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 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 did
they 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. 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 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 Project
Leo 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 Contents
GENERAL DOCUMENTATION
Volume I:
SUBMITTALS
Volume II:
PROJECT SPECIFICATIONS
Volume III:
SYSTEMS DOCUMENTATION
Volume IV:
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
A.
B.
Submittal Log
Approved Submittals
A.
B.
C.
Specification Listing
Record Specifications
Record Basis of Design (BOD)
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
LABORATORY SUPPORT EQUIPMENT
D.I. Point of Use Polishers
Chemical Fume Hoods
Radioisotope Hoods
Bio Safety Cabinets
Volume VIII:
"DIRTY" PROCESS UTILITIES
Laboratory Vacuum
Volume IX:
Volume X:
Volume XI:
"CLEAN" PROCESS UTILITIES
RO/DI Water System
Carbon Dioxide
Laboratory Compressed Dry Air
Volume XII:
Volume XIII:
Volume XIV:
Volume XV:
Volume XVI:
BUILDING UTILITIES
Domestic HW/CW
Natural Gas
Sanitary Waste & Vent
Lab Waste & Vent
Storm/Roof Drainage
Volume XVII:
Volume XVIII:
Volume XIX:
Volume XX:
FIRE/LIFE SAFETY SYSTEMS
Fire Alarm & HVAC Interface
Elevator Recall and Safety Sequences
Fire Sprinkler
Flammable Vapor Detection (LEL)
Volume V:
WET-SIDE HVAC
Preheat/Reheat - Boilers, Pumps
Condenser Water - Towers, Pumps
Refrigerated Water - Chillers, Pumps
Volume XXII:
Volume XXIII:
Volume XXIV:
Volume XXV:
Volume XXVI:
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
Volume VI:
CONTROLS SYSTEMS
BAS - Building Automation System
Volume XXVII:
ENVIRONMENTAL HEALTH & SAFETY
EH&S - Environmental Health & Safety
Volume VII:
LABORATORY SUPPORT EQUIPMENT
D.I. Point of Use Polishers
Chemical Fume Hoods
Radioisotope Hoods
Bio Safety Cabinets
Volume XXI:
APPENDICES
Appendix A:
Appendix B:
Appendix C:
Seismic Bracing Drawings, Calcs and Inspection
Sign-off - Mechanical/Plumbing Eqpt & Overhead
Balance Report - Air & Water
Commissioning Plan and Report
CENTRAL AIR HANDLING
GENERAL CONTRACTOR
MEP SIGN-OFF
GNE FACILITIES SIGN-OFF
SYSTEM DOCUMENTATION
GNE ENGINEERING SIGNOFF
TAB
SECTION
System Docs: TOP Matrix
SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION
SECTION 3a - PIPING
A
Piping Specifications
B
Piping Documentation
SECTION 1-GENERAL
A System Overview
i.
Equipment List
x
ii.
BOD - Basis of Design
x
C
i.
Construction Drawings and/or P&IDs
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
F
i.
Commissioning Plan
x
ii.
Final Commissioning Report
x
Warranty
G Owner Training Documentation
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
i.
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
vii.
Pipe Brazing/Soldering Procedure(s)
Installation Documentation/Field Verification
Pressure Test Report
ii.
Flushing Report
iii.
Cleaning and/or Passivation Report
iv.
Sanitization Plan and Report
v.
Field QC Reports/Particulate Report
x
i.
Ductwork Submittal
x
ii.
Insulation Submittal
x
iii.
Shop Drawings
iv.
Seismic Details and Stamped Drawings
x
v.
Specialty Ductwork
x
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
D
FAT Test Results
Welder Certification
Ductwork Specifications
x
B Test Reports
Weld Procedure(s)
vi.
Ductwork Documentation
A System Documentation
x
Seismic Details and Stamped Drawings
v.
B
C
Installation Guide and O&M Manuals
Specialty Piping / Plumbing Fixture Submittals
iv.
A
x
i.
iii.
SECTION 3b - DUCTWORK
x
SECTION 2 - EQUIPMENT
Piping Submittal
Valving Submittals
i.
B Drawings
x
i.
ii.
i.
Electrical Commodities Submittal
ii.
Seismic Details, Stamped Drawings and Inspection Reports/Sign-off
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
FMS - FACILITY
MANAGEMENT SYSTEM
x
SECURITY, INCLUDING
CCTV
x
UPS, PDU & BATTERIES
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
GENERATOR & ATS
x
x
EMERGENCY/STANDBY
POWER DISTRIBUTION
x
x
GROUNDING SYSTEM
x
x
LIGHTING & LIGHTING
CONTROL
x
x
NORMAL POWER SERVICE
& DISTRIBUTION
x
x
FIRE SPRINKLER
x
x
x
FLAMMABLE VAPOR
DETECTION SYSTEMS
(LEL, %O2)
x
x
x
ELEVATOR RECALL AND
SAFETY SEQUENCES
DOMESTIC HW / CW
x
FIRE ALARM SYSTEM AND
HVAC INTERFACE
x
LAB WASTE & VENT
x
x
STORM/ROOF DRAINAGE
x
x
NATURAL GAS
x
x
SANITARY WASTE & VENT
x
x
LABORATORY
COMPRESSED AIR
x
x
CARBON DIOXIDE
x
x
RO/DI WATER
PURIFICATION
x
x
LABORATORY VACUUM
REFRIGERATED WATER CHILLERS, PUMPS, ETC.
