Turn Over Packages, FAT and Commissioning

San Francisco Bay Area Chapter Commuter Conference May 13th 2008 Misha Anissimov, Genentech Mike Britting, Hathaway Dinwiddie Leo Santini, Hathaway Dinwiddie

FAT
Why do we need a Factory Acceptance Test? Who Benefits, who are the stakeholders? Who should be in charge, who should go? Is it worth the cost?

Basic FAT
Establish what needs to be tested Establish who needs to attend Establish the schedule Establish who will be responsible 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 project. 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 Owners 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 agents support network)

The Owners Representative : should have a solid working knowledge of Mechanical Systems design and function, and provide unbiased information to upper management. Commissioning Agent : Reviews Controls, Writes FPTs, executes FPTs Mechanical Engineer of Record : Owns the system design and Sequence of Operation. General Contractors MEP Coordinator : Will act as the enforcer in helping resolve issues between subcontractors. Mechanical Contractor Project Manager and Field Start Up Technician Controls Contractor Project 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 your own mind of exactly what you want to accomplish.

If you are using a generic specification, supplement this with your own building-specific attachment. What are some unique tests you want to include? 72 hour trends of all building zones? A 5-day quality of life check? A Cx agent Overview class for Facilities? Unusual systems which may require special attention? 100% vs. 10% point to point? Get Facilities Involved. All facilities engineers have pet peeves. Maybe they hate variable primary chilled water systems. Include specific tests in the scope to specifically address Facilities and User concerns.

Step 2: Choosing a Commissioning Agent

As always, word-of-mouth recommendations of Agents are a great starting point. This is 100% Labor.less cost means less Cx activity. PROPOSALS: Ask for sample Issues logs (what kind of problems did they uncover in past jobs?), Ask for sample Functional Performance Tests-FPTs (how are the tests written? Do the documents include generous amounts of hard data like pressure/temperatures/flows, or do the tests look too simplified pass/fail with no data recorded). Test data acquired in the field is useful later in troubleshooting. 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 with in the past and how they would test it.

Step 3: Preparation Preparation Preparation

THIRD PARTY OVERSIGHT: Be sure the contract and channels of communication are established so that the Owner always gets the real deal information from the Cx Agent. He is your person in the trenches making sure everything works. PLANNING: I like to start with dedicated Cx meetings early..right after 95% CD Documents are issued. That means dedicated Commissioning Meetings once a week, starting with a thorough document design review process 75% of Commissioning Problems are controls related. Start with a detailed Controls Sequence of Operation Review by the Cx Agent, Mechanical Engineer, and FACILITYS rep. You are building a Cx TEAM. After SOO , Get the Controls Programmers involved. Ask for Logic Diagrams to understand how the system will be programmed.

A Few Words about FPTs

Actively Review Functional Performance Tests especially key tests. Focus on the Objectives and the Results you would like to see. Beware of Boiler Plate FPTs. Are the tests custom tailored to your systems? FPTs are common sense and are the battle plan of Commissioning.

Step 4: Execution
The SOOs have been scrubbed, you know how the Control Systems will be programmed, the Functional performance tests have been created and reviewed by the Owner, you have adequate staffing for all trades-contractors, and you have PGE power to all systems! You are ready to start Cx activities! Embrace PROBLEMS: The more you find now, the better. Keep FACILITIES Involved: Witnessing tests is great facilities training.and establishes a comfort level before turnover. Cx is a coordinated team effort and delays WILL occur. Avoid the temptation to accelerate Cx activitiesthis will result in errors. Cx agents are not painters/sheetrockers, 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 projected 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 Owners 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 Contractors 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&Ms delivered to Facilities for SOPs 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:
Volume VII:

A. B. C. D. E. F. G.

Project Directory TOP Matrix As-Builts Record Set CD Master Punchlist Warranty Letters RFI Log w/Responses O & M Manuals

