Hvac Systems Commissioning Procedures
Hvac Systems Commissioning Procedures
Hvac Systems Commissioning Procedures
CEMP-ET
ER 1110-345-723
Washington, DC 20314-1000
31 July 1995
CEMP-ET
ER 1110-345-723
Regulation
No. 1110-345-723
31 July 1995
Engineering and Design
SYSTEMS COMMISSIONING PROCEDURES
1.
Purpose. This regulation provides policy and guidance for
developing systems commissioning procedures and executing systems
commissioning acceptance testing to verify that the construction
requirements are met and ensure that systems operate as indicated
in the plans and specifications, especially regarding sequences
of operation.
2.
Applicability. This regulation applies to all HQUSACE/OCE
elements, major subordinate commands, districts, and field
operating activities (FOA) having military and/or support for
others design and construction responsibilities.
3.
References.
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operation and demonstration. Testing of system elements and
interactions, beyond the individual technical sections, is often
needed. Such a concentrated requirement to verify that systems
operate as indicated in the plans and specifications, especially
regarding sequences of operation is a significant contributor to
customer satisfaction with the entire design and construction
process. Operation and maintenance functions are enhanced when
all of the responsible parties are cognizant of contract
compliance, construction quality, and performance and operational
parameters of the systems. The importance for a disciplined
approach to systems commissioning is intensified as the cost,
complexity, uniqueness, and magnitude of the project, system or
process involved increases. The need is further intensified by
the interdisciplinary interactions of the various systems
comprising the entire project. The concept and practice of
systems commissioning has long been recognized in the acceptance
of industrial processes, nuclear technology, aviation technology,
and similarly complex projects. The heating, ventilating, and
air conditioning (HVAC) industry has recognized a need to
formulate procedures for functional performance testing and
documentation of HVAC systems. ANSI/ASHRAE GUIDELINE 1-1989,
Guideline for Commissioning of HVAC Systems provides procedures
and methods for verifying and documenting the actual performance
of HVAC systems and evaluating their conformity with the design
intent.
5.
Guidance.
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commissioning requirements materialize less than optimally, the
procedures established in AR 415-15 shall be followed to properly
identify and program the necessary planning and design resources
and construction funding requirements.
(1) The using agency or other associated organizational
elements (e.g., Installation, DEH, MACON, etc.) shall identify
and substantiate any need for systems commissioning and the
associated construction cost on the DD Form 1391, Military
Construction Project Data, during project development. In the
case of work for others, a Memorandum of Understanding (MOU) or
the particular sow governing the work shall describe the concept
of systems commissioning.
(2) The design agent or other associated organizational
element (e.g., HQUSACE, MSC) may identify, validate, and
substantiate any need for systems commissioning and the
associated construction cost during the review stage of the
project development process, including review of DD Form 1391.
This identification shall also occur where the design agent
develops the 1391 as a support service to the using agency. In
the case of work for others, the design agent shall ensure that
the MOU or SOW requires that systems commissioning be identified
on a project specific basis, and for the design agent to
recommend systems commissioning during development of the design
SOW.
(3) The construction agent or associated organizational
element (e.g., HQUSACE, MSC) may identify and substantiate any
need for systems commissioning during participation in the design
process as described in ER 415-1-11.
(4) In the event a need for systems commissioning is
identified by elements outside the using agency, its application
and any cost or schedule implications must be coordinated and
approved by the using agency.
b. Systems commissioning represents testing, operation and
demonstration efforts to verify the intended design as reflected
in the contract documents has been achieved in the installed
construction. Systems commissioning extends beyond the testing,
operation and demonstration associated with individual technical
contract requirements typically identified in individual
specification sections. Systems commissioning requirements as
described herein are not appropriate for all projects or systems.
Projects or systems exhibiting at least two of the following
characteristics shall be considered as prime candidates for
systems commissioning as described herein:
(1)
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continuous operation or treatment beginning with an expected
input or load condition and resulting in an established
continuous output or condition.
(2) Large - The expected construction value of the project
or system exceeds $10 M if new construction is proposed, or $5 M
if renovation, rehabilitation, or alteration is proposed. In
applying this characteristic, the extent to which similar, but
smaller portions are essentially repeated, shall be considered.
(3) Complex The project or system is expected to consist
of intricately combined and interactive portions, the whole of
which has difficult to understand, analyze, or evaluate
performance characteristics.
(4) Unique The project or system involves technology or
specific equipment which is one of a kind and, excluding
prototypes and pilot operations, not more than one other
beneficially proven example exists.
(5) Significant consequential magnitude - The project or
system is critical to life safety, the mission of the
installation, or environmental quality. Failure of the project
or system to function as designed will result in a profound
degradation of these critical features.
(6) Requires systems operation and maintenance
documentation - The project or system has been identified as
described in ER 25-345-1 and requires systems operation and
maintenance documentation, shared as a two-step operation by the
designer and the construction contractor. Systems commissioning
is a natural corollary to systems operation and maintenance
documentation. It should be rare that the need for either would
exist without the other.
6.