x
x
VBSE'S - VENTILATED
BALANCE SAFETY
ENCLOSURES
PREHEAT-REHEAT
BOILERS, PUMPS
CONDENSER WATER TOWERS, PUMPS
x
x
BIO SAFETY CABINETS
BAG IN / BAG OUT
FILTRATION SYSTEM
x
x
CHEMICAL FUME HOODS
IDF/MDF BACKUP AC
UNITS
x
x
RADIOISOPTOPE HOODS
AIR TERMINAL ZONES
x
x
D.I. POINT OF USE
POLISHERS
RADIOISOTOPE EXHAUST
FANS
x
BAS - BUILDING
AUTOMATION SYSTEM
GENERAL LAB EXHAUST
"H" AREA EXHAUST FANS
Equipment List
Basis of Design (BOD)
SYSTEM DOCUMENTATION
MECHANICAL ROOM,
BOILER ROOM EXHAUST
FANS
REFR ROOM VENTIL,
REFRIGERANT LEAK
DETECTION, PURGE, EPO
CENTRAL AIR HANDLING
ECONOMIZER RETURN AIR
FAN
i.
ii.
TAB
SECTION
TOP VOLUME NO.
Master TOP Matrix
SECTION 1-GENERAL
A
System Overview
B
Drawings
x
x
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
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
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
D
Balance Report
x
x
x
x
x
x
x
x
x
x
x
x
x
E
Startup/Commissioning Test Plan
F
Warranty
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
i.
Commissioning Plan
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
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
SECTION 2 - EQUIPMENT
A System Documentation
i.
B
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
v.
x
x
Seismic and/or Structural Calculations
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
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
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Test Reports
i.
FAT Test Results
ii.
Field Test Results
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
iv.
Hood Certification
x
x
x
x
x
x
x
x
SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION
SECTION 3a - PIPING
A
Piping Specifications
B
Piping Documentation
x
x
x
x
x
x
x
x
x
x
x
x
x
i.
Piping Submittal and Material Certifications
x
x
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
iii.
Specialty Piping / Plumbing Fixture Submittals and Material Certifications
x
x
x
x
x
x
x
x
iv.
Seismic Details and Stamped Drawings
x
x
x
x
x
x
x
x
v.
Weld Procedure(s)
x
x
x
x
vi.
Welder Certification
x
x
x
x
Pipe Brazing/Soldering Procedure(s)
vii.
C
x
x
x
x
i.
Pressure Test Report and Drawings
x
x
x
x
x
x
x
x
x
x
x
x
x
Installation Documentation/Field Verification
ii.
Flushing Report and Drawings
x
x
x
iii.
Cleaning Report and Drawings
x
x
x
iv.
Sanitization Plan and Report
v.
Field QC Reports
x
Ductwork Specifications
B
Ductwork Documentation
x
x
x
x
x
x
x
x
i.
Ductwork Standards
x
x
x
x
x
x
x
x
ii.
Insulation Data
x
x
x
x
x
x
x
x
x
x
x
x
x
SECTION 3b - DUCTWORK
A
x
x
x
x
x
x
x
x
x
x
x
x
x
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
Task Name
Responsible
8
S
1
2
BUILDING 47 TURNOVER
SPARE PARTS IDENTIFIED & TURNED OVER
3
Spare Parts Identified by Facilities
GNE
4
Pricing Submitted to GNE for Approval
GNE
5
Order Spare Parts
Therma, REI, H
6
Spare Parts Turned Over to GNE
Therma, REI, H
7
FINAL PUNCHLIST (REFER TO PROJECT SCH)
8
Final Punchlist Walkthrough
9
Issue Final Punchlist
10
Make Corrections & Backcheck
11
12
13
14
15
Final Punchlist Complete
P&W, GNE
P&W, GNE
All Subs, HD, P&W, GN
P&W, GNE
BALANCE REPORT
Issue Balance Reports for TOP (Preliminary)
Therma
Issue Final Balance Reports
Therma
COMMISSIONING PACKAGE
16
Executed System Protocols Complete
AEI
17
Provide Final Commissioning Overview Package
AEI
18
AS-BUILTS, BOD, & SPECS RECORD SET
19
Final as-built, BOD & Specs Submitted to P&W
20
Other As-Builts Submitted to HD
21
Siemens Issue BAS as-builts
22
P&W Compile and Issue Record Set for TOP
Therma, REI, Siemens Security
Siemens FLS
BFP, Walker FMS
Siemens BAS
P&W
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
Task Name
Responsible
WARRANTY LETTERS
Submit warranty letters
ALL SUBS
TOP MANUALS
26
Submit Remaining TOP System Installation Docs
27
Submit Start-up & Testing Docs
28
Facilities & Engineering TOP Binder Review
29
Make TOP Revisions
30
TOP Substantially Complete
31
Insert Remaining Docs
32
RO/DI Piping Sanitization Reports
33
D.I. Point-of-use Polisher Docs
34
Final Balance Report
35
Final Commissiong Package & Presentation
36
As-Built Record Set
37
Mar 31, '08
Apr 7, '08
S T T S M W F
EH&S Binder & Section 7 EH&S Docs
38
System Training (See Training Schedule)
39
Certificate of Occupancy (Refer to Project Schedule for ac
40
Permit Binder Submitted
Therma, REI, Siemens, BF
Thyssen Krupp, Walker FMS, HD
Therma, REI, Siemens, Walker FM
GNE
Therma, REI, Siemens, BF
Thyssen Krupp, Walker FMS, HD
Therma
Therma/HD
Therma
AEI
P&W
GNE, HD
Therma, REI, Siemens, GNE, H
HD
All Subs, HD
Apr 14, '08
Apr 21, '08
S T T S M W F
Ap
S
Q&A