Transcript What Constitutes a Quality Commissioning Job

What
Constitutes a
Quality
Commissioning Job?
Agenda
• Preconstruction Services
– Brian Toevs, PE
• Construction Services
– Rusty Ross, PE, LEEDTM, CxA
• Client Relationship
– Mark Leafstedt, PE CCP CxA
Commissioning Process
Design Intent/
Owners Project
Requirements
Design Document
Review
Basis of
Design
Review
PLANNING
Project Timeline
Spec
Review
DESIGN
Submittal
Review
O & M Document
Review
Construction
Checklists
Pre-Functional
Testing
Functional
Testing
Cx
Report
Warranty
Review
Training
Review
Start-up
CONSTRUCTION ACCEPTANCE
Seasonal
Testing
OPERATIONS
Owner’s Requirements
•Owners need help defining their needs
We can help
•Get in early - During Predesign
•Attend meetings during Schematic Phase
•Attend more than one meeting
•Be an active member of the team
•Write the OPR for the owner
Owner’s Requirements
• Help the Architect write the OPR
• Initiate 1st draft of the Basis of Design
Then turn it over to the designers
• Be Proactive, Invite your self to the party
OR
• Better yet - have your own party
Owner’s Requirements
Have a “Core Values” party
• Participants should Include:
– Owner
– User Group Members and Leaders
– Maintenance staff
– Architect / Engineer
– Contractors / CM
• Plan for ½ to full day, for the exercise
Owner’s Requirements
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Participants are educated
We get "buy in"
Educational process accelerated
Decisions verified
Adversity diminished
Nuances of organization learned
Design process expedited
Remember: The OPR is a
non technical document,
that describes what needs
to happen for the Owner to
call this project a success.
Owner’s Requirements
Have Break-out
Sessions
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Ask questions
Unpack issues
Work through ideas
Discard bad ideas
Small groups to work
out concepts
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Get input up front
Un-Ravel the Owners
Requirements
Eliminate Preconceived Ideas
Create Concepts for discussion
Owner’s Requirements
Existing Conditions
Two Solutions
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Present Ideas to group
Not Complete Designs
Better Direction for team
Owner Requirements better Defined
Design Review
• Minimum-Review Systems Commissioned
• Best Practice Review Should Include:
– Mechanical
– Electrical
– Architectural
– Specifications
– Coordination among trades
Design Review
• To do a good HVAC review you have to
look at the Architecture
• Many HVAC problems are Architectural
Problems
• High performance buildings are failing:
– Designing smaller HVAC systems
– Normal Architectural Detailing
While this detail does
not show it, there is
batts insulation required
under the decking
Acoustical decking allows air to pass into
building on both sides of the corrugations
Batts insulation won’t seal the ends,
only filter the air
No details on this project address
acoustical corrugated decking
Corrugated Acoustical Roof Decking
Batts Insulation
Roof Insulation
Concrete Block Wall
Air Pathways
If the Architectural details are unclear the contractor has free
reign to do as much or as little as they want
Cx Specifications
• We’re not the designers but we can help
• Cx spec writing is more than writing Cx
specs
– Review Division 1 specs
– Review Mechanical specs
– Review Electrical specs
– Review / Write / Edit Cx Specs
Cx Specifications
• Request electronic specifications in
electronic format, i.e. MS Word, Word Perfect
• Edit specs with “Track Changes”
• Return electronic specs to designer, for
review and approval
– Engineer or Architect-of-record owns the
specs, we are only making suggestions
Cx Specifications
• Review Division 1 specs:
– Review submittal requirements
• Add submittal requirements for Commissioning
• Review O&M Requirements, modify submittal date to be just
after submittal approval
– Review payment application requirements
• Tie payment application to completion of checklist tracking
form
– Review substantial completion requirements
• Tie Cx completion to substantial completion
– Write Division 1 Cx Requirements Spec
Cx Specifications
• Review Mechanical Specs:
– Edit general requirements to reference Cx
– Edit Controls specs
• Review quality assurance requirements to be more
Cx friendly
• Tighten-up contractor qualifications
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List specific individuals assigned to project
Temporary programming / global commands