Action to be taken. Whenever the need for systems
commissioning is identified and the appropriate resources
authorized, the using agency, design agent, and construction
agent shall all actively participate as a team during the design
and construction process as outlined below. The particular
resources, processes, and responsibilities shall be documented in
the Project Management Plan (PMP) that is specifically developed
for that project. Minimum requirements of a PMP are described in
ER 5-7-1 (FR). It is expected that the using agency will fund
the participation of its own personnel in the commissioning
activities. For Corps of Engineers costs associated with
commissioning, funding shall be in accordance with the activities
performed. For design activities occurring prior to award of the
construction contract, appropriate Planning and Design (P&D)
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funds shall be utilized. For activities occurring after
construction contract award, design agent commissioning
activities shall be related to extension of design and will
therefore be funded by Engineering During Construction (EDC)
resources. Construction agent activities shall be funded with
Supervision and Administration (S&A) resources. Design agent
quality assurance support shall be available to and under the
control of the construction agent. QA support would be S&A
funded. Construction contractor activities associated with
executing the commissioning process during construction must be
included as contract requirements and therefore would be funded
with project construction funds.
a. The district, in its capacity as design agent, shall
ensure that the design SOW requires the design services necessary
to develop a contract specification section(s) using the
guidelines in Appendix A and, as outlined in Appendix B. The
district shall ensure that systems commissioning requirements
included in the construction contract will result in verification
of the design intent, as expressed in the plans and
specifications with the installed construction. The designer
will document the design intent for all systems requiring
commissioning as part of the commissioning requirements of the
contract. Districts shall ensure appropriate participation by
the designer after award and during execution of the systems
commissioning requirements. District Quality Management Programs
shall document the assurance procedures to be used to verify
compliance with these requirements. The district shall secure
documentation indicating the satisfaction of the using agency and
construction agent with the systems commissioning requirements
developed prior to bid opening. The review and certification
processes established by ER 415-1-li will serve to document both
the construction agent*s and the using agency*s satisfaction with
the systems commissioning requirements developed prior to bid
opening.
b. The district, in its capacity as construction agent,
shall ensure that the construction contractor provides all
necessary labor, services and materials to perform and document
the systems commissioning requirements. District Quality
Assurance Programs shall document the procedures to be used to
verify compliance with these requirements. During construction,
the Administrative Contracting Officer (ACO) will act as the
chairperson of the Commissioning Team.
c. The using agency, in its capacity as user/owner/operator
and ultimate customer, should make a continuous corporate
commitment to the systems commissioning process. The using
agency*s participation begins early in project development and
requires continuous representation through the
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design/construction process. Appropriate resources and
representation must be programmed and provided as required in the
commissioning process. While the Corps of Engineers is
ultimately responsible for a fully functional project, the using
agency should convey their commissioning concerns and functional
requirements clearly and early on a project specific basis, and
participate in witnessing and determining acceptability of
commissioning results. The design/construction elements and the
using agency should work together in developing realistic and
reasonable systems commissioning requirements to ensure adequate
and complete results, and recognize the cost and schedule
consequences associated with idealistic requirements.
d. Acceptance of the systems commissioning process, and the
completed construction, may require extrapolation or
interpretation of systems commissioning results to conditions
other than those experienced during actual execution. Normally,
an acceptable characteristic will be determined as a consensus of
the commissioning team comprised of the using agency, design
agent and construction agent. During construction, the ACO may
need to facilitate and mediate to establish a consensus. If
acceptable performance cannot be achieved, the necessary
corrective measures should be carried out. The ACO will identify
the construction deficiencies and/or design deficiencies causing
problems and pursue a course of corrective action. The designer
may be used to assist in diagnosing the cause of problems and
should always provide recommended solutions to design
deficiencies. The solutions to significant problems should be
approved by the commissioning team, including the user. If the
user cannot respond in a timely manner, decisions must be made
without user input. Needless contract delays cannot be
tolerated. The ACO must issue appropriate directions for
corrective measures, through proper contractual channels. In
cases of contractual disputes the appropriate contracting officer
shall determine final direction.
FOR THE COMMANDER:
2 Appendices
APP A Guidelines for the
Commissioning Process
APP B Outline for the
Preparation of Systems
Commissioning Specification
ROBERT H. GRIFFIN
Colonel, Corps of Engineers
Chief of Staff
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APPENDIX A
GUIDELINES FOR THE COMMISSIONING PROCESS
1.
Purpose
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(4) The total commissioning process is necessarily
iterative. Deficiencies in one individual system may impact the
commissioning of other individual systems as well as the
commissioning of the complete project. Deficiencies must be
rapidly resolved by the appropriate parties to permit timely
completion of the commissioning process.
2.
UTILIZATION
DEFINITIONS
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documentation, etc. required to perform the functional
performance testing in accordance with the commissioning plan.
d. Commissioning Team: The qualified persons that will plan
and carry out the overall commissioning process. The team is
composed of designers (Corps and/or Architect-Engineers), users
(facility, tenant, O&M) and the administrative contracting
officer (ACO) for the construction contract (representing Corps
construction). The individual participants on the team may change
as the design and construction process proceeds. Participation by
the user is not mandatory, but the value of this service to the
customer is directly proportional to their participation. The
team is supported by the contractor (including appropriate
subcontractors, suppliers and manufacturers). The Corps technical
manager is the facilitator and mediator for the team during the
design phases. During design, the Architect-Engineer or in-house
designers will prepare commissioning plans for approval of the
team. The ACO for the construction contract is the team
facilitator/mediator during the construction phase. In this
phase, the contractor will finalize the commissioning plans to
make them equipment specific and to match asbuilt conditions.
