The Nuts and Bolts of the Commissioning Process

Transcription

1 The Nuts and Bolts of the Process May 2, :30 Noon 15 th National Conference on Building Where the Industry Meets

2 Agenda Introduction Getting started When is commissioning required? Choosing a commissioning provider Choosing the best process Process Benefits Case studies Cost overview Discussion Agenda 2

3 George Oberlander Jr., I.E. Director, Facilities Management Group 22 years Facilities Management/ Experience Published author on facility management Expert in CMMS design and implementations Multi-discipline commissioning experience including hospitals, manufacturing, transit, and data center Introduction 3

4 Making the decision to use commissioning services on your project Were you satisfied with the end product? Was system functionality an issue after acceptance? Were systems integrated completely? Do system deficiencies cause productivity issues? Has documentation been completed? Were facilities staff fully-trained? Did your complex system work as intended? Did your systems function in a critical environment? When is commissioning required 4

5 is independent of the design management team Design professionals hire an independent agency The owner can contract an independent agency The public sector department often requires third-party representation A general contractor may hire third-party representation The design firm may provide an independent department for commissioning services Choosing a commissioning provider 5

6 There are different versions of commissioning to meet your needs LEED fundamental commissioning LEED extra credit commissioning ASHRAE Guideline 1 Retro Choosing the best process 6

7 can be applied to new or existing systems New Construction DESIGN Retro- FUNCTIONAL ANALYSIS CONSTRUCTION FUNCTIONAL PERFORMANCE TESTING O&M TRANSITION EQUIPMENT ASSESSMENT POST ACCEPTANCE O&M TRANSITION Process 7

8 Retro- verifies if installed systems operate as designed after BOD Retro- Differences: Improved documentation availability Functional assessment Historical precedence for O&M Historical precedence for operating costs Scheduling considerations Equipment assessment for O&M Equipment assessment for design compatibility Process 8

9 defines successful project using pass/fail criteria Validating & documenting facilities & their systems Verifying performance buildings energy related infrastructure Certifying systems meet owner s project requirements Assuring cost-effective management of facilities during the complete life cycle Process 9

10 benefits all team members Defines performance goals up front Uncovers problems early, preferably in design; corrects small problems before they are big problems Reduces change orders Ensures training and systems are fully documented Ensures long-term system performance and reliability Avoids assigning fault Ensures return on investment Process 10

11 A well-organized team maximizes success Agent Contractor representative Manufacturer's representative Technician with commissioning tool belt Process 11

12 The commissioning process links the design team to the building life cycle Design Phase Design Design Intent Intent Document Document Basis Basis of of Design Design Draft Draft Refined Refined Construction Phase Team Team Inspections Inspections Pre-Functional Pre-Functional Verification Verification Functional Functional O&M Transition Phase O&M O&M Manuals Manuals Verification Verification Reports Reports System System Documentation Documentation O&M O&M Training Training Warranty Warranty Seasonal Seasonal Testing Testing Post Acceptance Phase Process 12

13 requires cooperation of the entire team Owner Design Intent Time Required for Completion Construction Costs Responsibilities of Team Scope of Agent Enforces performance criteria development Maximizes documentation Owner representative and enforcer of the design intent. Conflict resolution Ensure DEP requirements are addressed by project team Contractor Participant in the Cx Process Timely delivery of Documentation Includes Cx in the Construction Schedule Understanding of Performance measures RESULTS Trained O&M Personal at BOD. Validated Energy Model LEED Certification Long term Life cycle management Functional Systems Reduction in equipment Maximize student retention Facilities Management Maintenance Facilities Standards Warranty Enforcement Staffing Spare Parts Evaluation Cleaning Costs Design Engineer Equipment Selection. Redundancy Reliability MEP Design Intent Basis of design Architect Space ning Site Selection Aesthetics Lighting Design Intent Basis of design documents Process 13

14 The Agent has a key role in the success of commissioning Provides direct interaction Enables on-site contractor to take testing certification, training and documentation to the next level Focuses on important system validation points which typically get overlooked Is owner representative when systems issues are uncovered Facilitates corrective action for all issues that impact the owner Provides oversight for conflict resolution Process 14

15 Design Phase commissioning defines the benchmarks of success Design Phase Design Design Intent Intent Document Document Basis Basis of of Design Design Draft Draft Refined Refined Construction Phase Team Team Inspections Inspections Pre-Functional Pre-Functional Verification Verification Functional Functional O&M Transition Phase O&M O&M Manuals Manuals Verification Verification Reports Reports System System Documentation Documentation O&M O&M Training Training Warranty Warranty Seasonal Seasonal Testing Testing Post Acceptance Phase Process 15

16 The Design Phase establishes the standard for the entire project Coordination of team Design phase commissioning plan Design intent/basis of design document is development Begin developing documentation Review of design documents Coordination of specifications Drawing/submittal review by CA Testing standards Process 16