Trending requirements / memory availability
instrument calibrations
Cx Specifications
• Review Mechanical Specs:
– Edit TAB Specs
• Review quality assurance requirements to be more
Cx friendly
• Tighten-up contractor qualifications
– List specific individuals assigned to project
– Write the Mechanical Cx requirements spec
– Develop SVC sheets and checklist tracking
form
– Write the Mechanical testing requirements
Bidding
• Cx Plan needs to be specific enough to
provide guidance but open enough for
updating
• Cx Plan should mirror the spec
requirements
• Keep it short, 15 to 20 pages plus
diagrams
• Define flow of Cx Process, documentation,
et cetera. Use Flow diagrams
Bidding
Commissioning Process Flow Chart – Construction Phase
Cx
Coordination
Meeting
Update
Cx Plan
CxA to Receive
Approved
Review
Contractor
Schedule
Shop Drawing
Submittals
EOMM and
SOMM
Submittal
Architect Will
Review and
Approve
EOMM and
SOMM
provided to
CxA
To: System
Readiness
Review Construction
Checklist and
Update as Required
Startup
Equipment Training
Plan Submittal
Develop Functional
Test Procedures
Architect and
Owner Will
Review and
Approve
Completed
Checklists
Submitted
Witnesses
Construction
Checklist
Completion
System Readiness
CxA Will
Review and
Approve
Equipment
Training
Sessions
To: Acceptance
Bidding
Commissioning Process Flow Chart – Construction Phase
Systems
Training
Sessions
FT’s
Performed
Reports
Written
Yes
Pa
ss
Functional
Completion
To: Warranty &
Deferred Testing
No
Deficiency
Resolution
Acceptance
Warranty
Period and
Operations
Review
Final Cx
Report
Yes
Deferred FT’s
Pa
ss
No
Deficiency
Resolution
Warranty and Deferred Testing
Construction Services
• Construction Phase
– Document Installation
– Prepare for acceptance phase
• Acceptance Phase
– Functional testing
– Owner training
– Final report/systems manual
• Post Occupancy and Warranty
– Opposed season functional testing
– Warranty review
Construction Services
• Construction Phase
– KO meeting for all team members
– Review shops
• Update Cx plan, PFCs and FPTs
– Integrate Cx into construction schedule
– Plan for owner preparation
• Training – Develop execution plan and schedule
• Record Documents – Review as project progresses
• O&Ms/Systems manual – Available early
– Document installation – execute PFCs
Commissioning Plan
Prefunctional Checklists (PFCs)
Chilled Water Piping
Chilled water piping installed per the detail on M5.1A
CHS & R piping at the coil is 4 inch per the schedule on sheet M1.1A.
Piping arrangement per the detail: CHS hdr - iso valve, pete's plug, thermometer; coil branch - flange, offset
connection for coil pull, B&G circ setter, pete's plug, gauge cock, coil, pete's plug, gauge cock, flange,
offset; return hdr - pete's plug, con
There is adequate room to pull the chilled water coil per M3.3A
Chilled water coil manual air vents installed per coil per the detail on M5.1A
Chilled water coil drains installed per coil per the detail on M5.1A
Thermometers installed 9" 15515-2.02-K
Piping system properly pressure tested for 6 hours at 125PSI per 15050-3.09
Piping system cleaned and properly flushed 15050-3.08
Chilled water coil clean
Humidifier Piping
Steam piping properly connected per the detail on M5.3A
Piping: Iso valve, strainer, union, control valve, union, humidifier, condensate w/ dirtleg(w/ blow down valve).
A cold condensate shut off sensor attached between the control valve & humidifier before the unit and
downstream of the humidifier on the cond
Steam piping 2" per sched on M1.1A
Piping system properly pressure tested for 6 hours at 125PSI per 15050-3.09
Piping system blown down w/ 5PSI steam and condensate wasted for 8 hours per 15050-3.08
yes/no
Master Deficiency List
Master Deficiency List
(latest deficiencies in bold text)
Date
February 3, 2005
Item
#
EQUIP #
/Spec
Section
1
Panel HCR2
2
Panel LCR2
DATE
FIV/ FPT/O&M
REVIEWED
8/9/2004
8/9/2004
DEFICIENCY
RESP.
FIV
The electrical working clearance for Panel HCR2 is not
per NEC 110. Panel LCR2 blocks the right portion of
the panel width within the 42" reqmt.
CEC
FIV
The electrical working clearance for Panel LCR2 is not
per NEC 110. The conduits at the floor in front of the
panel, penetrate the floor in front of the plane of the
panel can.
CEC
CEC
ACTION TAKEN
DATE Cx
VERIFIED
3
Panel HN3
8/9/2004
FIV
The electrical working clearance for Panel HN3 may
not be per NEC 110. The transformer and flexible
conduits @ the floor must be 42" from the panel
(exposed live parts).