The contractor will also perform the actual commissioning
procedures for approval of the team. It is critical that the
numerous commissioning responsibilities of the A-E and contractor
are clearly identified in their respective contracts. If
necessary, the commissioning team should recommend to the
appropriate contracting officer (design or construction) that
contract modifications be prepared. If the commissioning team is
unable to reach consensus on a particular issue, the situation
must be promptly resolved by the active facilitator/mediator.
Contractual disputes must receive final resolution by the
appropriate contracting officer.
e. Designer: The Architect-Engineer or Corps in-house design
group responsible for the design and preparation of contract
documents for the construction project.
f. Functional Performance Testing: That full range of
checks and tests carried out to determine if all components,
subsystems, systems, and interfaces between systems function in
accordance with the design intent, as identified in the contract
documents. In this context, function includes all modes and
sequences of control and operation, all interlocks and
conditional control responses, and all specified responses to
abnormal emergency conditions.
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g. User: The organizational groups that combine to provide
facilities, perform facility operation and maintenance and
perform actual missions at Corps construction project sites. For
Army construction this includes the major command, the
installation, the Directorate of Engineering and Housing and the
Tenant.
4.
AUTHORIZATION PHASE: The user should identify commissioning
requirements in the DD 1391 package. Anticipated systems within
the project should be identified. Commissioning may be
designated for any or all of these systems. Corps district
offices may use their vast construction expertise to assist the
user in preparation of the DD 1391. When appropriate for a
project, MSCs should discuss the need for commissioning through
the DD 1391 review process. The preparer should identify the
additional cost for construction in the DD 1391 documentation.
The added contract cost should be reflected in higher per unit
costs for the line items containing the systems which are to be
commissioned. Separate construction line items for commissioning
should be avoided. As a consequence of the higher contract cost,
additional funds will be available for design and contract
administration. If design costs above the standard level are
anticipated, the additional P&D costs shall be identified by the
MSC, along with any other special design instructions developed
during the DD 1391 review process. This will alert Programs
Management Division (CEMP-M) at HQUSACE of the need to provide
additional P&D funds in the design directive. The district
office shall identify the construction contract cost and time
impacts for commissioning and incorporate them in the ENG Form
3086 estimate.
5.
a. Corps design staff and the user must meet to identify the
systems expertise required of the designer, before A-E selection
takes place.
b. Corps design staff must identify the requirements for
systems expertise and commissioning experience in the selection
criteria and the Construction Business Daily (CBD) announcement.
The responsibilities of the designer throughout the commissioning
process must be highlighted.
c. Select a qualified designer.
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6.
PRE-DESIGN PHASE
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d. Definition of requirements. Define the systems
requirements for each occupancy, activity and/or physical area of
the proposed facility with reference to project criteria and
objectives.
e. System Design Concepts
(1) Develop conceptual designs for each system fulfilling
requirements of facility objectives. Address areas of
intersystem operation and dependency in the concept design.
(2) Define space requirements for equipment.
f. Documentation
(1) Prepare documentation of roles and responsibilities of
all parties during all phases of the commissioning process.
(2) Prepare written report defining design assumptions and
performance standards of proposed systems, most appropriate
conceptual approach and spatial requirements of the systems.
7.
DESIGN PHASE
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(5) Verification procedures. Considerable thought must be
given to adequacy of verification (testing) procedures and
location of instrumentation to give meaningful results. It may
be appropriate to permanently install some or all test equipment
for future use by the O&M staff.
(6) Commissioning documentation.
(7) Operation and performance.
c. Design Criteria. Design criteria and assumptions should
include appropriate specific design conditions for each space.
In addition, the following general considerations should be
specifically addressed.
(1) Code and permit requirements and impact on criteria.
(2) Noise and vibration criteria.
(3) Fire protection and life safety.
(4) Maintainability.
d. Description of Systems
(1) The description of each system and its intended
operation and performance should include design intent, system
and intersystem assumptions, and facility occupancy and
utilization.
(2) The description of the system should include basic
system type, major components, interrelation of components,
capacity and sizing criteria, control systems and sequence of
operation, including intersystem operations. If the system*s
complexity warrants, diagrams should be included for each mode of
operation, indicating specific component function and status.
(3) The operation and performance data should include
equipment selection and redundancy or backup criteria, intended
operation under all potential load or operational scenarios,
operation of system components in life safety modes, energy
conservation procedures and any other engineered operational mode
of the system.
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e. Commissioning Plans
(1) The commissioning plan is produced by the designer. It
must detail the implementation of the commissioning process. It
should include the requirements that each party involved in the
commissioning process will have to accomplish, including:
sequence, scheduling, cost estimate, documentation requirements,
verification procedures (including methods of measurement),
staffing requirements, etc.
(2) The parties involved at various stages of the
commissioning process will include the user, designers,
contractors, commissioning team, manufacturers, and other parties
as required.
(3) The needed staffing skills and qualifications shall be
specified for the following groups:
(a) Commissioning team. In its capacity as contract quality
control representative, the contractor must provide quality
control specialists knowledgeable of the various systems being
commissioned. The requirement for and qualifications of these QC
specialists must be included in the contract documents.