LABORATORY SUPPORT EQUIPMENT D.I. Point of Use Polishers Chemical Fume Hoods Radioisotope Hoods Bio Safety Cabinets "DIRTY" PROCESS UTILITIES Laboratory Vacuum "CLEAN" PROCESS UTILITIES RO/DI Water System Carbon Dioxide Laboratory Compressed Dry Air BUILDING UTILITIES Domestic HW/CW Natural Gas Sanitary Waste & Vent Lab Waste & Vent Storm/Roof Drainage FIRE/LIFE SAFETY SYSTEMS Fire Alarm & HVAC Interface Elevator Recall and Safety Sequences Fire Sprinkler Flammable Vapor Detection (LEL) ELECTRICAL & SPECIALTY SYSTEMS Normal Power Service & Distribution Emergency/Standby Distribution Grounding Lighting & Lighting Control Generator & ATS UPS, Batteries Security Including CCTV FMS - Facility Management System ENVIRONMENTAL HEALTH & SAFETY EH&S - Environmental Health & Safety

Volume VIII:

SUBMITTALS Volume II:

A. B.

Submittal Log Approved Submittals

Volume IX: Volume X: Volume XI:

PROJECT SPECIFICATIONS Volume III:

A. B. C.

Specification Listing Record Specifications Record Basis of Design (BOD)

SYSTEMS DOCUMENTATION Volume IV:

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 WET-SIDE HVAC Preheat/Reheat - Boilers, Pumps Condenser Water - Towers, Pumps Refrigerated Water - Chillers, Pumps CONTROLS SYSTEMS BAS - Building Automation System LABORATORY SUPPORT EQUIPMENT D.I. Point of Use Polishers Chemical Fume Hoods Radioisotope Hoods Bio Safety Cabinets

Volume XII: Volume XIII: Volume XIV: Volume XV: Volume XVI:

Volume XVII: Volume XVIII: Volume XIX: Volume XX:

Volume XXI:

Volume V:

Volume XXII: Volume XXIII: Volume XXIV: Volume XXV: Volume XXVI:

Volume VI:

Volume XXVII: APPENDICES Appendix A: Appendix B: Appendix C:

Volume VII:

Seismic Bracing Drawings, Calcs and Inspection Sign-off - Mechanical/Plumbing Eqpt & Overhead Balance Report - Air & Water Commissioning Plan and Report

System Docs: TOP Matrix

GNE FACILITIES SIGN-OFF GNE ENGINEERING SIGNOFF GENERAL CONTRACTOR MEP SIGN-OFF CENTRAL AIR HANDLING
SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION SECTION 3a - PIPING
A B Piping Specifications Piping Documentation i. ii. iii. iv. v. vi. vii.
x x

SECTION

TAB

SYSTEM DOCUMENTATION

Piping Submittal Valving Submittals Specialty Piping / Plumbing Fixture Submittals Seismic Details and Stamped Drawings Weld Procedure(s) Welder Certification Pipe Brazing/Soldering Procedure(s)

SECTION 1-GENERAL
A System Overview i. ii. Equipment List BOD - Basis of Design
C

Installation Documentation/Field Verification i. ii. Pressure Test Report Flushing Report Cleaning and/or Passivation Report Sanitization Plan and Report Field QC Reports/Particulate Report

B Drawings i. ii. iii. Construction Drawings and/or P&IDs Vendor Furnished Drawings As-Built Drawings
x x x x x

iii. iv. v.