4
Panel LCR5
8/9/2004
FIV
The electrical working clearance for Panel LCR5 is not
per NEC 110. The adjacent panel can blocks the right
portion of the panel width within the 36" reqmt.
CEC
5
AHU 1
8/9/2004
FIV
The chilled water coil pull is blocked by the header at
the coil.
B&K
Flanged connections have been provided in
the piping above the coil for piping removal for
coil pull.
JAH
9/20/04
6
RF 5A
8/9/2004
FIV
The relief duct is tapped into the back of the 90 degree
silencer.
B&K
PCA
Relief duct tap into 90o silencer approved and
designed by M&I Systems.
JAH
9/20/04
FIV
The FSDs at the floor entering the return (see sheet
M406) are not accessible without dismantling a section
of the fabricated return plenum. An access door is not
shown to be installed.
B&K
PCA
Removable access panels have been provided
in the return plenum for access to FSDs.
JAH
9/20/04
7
RF 5A and B
8/9/2004
Document Installation
Box access
Document Installation
Incorrect coil piping
Document Installation
Valve access
Document Installation
Lack of welding on grease duct
Construction Services
• Acceptance Phase
– Start-up
– Functional testing
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Verify controls
Simple to complex
Single to integrated
Coordinate w/ subs – controls, T&B
– Owner training
• Execute and monitor
• Systems training
– Final report/systems manual
Monitor Start-up
Construction filters not in place
The Field Team
Functional Performance Tests
(FPTs)
Mode
Test Procedure
Command the Chiller on by
the EMS WCM-4 to lead
Expected Response
1. CHW pump started by EMS
Pass Y/N/Note
Note 3
2. CW isolation valve opens; CW pump starts (interlocked w/ CHP)
3. Cooling tower isolation valve opens and CT is enabled
4. Chiller enabled by EMS
5. Chiller starts when water flows are proven
6. Chiller controls on internal chiller LCHW stpt
7. Valve in CWR modulates to control chiller condenser pressure
Open preheat valves to
increase the load above the
capacity of one chiller
Open preheat valves to
increase the load above the
capacity of two chillers
Staging sequence WCM 1 >WCM 2 >WCM 3 >WCM 4
Tons = .0417*GPM*(CHWRT-CHWRST)
1. SCHW flow from EMS __________ GPM Load _______ tons
Note 4&7
2. When lead chiller is at 90% full load amps, lag chiller#1 begins
start sequence after 15 minutes.
YES
Staging sequence WCM 1 >WCM 2 >WCM 3 >WCM 4
Tons = .0417*GPM*(CHWRT-CHWRST)
1. SCHW flow from EMS __________ GPM Load _______ tons
Note 4&7
2. When the average amperage of all operating chillers is above
90% full load amps, lag chiller#2 begins start sequence after 15
minutes.
YES
Functional Performance Tests
Construction Services
• Post Occupancy and Warranty
– Opposed season functional testing
• Peak summer
• Peak winter
– Warranty review
• Review building performance w/ owner & O&M staff
• Note any deficiencies
• Plan of action
Client Relationships 
Client Relationships
• WHO ARE THE CLIENTS?
– Owner? General Contractor? A/E
Consultants?..............Yes
– Does the client always hold the Cx contract?
• WHAT KIND OF CLIENTS?
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Participative or Non-Involved?
Demanding or Relaxed?
Sophisticated or Not?
Clear on Cx Expectations or Not?
• HOW DO YOU HANDLE DIFFERENCES?
Client Relationships
• IMPORTANCE OF COMMUNICATION
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Enlistment of an advocate
Prevent surprises
Build a cooperative environment
Reduce misunderstandings
Speed resolution
Must be clear, concise, factual, non-blaming
Professional use of all forms:
• Verbal or written
• Cx documents
Client Relationships
• WHY DO WE DOCUMENT?
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Communication
Set Expectations
Record and track events and results
Legacy
• WHAT MAKES OUR DOCUMENTATION
DIFFERENT?
– Independent Perspective
– Detail
– Resolution oriented rather than blame oriented
Client Relationships
• WHAT DEFICIENCIES DO YOU BRING TO THE
CLIENT?
– All? Cost impact ones? Design ones? Construction
ones? Long Term ones?
– Are all logged issues actually deficiencies?
• HOW DO WE GET RESOLUTION?
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Participate or pull away?
Resolve during or after discovery?
Get Client involved?
Can we reduce the number or deficiencies or time it
takes to resolve them?
Client Relationships
• SUMMARY
– Communicate
– Be Professional
– Listen
– Communicate
– Document
– Participate
– Communicate