing and Certification Must Understand Time Required for Testing Due to Sensitivity of Tests, Cannot Relieve Test Gas into Room Since Affects Next Test Duct Pressure Decay Test Hookup Detail Testing and Certification Identify Required Testing Containment Boundary Testing Room Integrity For BSL-3 Spaces Two part procedure Visual inspections Smoke test Not a pressure decay test SAFETIES & CONTROLS 12

15 Testing and Certification Identify Required Testing Primary Containment Testing Fume Hoods Biological Safety Cabinets HEPA Filter Housing Test Pressure Decay Testing HEPA Filter Installation Verification Scan Testing Testing and Certification Identify Required Testing Zone Controls Testing Normal Operation Standby Power Operation Failure Mode Testing System Controls Testing Normal Operation Standby Power Operation Failure Mode Testing 13

16 Commissioning Example CxA HVAC Component Verification Containment Devices Ventilation Equipment Heating Equipment Cooling Equipment COMPONENT VERFICATION (CV) TABLE MECHANICAL COMPONENTS Sampling Rate Failure Limit Air Handling Units (AHU 1.1, AHU 1.2) 100% 0% BSL3 Exhaust Fans (EF 1.1, EF 1.2) 100% 0% HEPA Filter Housings (BI/BO 1A&1B,2A&2B,3A&3B,4A&4B) 100% 0% Supply/Exhaust Valve Box Sound Attenuating Devices (SATT SVA1, SATT SVA2, SATT SVA3, SATT SVA4, SATT SVA5, 50% 10% SATT EVA1, SATT EVA2, SATT EVA3, SATT EVA4, SATT EVA5, SATT EVA6) Steam PRV Stations (PRV 1.1, PRV 2.1, PRV 2.2) 100% 0% Steam Condensate Pumps (CP 1.1, CP 1.2) 100% 0% Hot Water Unit Heater (UH 2.1, UH 2.2) Steam Unit Heater (UH 1.1, UH 1.2, UH 1.3, UH 1.4) 100% 0% Fan Coil Unit (FCU 1.1, FCU 1.2, FCU 1.3) Lab Area Supply Air Valve (SV A1, SV A2, SV A3, SV A4, SV A5) 100% 10% Lab Area Exhaust Air Valve (EV A1, EV A2, EV A3, EV A4, EV A5, EV A6) 100% 10% Biosafety Cabinets (BSCs) 100% 0% Autoclaves 100% 0% For Certification You Must - Document, Document, Document Bioseal Isolation Dampers 100% 0% Building Automation System (BAS) 100% 0% Domestic Cold/Hot Water Systems 50% 10% Lab Cold/Hot Water Systems 50% 10% Emergency Showers and Eyewash Stations 100% 0% Lab Vacuum System 100% 0% Lab Gas Systems (CO2) 100% 0% Pure Water System 100% 0% Fire Protection System 50% 10% Control Valve (V 1, V 2, V 3, V 4, V 5) 100% 0% Hot Water Duct Coil (RHC A1, RHC A2, RHC A3, RHC A4, RHC A5) 100% 0% Flash Tank (FT 1, FT 2) 100% 0% Air Cooled Air Conditioning Unit (ACCU 1, ACCU 1) 100% 0% Glycol Hot Water Pump (P 1.1, P 1.2) 100% 0% Hot Water Pump (P 2.1, P 2.2) 100% 0% Commissioning Example CxA Electrical Component Verification Main Equipment Safety Devices (Breakers) Normal & Emergency Power ELECTRICAL COMPONENTS Sampling Rate Failure Limit Automatic Transfer Switches 50% 10% Emergency Power Generator 100% 0% Transformers 100% 0% UPS System 100% 0% Fire Alarm Components 50% 10% Lighting Control Devices 50% 10% Distribution/Breaker Panels 50% 10% Emergency Power Circuits 50% 10% Normal Power Circuits 50% 10% VFD Drives (for AHU s, EF s, Pumps) 50% 10% For Certification You Must - Document, Document, Document 14

