Turn Over Packages, FAT and CommissioningSan Francisco Bay Area Chapter

Commuter Conference May 13th 2008Misha Anissimov, Genentech

Mike Britting, Hathaway DinwiddieLeo 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 Owner’s 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 agent’s support network)

• The Owner’s 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 FPT’s, executes FPT’s

• Mechanical Engineer of Record : Own’s the system design and Sequence of Operation.

• General Contractor’s 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 didthey uncover in past jobs?), Ask for sample Functional Performance Tests-FPT’s (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 FACILITY’S 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 FPT’s

• Actively Review Functional Performance Tests – especially key tests. Focus on the “Objectives” and the “Results” you would like to see.

• Beware of Boiler Plate FPT’s. Are the tests custom tailored to your systems?

• FPT’s are common sense and are the “battle plan” of Commissioning.

Step 4: Execution

• The SOO’s 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 activities—this will result in errors. Cxagents 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 Owner’s 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 ProjectLeo Santini, MEP Coordinator Hathaway Dinwiddie

Summary: The Contractor’s 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&M’s delivered to Facilities for SOP’s• 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 ContentsGENERAL DOCUMENTATIONVolume I: A. Project Directory

B. TOP MatrixC. As-Builts Record Set CDD. Master PunchlistE. Warranty LettersF. RFI Log w/ResponsesG. O & M Manuals

SUBMITTALSVolume II: A. Submittal Log

B. Approved Submittals

PROJECT SPECIFICATIONSVolume III: A. Specification Listing

B. Record SpecificationsC. Record Basis of Design (BOD)

SYSTEMS DOCUMENTATIONVolume IV: DRY-SIDE HVAC

Central Air HandlingEconomizer Return Air FanGeneral Lab Exhaust"H" Area Exhaust FansRadioisotope Exhaust FansAir Terminal ZonesIDF/MDF Backup AC UnitsMechanical Room, Boiler Room Exhaust FansRefrigeration Room Ventilation, Refigerant Leak Detection, Purge & EPOBag In / Bag Out Filtration System

Volume V: WET-SIDE HVACPreheat/Reheat - Boilers, PumpsCondenser Water - Towers, PumpsRefrigerated Water - Chillers, Pumps

Volume VI: CONTROLS SYSTEMSBAS - Building Automation System

Volume VII: LABORATORY SUPPORT EQUIPMENTD.I. Point of Use PolishersChemical Fume HoodsRadioisotope HoodsBio Safety Cabinets

Volume VII: LABORATORY SUPPORT EQUIPMENTD.I. Point of Use PolishersChemical Fume HoodsRadioisotope HoodsBio Safety Cabinets

"DIRTY" PROCESS UTILITIESVolume VIII: Laboratory Vacuum

"CLEAN" PROCESS UTILITIESVolume IX: RO/DI Water SystemVolume X: Carbon DioxideVolume XI: Laboratory Compressed Dry Air

BUILDING UTILITIESVolume XII: Domestic HW/CWVolume XIII: Natural GasVolume XIV: Sanitary Waste & VentVolume XV: Lab Waste & VentVolume XVI: Storm/Roof Drainage

FIRE/LIFE SAFETY SYSTEMSVolume XVII: Fire Alarm & HVAC InterfaceVolume XVIII: Elevator Recall and Safety SequencesVolume XIX: Fire SprinklerVolume XX: Flammable Vapor Detection (LEL)

ELECTRICAL & SPECIALTY SYSTEMSVolume XXI: Normal Power Service & Distribution

Emergency/Standby DistributionGrounding

Volume XXII: Lighting & Lighting ControlVolume XXIII: Generator & ATSVolume XXIV: UPS, BatteriesVolume XXV: Security Including CCTVVolume XXVI: FMS - Facility Management System

ENVIRONMENTAL HEALTH & SAFETYVolume XXVII: EH&S - Environmental Health & Safety

APPENDICESAppendix A: Seismic Bracing Drawings, Calcs and Inspection

Sign-off - Mechanical/Plumbing Eqpt & OverheadAppendix B: Balance Report - Air & WaterAppendix C: Commissioning Plan and Report