C Punchlists/Mechanical Completion Letter D Balance Report E Startup/Commissioning Test Plan i. ii. F Commissioning Plan Final Commissioning Report

SECTION 3b - DUCTWORK
A B Ductwork Specifications Ductwork Documentation i. Ductwork Submittal Insulation Submittal Shop Drawings Seismic Details and Stamped Drawings Specialty Ductwork
x x x x x

ii.
x x x

iii. iv. v. C

Warranty

G Owner Training Documentation

SECTION 2 - EQUIPMENT
A System Documentation i. ii. iii. iv. v. vi. vii. Installation Guide and O&M Manuals Contractor/Vendor Supplied Equipment Submittals/Drawings Equipment Prefunction Checklist HEPA Filter Certification Seismic and/or Structural Calculations Labeling Document Recommended Spare Parts List
x x x x x x

Installation Documentation i. ii. Ductwork Leak Tests Seismic Inspection reports & Sign-off
x x

SECTION 4 - ELECTRICAL
A Electrical Specifications B C Single Line Diagrams Electrical Documentation i. ii. D Electrical Commodities Submittal Seismic Details, Stamped Drawings and Inspection Reports/Sign-off

B Test Reports i. ii. iii. iv. FAT Test Results Field Test Results Contractor/Vendor Startup Reports Hood Certifications (GNE)
x x

Electrical Equipment Checkout i. ii. Ground System Testing Transformer Testing/Reports a. Tilt-Meter Testing b. Insulation Resistance Test Report iii. Megger Testing a. Switchgear/Switchboards

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION SECTION 3a - PIPING

A Piping Specifications

Master TOP Matrix

ECONOMIZER RETURN AIR FAN NORMAL POWER SERVICE & DISTRIBUTION "H" AREA EXHAUST FANS FIRE ALARM SYSTEM AND HVAC INTERFACE SANITARY WASTE & VENT RADIOISOTOPE EXHAUST FANS MECHANICAL ROOM, BOILER ROOM EXHAUST FANS REFR ROOM VENTIL, REFRIGERANT LEAK DETECTION, PURGE, EPO REFRIGERATED WATER CHILLERS, PUMPS, ETC. CENTRAL AIR HANDLING RADIOISOPTOPE HOODS STORM/ROOF DRAINAGE GENERAL LAB EXHAUST CHEMICAL FUME HOODS ELEVATOR RECALL AND SAFETY SEQUENCES LABORATORY VACUUM UPS, PDU & BATTERIES SYSTEM DOCUMENTATION SECTION 1-GENERAL
A System Overview i. ii. B Equipment List Basis of Design (BOD)
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

Drawings i. ii. iii. Construction Drawings and/or P&IDs Vendor Furnished Drawings As-Built Drawings
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

C D E

Punchlists/Mechanical Completion Letter Balance Report Startup/Commissioning Test Plan i. ii. Commissioning Plan Final Commissioning Report

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x

x x x x x x x x x x

x x x x

x x x x

x x x

x x x x x x x x

x x x x

x x x

x x x

x x x

x x

x x x x

x x x x

x x x x

x x x x

x x x x x x

Warranty

G Owner Training Documentation

SECTION 2 - EQUIPMENT
A System Documentation i. ii. iii. iv. v. vi. vii. B Installation Guide and O&M Manuals Contractor/Vendor Supplied Equipment Drawings/Submittals Equipment Installation Checklist (Including Identification) HEPA Filter Certification Seismic and/or Structural Calculations Labeling Document Recommended Spare Parts List
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

Test Reports i. ii. iii. iv. FAT Test Results Field Test Results Contractor Startup Reports Hood Certification
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION SECTION 3a - PIPING

A B Piping Specifications Piping Documentation i. ii. iii. iv. v. vi. vii. C Piping Submittal and Material Certifications Valving Submittals and Material Certifications Specialty Piping / Plumbing Fixture Submittals and Material Certifications Seismic Details and Stamped Drawings Weld Procedure(s) Welder Certification Pipe Brazing/Soldering Procedure(s)
x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

Installation Documentation/Field Verification i. ii. iii. iv. v. Pressure Test Report and Drawings Flushing Report and Drawings Cleaning Report and Drawings Sanitization Plan and Report Field QC Reports
x x x x x x x x x x x x x x x x x x x x x x x x x

SECTION 3b - DUCTWORK
A B Ductwork Specifications Ductwork Documentation i. ii. Ductwork Standards Insulation Data
x x x x x x x x x x x x x x x x x x x