17 The is the steering document for the project Identifies strategies and responsibilities Outlines overall process, schedule, and documentation requirements Process 17

18 Design intent defines pass/fail performance criteria Definition of facilities functional requirements Performance metrics are defined to ensure systems are commissionable Defined limits and restrictions of systems Budget considerations Diversity considerations Design assumptions of the facility and systems References for code compliance requirements Documents the reasons why a decision was made Forces project team to develop a basis of design using performance measures Process 18

19 Early document submittals benefit the commissioning process O&M Documents (Adequate time for preparation prior to receipt of equipment): Define detailed O&M requirements in specifications Include required documents in specifications for early submission: Shipping and Handling Factory Testing Installation Maintenance Documents Field Testing Preliminary submittals to be included with shop drawings Final complete submission due at receipt of equipment Process 19

20 Construction Phase ensures the systems & equipment operate as per the Design Intent - The Process Design Phase Design Design Intent Intent Document Document Basis Basis of of Design Design Draft Draft Refined Refined Construction Phase Team Team Inspections Inspections Pre-Functional Pre-Functional Verification Verification Functional Functional O&M Transition Phase O&M O&M Manuals Manuals Verification Verification Reports Reports System System Documentation Documentation O&M O&M Training Training Warranty Warranty Seasonal Seasonal Testing Testing Post Acceptance Phase Process 20

21 The Construction Phase executes the Design Intent Construction Phase Commission Design Intent is updated Facilitate Construction Phase coordination meetings Coordinated drawing review Review O&M documentation Evaluate installations for maintenance access and replacement criteria Witness testing and review testing results Review TAB documentation and coordination TAB verification review and deficiency report Process 21

22 Construction Phase testing reveals component deficiencies Pre-functional Testing: Documentation has been delivered and is correct Manufacturer properly tested and certified systems Critical system testing performed and accepted Inspection of equipment upon delivery Equipment specifications are correct per design Equipment is properly identified Process 22

23 Construction Phase testing reveals system deficiencies Functional Testing: Safety systems are functional per design Calibration and testing of control systems Inventory test points and measured values System integrity testing Witness testing Document non-conformances of system Coordinate corrective action plan Verify critical documentation for design specifications Process 23

24 Testing checklists must contain the details of installed systems NBMA - MEP SYSTEMS COMMISSIONING EQUIPMENT FUNCTIONAL PERFORMANCE TEST CHECKLIST Notice: This is not a punch list. Check-off indicates system is in general compliance, was readied for functional testing, and was tested. Punch listing is performed by the engineer of record, not the commissioning team. Generator Mfg./Size: Model: Location: PERCENT OF OF SYSTEMS OR UNITS TO UNDERGO TESTING [Enter 10%, 20%, 50%, or All]. [ SYSTEM NO. [EQUIPMENT ITEM] TAG. NO. [Enter Tag No. or Symbol From s] Contract Spec or Dwg. Reference [Enter Reference] PART ITEM DESIGN VALUE ACTUAL VALUE PASS/FAIL A PRE-START AND START-UP CHECKLIST COMPLETED! [Mandatory] B Demonstrate operation of system or unit in accordance with design intent and Contract Documents. Contractor will verify operation by performing the following tests. Open normal power breaker: ATS transfers load to generator Motorized exhaust louver cycles open Generator starts, emergency lighting and exit signs to full brilliance within 10 seconds Remote enunciator signals generator "on". Process 24

25 Construction Phase testing has inter-system requirements Multi vendor systems normally not tested Contract requirements needs to be defined early Agent has a primary responsibility to define and execute these tests Process 25

26 Correct deficiencies prior to substantial completion Oversight of Agent improves quality and removes the financial burden from the owner Testing is validated Performance of testing agency is improved Direct coordination of separate entities is ensured Documentation of performance Documentation of deficiencies Follow-up and corrective action Resolution is executed prior to facility occupancy in most cases Corrective action is performed while contractor is on-site Final payment retention can be enforced Benefits of Successful 26

27 Like a technician, the Authority has essential tools Infrared thermometer Voltmeter Ammeter Air flow capture hood Ultrasonic flow meter Infrared camera Building Management System CMMS RPM meter Digital manometer Honeywell display module The tool belt 27

28 O&M Transition Phase ensures people & processes are in place to enforce Design Intent - The Process Design Phase Design Design Intent Intent Document Document Basis Basis of of Design Design Draft Draft Refined Refined Construction Phase Team Team Inspections Inspections Pre-Functional Pre-Functional Verification Verification Functional Functional O&M Transition Phase O&M O&M Manuals Manuals Verification Verification Reports Reports System System Documentation Documentation O&M O&M Training Training Warranty Warranty Seasonal Seasonal Testing Testing Post Acceptance Phase Process 28