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A System Overview

i. Equipment List x

ii. BOD - Basis of Design x

B Drawings

i. Construction Drawings and/or P&IDs x

ii. Vendor Furnished Drawings x

iii. As-Built Drawings x

C Punchlists/Mechanical Completion Letter x

D Balance Report x

E Startup/Commissioning Test Plan

i. Commissioning Plan x

ii. Final Commissioning Report x

F Warranty x

G Owner Training Documentation x

SECTION 2 - EQUIPMENT

A System Documentation

i. Installation Guide and O&M Manuals x

ii. Contractor/Vendor Supplied Equipment Submittals/Drawings x

iii. Equipment Prefunction Checklist x

iv. HEPA Filter Certification

v. Seismic and/or Structural Calculations x

vi. Labeling Document x

vii. Recommended Spare Parts List x

B Test Reports

i. FAT Test Results

ii. Field Test Results x

iii. Contractor/Vendor Startup Reports x

iv. Hood Certifications (GNE)

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION

SECTION 3a - PIPING

A Piping Specifications

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION

SECTION 3a - PIPING

A Piping Specifications

B Piping Documentation

i. Piping Submittal

ii. Valving Submittals

iii. Specialty Piping / Plumbing Fixture Submittals

iv. Seismic Details and Stamped Drawings

v. Weld Procedure(s)

vi. Welder Certification

vii. Pipe Brazing/Soldering Procedure(s)

C Installation Documentation/Field Verification

i. Pressure Test Report

ii. Flushing Report

iii. Cleaning and/or Passivation Report

iv. Sanitization Plan and Report

v. Field QC Reports/Particulate Report

SECTION 3b - DUCTWORK

A Ductwork Specifications x

B Ductwork Documentation

i. Ductwork Submittal x

ii. Insulation Submittal x

iii. Shop Drawings

iv. Seismic Details and Stamped Drawings x

v. Specialty Ductwork x

C Installation Documentation

i. Ductwork Leak Tests x

ii. Seismic Inspection reports & Sign-off x

SECTION 4 - ELECTRICAL

A Electrical Specifications

B Single Line Diagrams

C Electrical Documentation

i. Electrical Commodities Submittal

ii. Seismic Details, Stamped Drawings and Inspection Reports/Sign-off

D Electrical Equipment Checkout

i. Ground System Testing

ii. Transformer Testing/Reports

a. Tilt-Meter Testing

b. Insulation Resistance Test Report

iii. Megger Testing

a. Switchgear/Switchboards

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SECTION 1-GENERAL

A System Overview

i. Equipment 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

ii. 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

B Drawings

i. Construction Drawings and/or P&IDs x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

ii. Vendor Furnished Drawings x x x x x x x x x x x x x x x x x x x x x x x

iii. 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

C Punchlists/Mechanical Completion Letter x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

D Balance Report x x x x x x x x x x x x x

E Startup/Commissioning Test Plan

i. Commissioning Plan x x x x x x x x x x x x x x x x x x x x x x x x x x x x

ii. 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

F Warranty x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

G Owner Training Documentation x 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 2 - EQUIPMENT

A System Documentation

i. Installation Guide and O&M Manuals x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

ii. Contractor/Vendor Supplied Equipment Drawings/Submittals x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

iii. Equipment Installation Checklist (Including Identification) x x x x x x x x x x x x x x x x x x x x x x x x x x x

iv. HEPA Filter Certification x x

v. Seismic and/or Structural Calculations x x x x x x x x x x x x x x x x x x x x

vi. Labeling Document x x x x x x x x x x x x x x x x x x x x

vii. 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

B Test Reports

i. FAT Test Results x

ii. Field Test Results x x x x x x x x x x x x x x x x x x x x x x x x x x

iii. Contractor Startup 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

iv. Hood Certification x x x x

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION

SECTION 3a - PIPING

A Piping Specifications x x x x x x x x x x x x x

B Piping Documentation

i. Piping Submittal and Material Certifications x x x x x x x x x x x x x

ii. Valving Submittals and Material Certifications x x x x x x x x x x

iii. Specialty Piping / Plumbing Fixture Submittals and Material Certifications x x x x x x x x x