FMS - FACILITY MANAGEMENT SYSTEM

EMERGENCY/STANDBY POWER DISTRIBUTION

BIO SAFETY CABINETS

BAS - BUILDING AUTOMATION SYSTEM

FLAMMABLE VAPOR DETECTION SYSTEMS (LEL, %O2)

SECURITY, INCLUDING CCTV

CONDENSER WATER TOWERS, PUMPS

AIR TERMINAL ZONES

VBSE'S - VENTILATED BALANCE SAFETY ENCLOSURES

LIGHTING & LIGHTING CONTROL

GROUNDING SYSTEM

IDF/MDF BACKUP AC UNITS

BAG IN / BAG OUT FILTRATION SYSTEM

LAB WASTE & VENT

DOMESTIC HW / CW

GENERATOR & ATS

TOP VOLUME NO.

PREHEAT-REHEAT BOILERS, PUMPS

LABORATORY COMPRESSED AIR

D.I. POINT OF USE POLISHERS

CARBON DIOXIDE

FIRE SPRINKLER

NATURAL GAS

RO/DI WATER PURIFICATION

SECTION

TAB

TOP Manuals: Review Sheet

GENENTECH BLDG 46, 47, 48
TOP REVIEW SHEET
N AME : D ATE : S YSTEM /S COPE :

REVIEW SHEET
SECTION COMMENTS RESPONSIBLE CORRECTED

Turn Over Schedule

ID 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Task Name BUILDING 47 TURNOVER SPARE PARTS IDENTIFIED & TURNED OVER Spare Parts Identified by Facilities Pricing Submitted to GNE for Approval Order Spare Parts Spare Parts Turned Over to GNE FINAL PUNCHLIST (REFER TO PROJECT SCH) Final Punchlist Walkthrough Issue Final Punchlist Make Corrections & Backcheck Final Punchlist Complete BALANCE REPORT Issue Balance Reports for TOP (Preliminary) Issue Final Balance Reports COMMISSIONING PACKAGE Executed System Protocols Complete Provide Final Commissioning Overview Package AS-BUILTS, BOD, & SPECS RECORD SET Final as-built, BOD & Specs Submitted to P&W Other As-Builts Submitted to HD Siemens Issue BAS as-builts P&W Compile and Issue Record Set for TOP Therma, REI, Siemens Security Siemens FLS BFP, Walker FMS Siemens BAS P&W AEI AEI Therma Therma P&W, GNE P&W, GNE All Subs, HD, P&W, GN P&W, GNE GNE GNE Therma, REI, H Therma, REI, H Responsible 8 S Mar 24, '08 M W F Mar 31, '08 Apr 7, '08 S T T S M W F Apr 14, '08 Apr S T T S M

Turn Over Schedule - Continued

ID 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 Task Name WARRANTY LETTERS Submit warranty letters TOP MANUALS Submit Remaining TOP System Installation Docs Submit Start-up & Testing Docs Facilities & Engineering TOP Binder Review Make TOP Revisions TOP Substantially Complete Insert Remaining Docs RO/DI Piping Sanitization Reports D.I. Point-of-use Polisher Docs Final Balance Report Final Commissiong Package & Presentation As-Built Record Set EH&S Binder & Section 7 EH&S Docs System Training (See Training Schedule) Certificate of Occupancy (Refer to Project Schedule for ac Permit Binder Submitted Therma Therma/HD Therma AEI P&W GNE, HD Therma, REI, Siemens, GNE, H HD All Subs, HD Therma, REI, Siemens, BF Thyssen Krupp, Walker FMS, HD Therma, REI, Siemens, Walker FM GNE Therma, REI, Siemens, BF Thyssen Krupp, Walker FMS, HD ALL SUBS Responsible Mar 31, '08 Apr 7, '08 S T T S M W F Apr 14, '08 Apr 21, '08 S T T S M W F Ap S

Q&A