Engineering Testing and Commissioning

1. What
Constitutes a
Quality
Commissioning Job?

2. Agenda
• Preconstruction Services
–Brian Toevs, PE
• Construction Services
–Rusty Ross, PE, LEEDTM
, CxA
• Client Relationship
–Mark Leafstedt, PE CCP CxA

3. Commissioning Process
Project Timeline
PLANNING DESIGN CONSTRUCTION ACCEPTANCE OPERATIONS
Design Intent/
Owners Project
Requirements
Functional
Testing
Cx
Report
O & M Document
Review
Construction
Checklists
Submittal
Review
Basis of
Design
Review
Spec
Review
Design Document
Review
Training
Review
Seasonal
Testing
Warranty
Review
Pre-Functional
Testing
Start-up

4. Owner’s Requirements
•Owners need help defining their needs
We can help
•Get in early - During Predesign
•Attend meetings during Schematic Phase
•Attend more than one meeting
•Be an active member of the team
•Write the OPR for the owner

5. Owner’s Requirements
• Help the Architect write the OPR
• Initiate 1st
draft of the Basis of Design Then
turn it over to the designers
• Be Proactive, Invite your self to the party
OR
• Better yet - have your own party

6. Owner’s Requirements
Have a “Core Values” party
• Participants should Include:
– Owner
– User Group Members and Leaders
– Maintenance staff
– Architect / Engineer
– Contractors / CM
• Plan for ½ to full day, for the exercise

7. Owner’s Requirements
• Participants are educated
• We get "buy in"
• Educational process accelerated
• Decisions verified
• Adversity diminished
• Nuances of organization learned
• Design process expedited
Remember: The OPR is a
non technical document,
that describes what needs
to happen for the Owner to
call this project a success.

8. Owner’s Requirements
Small groups to work
out concepts
• Get input up front
• Un-Ravel the Owners
Requirements
• Eliminate Preconceived Ideas
Have Break-out
Sessions
• Ask questions
• Unpack issues
• Work through ideas
• Discard bad ideas
Create Concepts for discussion

9. Owner’s Requirements
• Present Ideas to group
• Not Complete Designs
• Better Direction for team
• Owner Requirements better DefinedTwo Solutions
Existing Conditions

10. Design Review
• Minimum-Review Systems Commissioned
• Best Practice Review Should Include:
– Mechanical
– Electrical
– Architectural
– Specifications
– Coordination among trades

11. Design Review
• To do a good HVAC review you have to
look at the Architecture
• Many HVAC problems are Architectural
Problems
• High performance buildings are failing:
– Designing smaller HVAC systems
– Normal Architectural Detailing

12. No details on this project address
acoustical corrugated decking
While this detail does
not show it, there is
batts insulation required
under the decking
Acoustical decking allows air to pass into
building on both sides of the corrugations
Batts insulation won’t seal the ends,
only filter the air

13. Roof Insulation
Corrugated Acoustical Roof Decking
Batts Insulation
Concrete Block Wall Air Pathways
Therm
alEnvelop
?

14. If the Architectural details are unclear the contractor has free
reign to do as much or as little as they want

15. Cx Specifications
• We’re not the designers but we can help
• Cx spec writing is more than writing Cx
specs
– Review Division 1 specs
– Review Mechanical specs
– Review Electrical specs
– Review / Write / Edit Cx Specs

16. Cx Specifications
• Request electronic specifications in
electronic format, i.e. MS Word, Word Perfect
• Edit specs with “Track Changes”
• Return electronic specs to designer, for
review and approval
– Engineer or Architect-of-record owns the
specs, we are only making suggestions

17. Cx Specifications
• Review Division 1 specs:
– Review submittal requirements
• Add submittal requirements for Commissioning
• Review O&M Requirements, modify submittal date to be just
after submittal approval
– Review payment application requirements
• Tie payment application to completion of checklist tracking
form
– Review substantial completion requirements
• Tie Cx completion to substantial completion
– Write Division 1 Cx Requirements Spec

18. Cx Specifications
• Review Mechanical Specs:
– Edit general requirements to reference Cx
– Edit Controls specs
• Review quality assurance requirements to be more
Cx friendly
• Tighten-up contractor qualifications
– List specific individuals assigned to project
– Temporary programming / global commands
– Trending requirements / memory availability
– instrument calibrations