(b) Operation and maintenance teams.
f. Documentation Requirements
(1) The documentation requirements for each party involved
in the commissioning process shall be detailed in the contract
documents, prepared by the designer. This documentation will be
further detailed and submitted by the contractor for approval
during the construction phase.
(2) The contract documents shall contain commissioning
process requirements which include the following:
(a) Detailed verification procedures for the tests to be
performed by each party in the commissioning process. Detailed
procedures for intersystem testing to be performed cooperatively
by multiple parties. At the end of the process, every mode of
systems operation, all system equipment, components and zones and
every item in the control sequence description should have been
proved operational under all normal operational modes, including
part and full load and under abnormal or emergency conditions.
This must include every individual interlock and conditional
control logic. Temporary upsets of systems, such as distribution
fault, control loss, setpoint change, equilibrium upset, and
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component failure, should be imposed at different operating loads
to determine system stability and recovery time. The procedures
must anticipate scenarios which cannot be performed naturally due
to such factors as lack of load or seasonal conditions. Methods
of simulation must be described in great detail. Although not
desirable, it may sometimes be necessary and acceptable to
postpone testing, pending the appropriate climatic conditions,
provided all parties understand the contractual implications.
(b) Detailed checklists for performance testing.
(c) Report forms that will be used to submit test data and
results.
(d) Calibration data for test equipment.
(e) Sequence and schedule of procedures. Requirements for
incorporation of all commissioning activities in the contractors
schedule.
g. Commissioning documentation should be prepared and
submitted to the commissioning team at the completion of the
commissioning process. The contracts for the Architect-Engineer
and the construction contractor must contain those documentation
requirements to be performed by each of them. This documentation
should include readiness, start-up and performance checklists of
the commissioning plan with actual results achieved. Items 1
thru 6 below shall be provided by the construction contractor.
Item 7 shall be provided by the designer.
(1) Tests, corrective action and adjusting, retesting.
(2) Operational performance verification tests of all
equipment.
(3) Control schematics, performance reports and checklists
for verification of the total system and subsystems.
(4) Operating data to include all necessary instructions to
the owners maintenance and operation staff in order to operate
the system to specified standards.
(5) Maintenance data to include all necessary information
required to maintain all equipment in continuous operation.
(6) As-built documents for the systems to include all
equipment, components and controls.
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(7) The operation and maintenance manual must address
simultaneous operation and maintenance of all the building
systems and must specifically consider all intersystem
relationships and impacts.
h. Operation and Performance. The schedules for the
participation of the operations and maintenance personnel during
the construction phase and the subsequent phases of the
commissioning process.
8.
CONSTRUCTION PHASE
a. Introduction
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operations and maintenance manual for training and subsequent use
of the operations and maintenance staff.
c. Operation. During critical points of the construction
phase, the facility operations and maintenance staff should be
available at the site for the purpose of observing construction,
especially during equipment installations. This is an
opportunity for the user to gain familiarity with the facility
systems, but is not to delay the construction process.
d. Submittals
(1) Submittals must be reviewed prior to construction, in
accordance with ER 415-1-10, Contractor Submittal Procedures.
The construction schedule submittal is of particular importance.
It must provide sufficient time near the end of the contract for
the various commissioning activities, including adjustments,
corrective actions and retesting. Shop drawings, equipment
catalog cuts and details, testing procedures, the commissioning
plan and commissioning documentation format are also critical
submittals.
(a) Equipment submittals should include complete performance
data for each piece of equipment -- capacity, flow rates,
velocity, pressure losses, horsepower, motor speed (rpm),
electrical data, etc. Submittals should also describe testing
procedures used to verify performance. After review of equipment
submittals, the equipment operations and maintenance information
(including parts lists, installation instructions and special
tool needs) should be submitted in accordance with specifications
requirements.
(b) Because of the importance of the control systems to the
proper operation of systems, control submittals should be
carefully reviewed to ensure they include all information needed
by the operations and maintenance staff to keep the control
systems adjusted and calibrated. Information should include the
following.
- A fully labeled control piping, wiring or fiber optic
schematic, which shows point-to-point piping, wiring or cable and
includes all performance parameters such as setpoints, throttling
ranges, actions, spans, proportional bands and other control
component adjustment or setting data. Locations of pneumatic
test ports, electronic system terminal strips or fiber optic
terminals and equipment should be indicated on the schematic
drawings.
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- Fully labeled elementary electrical ladder diagrams.
Sequence of operation (narrative description of control
system functions) cross-referenced to the control schematics and
elementary electrical ladder diagrams.
- Specification sheets for each control component.
(c) The commissioning plan should be prepared following the
format described in the contract specifications. It should
detail how the commissioning process will be organized, scheduled
and documented to include the following items.
- The organization of the commissioning team (Corps design
and construction personnel; A-E; testing specialists;
contractors, vendors and manufacturers; User*s operations and
maintenance staff, etc.)
- A list of activities required to commission the subsystems
and systems and the functions of each member of the commissioning
team.
- A logical sequence schedule for each commissioning
activity coordinated with all members of the commissioning team.
- Commissioning plan documentation forms for all components
and systems submitted.