17 Commissioning Example For Each Component Develop Specific Checklist Testing and Certification Once components are confirmed to be operating properly, each system can then be tested. Operational tests must be done on normal power and standby power System Failure Tests are Also Performed SYSTEM TEST (ST) TABLE MECHANICAL SYSTEM TESTS Sampling Rate Failure Limit Chilled Water System N/A N/A Hot Water System N/A N/A Steam System N/A N/A Air Handling Units (AHU 1.1, AHU 1.2) 100% 0% BSL3 Exhaust Fans (EF 1.1, EF 1.2) 100% 0% VFD (for fans and pumps) 100% 0% Lab Area Supply Air Valve (SV #) 100% 0% Lab Area Exhaust Air Valve (EV #) 100% 0% Biosafety Cabinets (BSCs) 100% 0% Autoclaves 100% 0% Building Automation System (BAS) 100% 0% Domestic Cold/Hot Water Systems 50% 10% Lab Cold/Hot Water Systems 50% 10% Emergency Showers and Eyewash Stations 100% 0% Lab Gas Systems (CO2) 100% 0% Pure Water System 100% 0% Fire Protection System 50% 10% Containment TAB Verification 100% 0% Non Containment TAB Verification 50% 10% BSL 3 Boundary Integrity Testing 100% 0% ELECTRICAL SYSTEM TESTS Sampling Rate Failure Limit Fire Alarm System 50% 0% Lighting Control System 50% 10% UPS System 100% 0% Emergency Power Generator 100% 0% 15

18 Testing and Certification Finally Integrated System Tests are Performed INTEGRATED SYSTEM TEST (IST) TABLE INTEGRATED SYSTEM TEST Sampling Rate Failure Limit Lab Module (Note 1) N/A N/A Emergency Power Failure N/A N/A How does failure of one system affect another?? Should non-bsl-3 systems shut down on BSL-3 supply air failure? Should non-bsl-3 systems shut down on BSL-3 exhaust air failure? Testing and Certification All testing and results must be included in submission to certifying agency. Typically included in the Design Intent Document No specifics on how to document. Video of tests have been used in the past. Before testing must clearly identify pass-fail criteria ( e.g. airflow shall not be reversed ) 16

19 Submit Appropriate Checklist BMBL 5th Edition BSL-2 BMBL 5th Edition BSL-3 Submit Appropriate Checklist ABSL-2 with NIH Req mts ABSL-3 with NIH Req mts 17

20 Updated Standards Always check for current updated requirements Due to timing of projects, new requirements may affect design: BMBL 4 th Edition: Consideration should be given to installing an HVAC control system to prevent sustained positive pressurization of the laboratory. BMBL 5 th Edition: The laboratory shall be designed such that under failure conditions the airflow will not be reversed. Sample Cx Issues Upon BSL-3 System Failure Reverse Airflow 45 Seconds Cause: Temporary Loss of Exhaust Header Static Resolution: Close Supply Valves In Lab, Pressurize Clean Corridor Note: Must Not Make Lab Too Negative on Supply Closure Loss of Exhaust Header Static Pressure Cause: Failed Fan Isolation Damper Closes Too Slow Resolution: Consider Backdraft Damper Note: Must Meet Code for Isolation with Fan Offline Upon BSL-3 System Failure Reverse Airflow Cause Signal Delay Between Fan Failure and Room Response Hard Wire Signal to Pressurize Clean Corridor Upon Startup Large Negative Pressure in Labs Cause: Supply and Exhaust Valve Actuator Speeds Did Not Match Resolution: Slow Down Ramping of Fans and Exhaust Valves to Match Supply 18

21 MODULE 4 MECHANICAL, ELECTRICAL, PLUMBING CONSIDERATIONS I Tradeline Takeaways Commissioning Is Planned Verification of System Performance For BSL-3, Falure Testing Should be Identified Early in Design to Ensure Component Performance Can be Specified Failure Testing Not Identified During Design May Have Unintended Consequences (Duct, Ceiling or Wall Damage) Questions? 19

22 MODULE #6 COMMISSIONING, VALIDATION, CERTIFICATIONS MICHAEL WALSH PRINCIPAL, R.G. VANDERWEIL ENGINEERS, LLP 274 Summer Street, Boston, MA (T) (F)

23 Date: Session: Presenters: Metrics Tools Resources Innovative Ideas Proofs

24 Date: Session: Presenters: Metrics Tools Resources Innovative Ideas Proofs

25 Date: Session: Presenters: Metrics Tools Resources Innovative Ideas Proofs

26 Date: Session: Presenters: Metrics Tools Resources Innovative Ideas Proofs