iv. Seismic Details and Stamped Drawings x x x x x x x x x x x

v. Weld Procedure(s) x x x x

vi. Welder Certification x x x x

vii. Pipe Brazing/Soldering Procedure(s) x x x x x x x

C Installation Documentation/Field Verification

i. Pressure Test Report and Drawings x x x x x x x x x x x x x

ii. Flushing Report and Drawings x x x x x

iii. Cleaning Report and Drawings x x x

iv. Sanitization Plan and Report x x

v. Field QC Reports x x

SECTION 3b - DUCTWORK

A Ductwork Specifications x x x x x x x x

B Ductwork Documentation

i. Ductwork Standards x x x x x x x x

ii. Insulation Data x x x

TOP Manuals: Review Sheet

GENENTECH BLDG 46, 47, 48 T O P R E V I E W S H E E T

NAME:

DATE:

SYSTEM/SCOPE:

REVIEW SHEET

SECTION COMMENTS RESPONSIBLE CORRECTED

Turn Over ScheduleID Task Name Responsible

1 BUILDING 47 TURNOVER2 SPARE PARTS IDENTIFIED & TURNED OVER3 Spare Parts Identified by Facilities GNE4 Pricing Submitted to GNE for Approval GNE5 Order Spare Parts Therma, REI, H6 Spare Parts Turned Over to GNE Therma, REI, H7 FINAL PUNCHLIST (REFER TO PROJECT SCH)8 Final Punchlist Walkthrough P&W, GNE9 Issue Final Punchlist P&W, GNE10 Make Corrections & Backcheck All Subs, HD, P&W, GN11 Final Punchlist Complete P&W, GNE12 BALANCE REPORT13 Issue Balance Reports for TOP (Preliminary) Therma14 Issue Final Balance Reports Therma15 COMMISSIONING PACKAGE16 Executed System Protocols Complete AEI17 Provide Final Commissioning Overview Package AEI18 AS-BUILTS, BOD, & SPECS RECORD SET19 Final as-built, BOD & Specs Submitted to P&W Therma, REI, Siemens Security

Siemens FLS20 Other As-Builts Submitted to HD BFP, Walker FMS21 Siemens Issue BAS as-builts Siemens BAS22 P&W Compile and Issue Record Set for TOP P&W

S M W F S T T S M W F S T T S M8 Mar 24, '08 Mar 31, '08 Apr 7, '08 Apr 14, '08 Apr

Turn Over Schedule - ContinuedID Task Name Responsible

23 WARRANTY LETTERS24 Submit warranty letters ALL SUBS25 TOP MANUALS26 Submit Remaining TOP System Installation Docs Therma, REI, Siemens, BF

Thyssen Krupp, Walker FMS, HD27 Submit Start-up & Testing Docs Therma, REI, Siemens, Walker FM28 Facilities & Engineering TOP Binder Review GNE29 Make TOP Revisions Therma, REI, Siemens, BF

Thyssen Krupp, Walker FMS, HD30 TOP Substantially Complete31 Insert Remaining Docs32 RO/DI Piping Sanitization Reports Therma33 D.I. Point-of-use Polisher Docs Therma/HD34 Final Balance Report Therma35 Final Commissiong Package & Presentation AEI36 As-Built Record Set P&W37 EH&S Binder & Section 7 EH&S Docs GNE, HD38 System Training (See Training Schedule) Therma, REI, Siemens, GNE, H39 Certificate of Occupancy (Refer to Project Schedule for ac HD40 Permit Binder Submitted All Subs, HD

S T T S M W F S T T S M W F SMar 31, '08 Apr 7, '08 Apr 14, '08 Apr 21, '08 Ap

Q & A