(2) The procedures for testing should be performed in
accordance with the contract requirements, as detailed in the
commissioning plan.
e. Construction Phase Activities
(1) Quality control compliance testing, adjusting and
balancing work must be performed prior to functional performance
testing. Operational tests should also be conducted on
equipment, duct, pipe, conductors and control systems to verify
that mechanical and electrical characteristics meet design
requirements.
(2) Controls testing and calibration should begin before or
concurrent with, and be completed subsequent to, the systems
testing. Testing should include all possible operating
conditions and ranges of devices.
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(3) The commissioning team shall have the opportunity to
witness any or all start-up, testing, balancing and calibration
activities which are performed as part of the contractual quality
assurance program.
f. Documentation
(1) Controls testing should be accomplished on each control
device. All system interlocks, interconnections and safety
devices should be checked for proper function.
(2) All control devices should be adjusted and calibrated.
All control settings should be verified by comparing actual input
and output values to calculated values.
(3) All testing, adjusting and balancing work should be
substantially complete with reports submitted and approved prior
to the verification and acceptance phase.
(4) Training, warranty, special tools and spare parts should
be taken into account under the construction phase.
(5) Contractor and equipment warranties shall be verified.
(6) Special tools and spare parts list shall be verified.
9.
ACCEPTANCE PROCEDURES
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c. General
(1) The functional performance test checklists contained in
the approved commissioning plan should be used to document the
results of the functional performance testing process.
(2) The functional performance testing process should be
accomplished for all equipment, subsystems, systems and system
interfaces. There may be several similar pieces of equipment,
systems, etc., on a project. All must be tested for acceptance
and there should be a separate checklist for each to ensure
documentation specific to each is complete.
(3) Functional performance testing should progress from
equipment or components through subsystems to complete systems.
Functional performance testing will have to consider sequences of
testing, starting with components and progressing towards
complete systems. As a result, the causes of any functional
problems should be easier to locate and correct.
(4) The specific tests, and the most efficient order of
testing, will vary widely depending on the type of system, the
number of systems, the sequence of construction, the relationship
between building systems and specific tenant work, the degree of
interaction between systems, the complexity of the controls
sequence, the impact of system failures on health or safety and
other factors.
d. Equipment and Subsystem Functional Performance Tests.
Operate the equipment and subsystems through all specified modes
of control and sequences of operation. Include full and part load
and emergency conditions, as required by the contract
specifications and the commissioning plan.
e. Systems Functional Performance Test. Following the
equipment and subsystem functional performance testing, the
overall systems must receive functional performance testing.
Each system must be operated through all modes of operation,
safeties, interlocks, load conditions and disturbances, in
accordance with the contract specifications and the commissioning
plan.
f. Verification and Documentation
(1) As each individual check or test is accomplished, the
commissioning team should observe the physical responses of the
system and compare them to the specified requirements to verify
the test results. The actual physical responses of system
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components must be observed. Reliance on control signals or
other indirect indicators is not adequate. The input and output
signals for each control component also need to be observed to
confirm they are correct for each physical condition.
(2) Verification of the testing, adjusting and balancing
report should be an integral part of functional performance
testing.
(3) The commissioning team should record the result of each
individual check or test on the pre-approved test and report form
included in the commissioning plan, indicating acceptability or
non-acceptability of the results.
g. Deferred Functional Performance Tests
(1) If any check or test cannot be accomplished for seasonal
reasons, lack of occupancy or for other reasons, this fact should
be noted along with an indication of when the test will be
scheduled.
(2) If any check or test cannot be accomplished due to
building structure or other building system deficiencies outside
the scope of the systems work, these deficiencies should be
resolved and corrected by the appropriate parties before
completion of the commissioning process.
(3) Every check or test for which acceptable performance was
not achieved should be repeated after the necessary corrective
measures have been completed. This retesting process shall be
repeated until acceptable performance is achieved.
h. Corrective Measures. If acceptable performance cannot be
achieved, then the necessary corrective measures should be
carried out. Normally, the ACO will identify the construction
and/or design deficiencies causing problems and pursue a course
of corrective action. The designer may be used to assist in
diagnosing the cause of problems and should always provide
recommended solutions to design deficiencies. The solutions to
significant problems should be approved by the commissioning
team, including the user. If the user cannot respond in a timely
manner, decisions must be made without user input. Needless
contract delays shall not be tolerated. The ACO must issue
appropriate directions for corrective measures, through proper
contractual channels.
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i. Intersystem Functional Performance Tests
(1) When the functional performance of all individual
systems has been proved, the interface or coordinated interaction
responses between systems should be checked.
(2) The approach to intersystem performance testing should
follow that previously described for systems.
j. Acceptance Documentation. A copy of the commissioning
plan and functional performance test results should be added to
the previously approved operations and maintenance manuals. Test
reports should be submitted to the designer for review and
approval.
k. Operator Training
(1) The system operator should be on site periodically
during the construction phase, particularly during startup of
equipment, testing, adjusting and balancing and during the entire
functional performance testing process.
(2) Operator training should provide a complete overview of
all equipment, components and systems with an emphasis on the
following items:
(a) Documentation in the final operations and maintenance
manuals.
(b) How to use the operations and maintenance manuals.
(c) System operational procedures for all modes of
operation.
(d) Acceptable tolerances for system adjustments in all
operating modes.