29 The O&M Transition Phase gets O&M data ready for building occupancy date O&M Manuals: Description and Operation Verify that operational recommendations are outlined. Inspection, Maintenance and Troubleshooting Verify that maintenance and troubleshooting recommendations are outlined. Spare Parts Recommended spare parts are identified and documented for owner. Process 29

30 In the O&M Transition Phase, verification reports are transferred to the OM staff Final acceptance parameters are defined Confirmation of working systems is documented Functional procedure can be use for future troubleshooting procedures Process 30

31 During the O&M Transition Phase, accurate system documentation is delivered O&M Requirements: Safe Practices Verify all safety recommendations are outlined Specifications/Ratings and Operational Parameters Verify specifications are correct per bill of materials Figures and Diagrams Verify that appropriate figures and diagrams are accurate. Process 31

32 The Agent ensures staff is trained on installed systems Training: Review all of the primary components for the design. Safety systems incorporated in the design. Satisfy manufacture recommendations while fulfilling operations needs. Ensure that the training, O&M and system manuals are complete Process 32

33 Post Acceptance Phase verifies that the design intent is maintained after BOD - The Process Design Phase Design Design Intent Intent Document Document Basis Basis of of Design Design Draft Draft Refined Refined Construction Phase Team Team Inspections Inspections Pre-Functional Pre-Functional Verification Verification Functional Functional O&M Transition Phase O&M O&M Manuals Manuals Verification Verification Reports Reports System System Documentation Documentation O&M O&M Training Training Warranty Warranty Seasonal Seasonal Testing Testing Post Acceptance Phase Process 33

34 During the Post Acceptance Phase, warranty enforcement procedures are put in place Warrant and Liability Manufacture requirements are incorporated in the commissioning program. Manage warranty options through qualification period Process 34

35 Post Acceptance Phase: Continuous monitoring of the design intent Submittal of Report Functional performance tests for seasonal condition Deficiency and open issue review Warranty management and develop follow-up schedules Develop re-commissioning manual Process 35

36 can provide critical data for facilities management Data for a maintenance management system System data readily available and documented Metrics determined for control points Integration issues can be minimized with correct planning Maintenance program can be in place at BOD Higher quality of maintainability and operability Optimize system efficiency over life cycle Maintenance program can be set up to recommision the facility Benefits of Successful 36

37 ensures stand-by power at Building Occupancy Date 1500KW Emergency Generator: Pre-functional testing minimizes impact to functional operation Generally the equipment is not ready to test when startup is required Integrated systems are typically deficient coordinates debugging the integrated systems since they are tested that way Equipment failures are prevalent unless factory tested Coordination of responsible trades and manufactures during witnessed testing Functional operation uncovers component deficiencies validated full functionality Case Studies 37

38 Plenum integrity verified during the commissioning process HVAC System Air Distribution System: Inspections indicated conduit penetrations were not sealed in a pressurized plenum Pressure losses resulted in loss of static pressure Air handlers were not modulating below 100% Low air flows resulted in high humidity and temperatures in cooling conditions Heat recovery systems would not function correctly due to low return air Contractor was notified of deficiencies early but issues were not corrected deficiencies identified and forced corrective action on items which may of slipped by Case Studies 38

39 ensures a multi-vendor control system functions as designed HVAC Acceptance Testing: Different vendors for building management and terminal equipment result in integration issues Equipment has multiple control strategies Diagnostics and trending critical in operations analysis Design intent requirements for measurable standards critical Testing and Balancing direct oversight dictates that each component functions as an integrated system Case Studies 39

40 Identification of functional issues prior to owner acceptance Oversight of Functional Operation: During manual operation of the switch it was found that the generator neutral bus and primary facility bus were at different potentials. The ATS was configured for 4 pole operation and the neutral terminations were not connected correctly for the neutral isolation. The generator neutral bus had to be grounded at the unit and the primary neutral lead for the generator and facility neutral circuit had to be swapped to correct the problem. focuses on the details! Case Studies 40

41 75% of commissioning cost is in the first 2 phases 35 Cost % of Effort By Phase DESIGN CONS O&M POST Cost Overview 41

42 Depending on the size of the building Cx ranges from 1% to 3.5% of MEP cost 4.0% 3.5% 3.0% 2.5% 2.0% 1.5% 1.0% 0.5% 0.0% 2M 4M 6M 8M 10M Cost Distribution of Percentage of MEP 12M 14M 16M 18M 20M 22M 24M Column 3 ENH CX FUN Cx Cost Overview 42

43 The life cycle approach maximizes success Design Phase Design Intent Construction Phase Systems & Equipment O & M Transition Phase People & Processes Post Acceptance Phase Life Cycle Conclusion 43

44 Questions & Discussion Gannett Fleming, Inc Discussion 44