(e) Procedures for dealing with abnormal conditions and
emergency situations for which there is a specified system
response.
l. Final Acceptance. When requirements of the commissioning
plan have been completed and satisfactorily documented and
required documentation has been completed, submitted to the
designer and accepted, the commissioning team should recommend
final acceptance of the building systems.
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10.
POST-ACCEPTANCE PHASE
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(2) Retest system periodically to measure the actual
performance. System functional performance test checklists used
in the acceptance phase should be a guide for retesting.
(3) Develop and maintain a standard method of recording
complaints received regarding systems and operation.
(4) Discrepancies between predicted performance and actual
performance and/or an analysis of the complaints received may
indicate a requirement to recommission the system or review the
commissioning plan.
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APPENDIX B
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OUTLINE SPECIFICATION
31 July 1995
SYSTEMS COMMISSIONING
NOTE: Only systems commissioning activities which occur during project
construction will be defined in the contract specifications. This
specification section may be inserted into the General Provisions of the
Contract Specifications, or the Technical Provisions as determined by the
design engineer. Other specification sections having activities affecting
systems commissioning will make reference to this section, and will direct
that those activities be coordinated to permit overall systems
commissioning as specified herein. Each project will require adaption of
this specification to meet requirements of design intent, project location,
construction methods, and construction team organization and management
structure.
PART 1
1.1
GENERAL REQUIREMENTS
DESCRIPTION OF WORK
1.1.1
The System as referred to in this section of the specifications
shall include, but not be limited to, the following subsystems and components
of subsystems:
.
1.1.2
The Contractor shall verify operational and functional performance of
the System for compliance with the Design Intent as described (in the
following Section(s) of the Contract Specifications:
.]
[and] [below for the following subsystems:
.]
NOTE: The design engineer will include in the specifications a complete
description of system operation and performance data for informational
purposes only. Design Intent information specified herein shall include:
(a) the general philosophy and goals of the total system, (b) an
explanation of selected components of the overall system and the expected
interaction between components and subsystems, (c) data on performance
requirements of the total system, (d) performance requirements of designated
zones, and (e) an overview of control systems and their integration with
other systems.
1.1.3
The Contractor shall document all tests and inspections performed on
the System as part of the commissioning process.
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1.1.4
The Contractor shall verify the existence and application of operation
and maintenance (O&M) manuals, as-built or record drawings and documents,
spare parts lists, special tools lists, and other items as may be specified
herein for support of the System. Contractor shall make any and all necessary
corrections to O&M manuals and procedures if errors are discovered during the
commissioning process.
1.1.5
The Contractor shall coordinate and direct training of personnel for
the operation and maintenance of the System in accordance with detailed
requirements found in the technical and execution sections of this
specification.
1.1.6
The Systems Commissioning Team as referred to in this section of the
specifications shall be composed of the team members listed below. The
Contractor shall be added to the Team after contract award, and shall
designate members from the Contractor Group to participate in the
precommissioning activation inspection and the functional performance testing
specified herein. In addition, the Government will be represented by an
official of the Contracting officer, the Designer or Design Agent
Representative, and the Using Agency. All commissioning inspections and
testing will be accomplished in the presence of a representative of the
Contracting officer.
NOTE: Where possible, the Designer, or a Design Agent Representative, shall
be included as a member of the Commissioning Team. The planning and
programming of either Title II services or in-house support will be required
for the participation of the Design Agent Representative. For certain
highly complex systems, it may be appropriate to include a manufacturer*s
representative as a member of Contractor Group on the Commissioning Team.
Designer shall consider the degree to which such participation is required
to assure fulfillment of the full contract requirements. Due to the added
costs, this option should be only utilized where absolutely necessary to
assure provision of a fully functioning system in accordance with design
intent.
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c.
d.
NOTE: The design engineer will list special requirements (if any) for
qualification of the Commissioning Team, such as previous work experience,
licensing, registration, membership in societies, etc. See Appendix A for
guidance in selecting special requirements.
1.2
1.2.1
The Contractor shall review and verify the commissioning schedule and
requirements for the interface between all building and construction trades in
order to prevent delays in the commissioning process. Contractor*s
verification shall be indicated by his signed approval.
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NOTE: The extent to which each commissioning activity is required on a
particular project shall be clearly defined in the Commissioning Plan.
1.2.2 Commmissioning Plan. The commissioning plan shall be prepared by the
Contractor. It shall describe how the commissioning process will be organized,
scheduled, and documented. The plan shall include:
a. The composition of each Subcontractor*s group representation to the
Commissioning Team.
b. A list of activities required to commission the system and its
subsystems.
c. A schedule for each activity linked to the master project schedule
to make possible the coordination necessary between trades and trade
divisions.
1.2.3 Precommissioning Meeting. ________ [days] [months] prior to start of
the scheduled systems activation inspection, the Contractor shall hold a
precommissioning meeting with all Team members in attendance. The purpose of
the meeting is to prepare for the systems activation inspection, and to ensure
that all Team members are ready to begin full-scale commissioning. In the
event that the Contractor is unable to hold the precommissioning meeting, or
conduct the systems activation inspection, at the scheduled times as shown in
the Commissioning Plan, the following remedies will apply:
.
Note: Designer must ensure that the time provided between the
precommissioning meeting and the systems activation inspection is adequate
to allow each Commissioning Team member to assemble representatives of their
group and prepare for full-scale commissioning. For a complex project this
may require more than 30 days. Therefore, a minimum of 30 days will be
specified. Sufficient notification time will be also allowed for the
precommissioning meeting.
1.2.4 Systems Activation. After the physical installation of all systems and
subsystems has been completed, the Contractor shall insure that all building
services, such as electrical power, central steam supply, natural gas, water,
sewer, etc., have been connected and started. The System shall be activated
after the following building services have been connected and started: ______
.
The Commissioning Team shall perform a system activation inspection to ensure
that the system is operational and ready for testing and balancing. All
subsystems shall have been inspected, started by trained personnel, and tested
by the Contractor to ensure that they function as required, and that all
subsystems are operational at the time commissioning activities begin.
1.2.5 Testing, Balancing and Adjusting. Testing, balancing and adjusting of
the System shall be accomplished by [the Contractor) [___________________] in
accordance with Section[s] ___________________________________ of the contract
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specifications. The Testing, Balancing and Adjusting Report shall be submitted
to the Contracting Officer, and members of the Commissioning Team who have not
received the information.
NOTE: Testing, balancing and adjusting of the System shall be performed by
a single organization approved by the Contractor as having the knowledge and
experience to carry out the work. The scope of testing, balancing and
adjusting shall be clearly defined in the contract specifications and on the
drawings, and shall include Ca) details of all systems to be tested and
balanced, (b) specific performance requirements, and (c) required
documentation.
Procedures for testing, balancing and adjusting shall be performed in
accordance with the standards set forth in Sections ______________ of the
specifications.
NOTE: Designer shall include standards such as (a) HVAC: Testing,
Adjusting & Balancing published by the Sheet Metal and Air Conditioning
Contractors National Association, Inc., (b) National Standards published
by the Associated Air Balance Council, (c) ASHRAE Standards published by
the American Society of Heating, Refrigeration and Air Conditioning
Engineers, (d) National Fire Protection Standards published by the
National Fire Protection Association, and (e) Operation of Municiple
Wastewater Treatment Plants--MOP 11 published by the Water Environment
Federation.
1.2.6 System Performance Verification, System performance verification shall
be accomplished in accordance with the System and Subsystem performance check
lists which are included herein. The verification procedure shall include:
a. Testing and verification that all systems and subsystems perform to
the standards in Sections _______________________. A report indicating
that testing has been performed and has verified the system to be in
conformance with the contract shall be made available to the
Commissioning Team.
b. Completion of the verified check lists signed by the Contractor, and
the required Commissioning Team members..
c. Joint investigation and correction of problem conditions where a
system, sub-system, or equipment component does not achieve specified
performance standards.
d. Recording seasonal and occupancy conditions in effect at time of the
verification described heretobefore.
1.2.7 Demonstration and Instruction. A systems demonstration and operating
instructional (D&I) program shall be organized and developed by the
Contractor, and presented to the Using Agency operating and maintenance staff.
The Program shall include, but not be limited to, the following:
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a. Detailed schedule of instruction periods for specific sections of
the installation.
b.
CONDITIONS OF WORK
The Contractor shall furnish all labor, equipment and materials to accomplish
complete systems commissioning as specified in this section of the
specifications.
NOTE: Design engineer will describe any special requirements for
commissioning due to unique work conditions, labor requirements,
availability of equipment and materials, project location, etc. See Appendix
A for guidance on selecting special requirements for work conditions. In
some cases, for example where a long commissioning period is required for a
wastewater treatment plant, it may be feasible to utilize existing
installation manpower under contractor/A-E supervision.
1.4
WORK SCHEDULE
The Contractor shall complete interim systems commissioning during the initial
start-up and operations phase, and shall complete follow-up and final systems
commissioning during the final construction inspection and acceptance phase.
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NOTE: Designer will estimate the approximate dates of commissioning and
describe any special requirements for the commissioning process such as
special loading conditions and seasonal variations in weather or climatic
conditions. These dates may change as the date of contract award approaches.
Note that on larger projects, commissioning will begin only after beneficial
occupancy of the project.
1.6
REFERENCES
DOCUMENTATION
SUBMITTALS
The Contractor shall submit to the Contracting Officer for approval the
following items prior to starting the commissioning process:
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NOTE: Submittals must be limited to those necessary for adequate quality
control. The importance of an item in the project should be one of the
primary factors in determining if a submittal for the item should be
required.
1.8.1 Contractor Commissioning Representatives. A list of Contractor
representatives on the Commissioning Team and their qualifications shall be
submitted at least ______ [weeks] (months] prior to the start of precommissioning checks. Any proposed revision to this list must be submitted
prior to the start of the impacted work.
1.8.2
Commissioning Plan
NOTE: Designer will identify all components of the plan for conducting and
completing systems commissioning. See Appendix A for guidance in developing
the systems commissioning plan.
1.8.3
Training Plan
NOTE: Designer will identify all elements of the plan to train personnel
from the Using Agency in the operation and maintenance of the System. See A
for guidance in developing the training plan.
1.8.4
Testing Equipment
NOTE: Designer will identify and specify all testing equipment, apparatus,
related tools, etc., the systems to be tested with such equipment, the
reason the equipment is required, the source for obtaining the equipment,
and the price and delivery date of each component or element. The contractor
will be required to provide all such items.
1.8.5 Test Procedures. Detailed procedures for precommissioning checks and
functional performance tests shall be submitted at least _____ [weeks]
(months] prior to the start of precommissioning checks.
1.8.6 Test Schedules. Schedule for precommissioning checks and functional
performance tests shall be submitted at least _____ [weeks] [months] prior to
the start of precommissioning checks.
1.8.7 Test Reports. Completed precommissioning checklists and functional
performance test checklists shall be organized by system and by subsystem and
submitted together. The results of failed tests shall be included along with a
description of the corrective action taken.
1.9
CONTRACTOR RESPONSIBILITIES
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1.9.1 The Contractor shall deliver a commissioned installation to the
Government that meets all performance requirements in accordance with the
contract documents.
1.9.2 The Contractor shall provide all necessary access facilities to those
working on the installation of all systems so that the Commissioning
requirements can be fulfilled completely.
1.9.3 The Contractor shall consult with subcontractors to ensure that
sufficient time is allowed and fully identified on the Master Schedule for the
proper commissioning of all systems.
1.9.4 The Contractor shall plan, organize and implement the commissioning
process as identified in the Contract Specifications.
1.9.5 The Contractor shall arrange consultation with the Contracting Officer
to provide clarification of the design described in the specifications, if the
subcontractor deems such a meeting necessary.
1.9.6 The Contaractor shall assign a Commissioning Team, comprised of
qualified sub-trade specialists who are coordinated by a competent,
experienced supervisory person.
1.9.7 The Contractor shall supply complete instruction and information
relating to the operation and maintenance of all equipment and systems.
1.9.8 The Contractor shall deliver a system that performs within the ability
of the equipment and design specified in the contract.
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NOTE: Design engineer will list applicable specification sections that
identify other responsibilities, including various trades involved in the
work, during the systems commissioning process. The Owner or Using Agency
will (a) provide an operations and maintenance staff that possesses
sufficient skills, education and aptitude to be able to operate and maintain
the installation following an appropriate period of instruction, (b) assign
selected staff to observe the installation and commissioning prior to final
demonstration and turnover, in order to become fully familiar with the
installation and the design intent of the system, Cc) ensure that the Design
Authority*s contract includes such services that are defined herein as the
Design Authority*s responsibility, (d) arrange the schedule of occupancy
such that the commissioning process can be carried out without undue
interference. The Design Agent or Authority will (a) ensure that the
commissioning process is fully identified and specified in contract
documents, (b) include in the contract documents a complete descripion of
the systems operation and performance and requirements for commissioning the
system, Cc) specify equipment and appurtenances to meet the design criteria,
(d) verify and certify the performance of systems on completion of the
testing, balancing and adjusting process, (e) specify in contract documents
check lists for performance testing and verification, (f) assign a qualified
person to work with the Contractor and Owner on the entire commissioning
process, and Cg) issue a definitive deficiency list at the time of system
activation and on completion of the systems performance verification
procedure.
PART 2
2.1
PRODUCTS
2.1.1 The Contractor shall provide the following testing and instrumentation
equipment to be used in the commissioning process:
.
NOTE: Designer will list applicable equipment to be used for testing and
instrumentation during the systems commissioning process, with special
emphasis placed on load simulation.
2.1.2 The Contractor shall provide all utilities necessary to carry out
testing and instrumentation as part of commissioning process, including such
expendible items as water, fuels, chemicals and other materials. The
Contractor shall also provide any equipment or device required for access such
as platforms, scaffolds, ladders.
PART 3
3.1
EXECUTION
GENERAL
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The Contractor shall coordinate with the Commissioning Team in the
construction phase of the project to assure compliance with all systems
commissioning requirements.
3.2
PROCEDURES
3.2.2.2 Requirements for documentation as listed [in this Section] [and] [in
Section(s) __________________] of the Contract Specifications.
3.2.2.3 Requirements for documentation of commissioning tests and inspections
required by code authorities and governing agencies.
3.2.2.4 Requirements for the commissioning program during specific
operational seasons with partial and full loads as specified [in this Section]
[and] [in Section(s) __________________] of the Contract Specifications.
3.2.2.5 Requirements and format for a training program for operations and
maintenance personnel.
3.3
TESTS
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NOTE: Where checking, testing, and inspection methods are not specified in
other Sections, methods shall be established and provided in this Section
which will provide the information required. Testing and verification
requirements in related Sections are independent of the requirements of this
Section, and shall not be used to satisfy any of the requirements specified
in this Section.
All testing and verification required in this Section shall be performed
during the Commissioning phase. The Contractor shall provide all materials,
services, and labor required to perform the pre-commissioning checks and
functional performance tests.
3.3.1.1
Pre-Commissioning Checks
Functional performance tests shall be performed for the items indicated on the
checklists in Section(s) ____________________________________. Functional
performance tests shall begin only after all pre-commissioning checks have
been successfully completed. Tests shall prove that all modes and sequences of
operation are correct, and shall verify all other relevant contract
requirements. By verify it is meant that contract requirements are satisfied
by testing results. Testing shall begin with equipment or components and shall
progress through subsystems to complete systems. Upon failure of a functional
performance test checklist item, the Contractor shall correct all deficiencies
in accordance with the applicable contract requirements. Testing of the
checklist shall then be repeated until it has been completed without errors.
END OF SPECIFICATION
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