19. Cx Specifications
• Review Mechanical Specs:
– Edit TAB Specs
• Review quality assurance requirements to be more
Cx friendly
• Tighten-up contractor qualifications
– List specific individuals assigned to project
– Write the Mechanical Cx requirements spec
– Develop SVC sheets and checklist tracking
form
– Write the Mechanical testing requirements

20. Bidding
• Cx Plan needs to be specific enough to
provide guidance but open enough for
updating
• Cx Plan should mirror the spec
requirements
• Keep it short, 15 to 20 pages plus
diagrams
• Define flow of Cx Process, documentation,
et cetera. Use Flow diagrams

21. Bidding
To: System
Readiness
Cx
Coordination
Meeting
Update
Cx Plan
Review
Contractor
Schedule
CxA to Receive
Approved
Shop Drawing
Submittals
EOMM and
SOMM
Submittal
Architect Will
Review and
Approve
EOMM and
SOMM
provided to
CxA
Review Construction
Checklist and Update
as Required
Architect and
Owner Will
Review and
Approve
Develop Functional
Test Procedures
Startup
Witnesses
Construction
Checklist
Completion
Equipment Training
Plan Submittal
Completed
Checklists
Submitted
Equipment
Training
Sessions
CxA Will
Review and
Approve
To: Acceptance
System Readiness
Commissioning Process Flow Chart – Construction Phase

22. Bidding
Acceptance
Systems
Training
Sessions
Pa
ss
FT’s
Performed
Reports
Written
Functional
Completion
Deficiency
Resolution
No
Yes
To: Warranty &
Deferred Testing
Warranty
Period and
Operations
Review
Deficiency
Resolution
Deferred FT’s Pa
ss
Final Cx
Report
No
Yes
Warranty and Deferred Testing
Commissioning Process Flow Chart – Construction Phase

23. Construction Services
• Construction Phase
– Document Installation
– Prepare for acceptance phase
• Acceptance Phase
– Functional testing
– Owner training
– Final report/systems manual
• Post Occupancy and Warranty
– Opposed season functional testing
– Warranty review

24. Construction Services
• Construction Phase
– KO meeting for all team members
– Review shops
• Update Cx plan, PFCs and FPTs
– Integrate Cx into construction schedule
– Plan for owner preparation
• Training – Develop execution plan and schedule
• Record Documents – Review as project progresses
• O&Ms/Systems manual – Available early
– Document installation – execute PFCs

25. Commissioning Plan

26. Prefunctional Checklists (PFCs)
Chilled Water Piping yes/no
Humidifier Piping
There is adequate room to pull the chilled water coil per M3.3A
Piping arrangement per the detail: CHS hdr - iso valve, pete's plug, thermometer; coil branch - flange, offset
connection for coil pull, B&G circ setter, pete's plug, gauge cock, coil, pete's plug, gauge cock, flange,
offset; return hdr - pete's plug, con
Piping system properlypressure tested for 6 hours at 125PSI per 15050-3.09
Piping system cleaned and properlyflushed 15050-3.08
Piping system properlypressure tested for 6 hours at 125PSI per 15050-3.09
Steam piping 2" per sched on M1.1A
Chilled water coil manual air vents installed per coil per the detail on M5.1A
Chilled water coil drains installed per coil per the detail on M5.1A
Thermometers installed 9" 15515-2.02-K
CHS & R piping at the coil is 4 inch per the schedule on sheet M1.1A.
Piping: Iso valve, strainer, union, control valve, union, humidifier, condensate w/ dirtleg(w/ blow down valve).
Acold condensate shut off sensor attached between the control valve & humidifier before the unit and
downstream of the humidifier on the cond
Chilled water coil clean
Steam piping properlyconnected per the detail on M5.3A
Piping system blown down w/ 5PSI steam and condensate wasted for 8 hours per 15050-3.08
Chilled water piping installed per the detail on M5.1A

27. Master Deficiency List
Date
Item
#
EQUIP #
/Spec
Section
DATE
REVIEWED
FIV/ FPT/O&M DEFICIENCY RESP. ACTION TAKEN
DATE Cx
VERIFIED
1 Panel HCR2 8/9/2004 FIV
The electrical working clearance for Panel HCR2 is not
per NEC 110. Panel LCR2 blocks the right portion of
the panel width within the 42" reqmt.
CEC
2 Panel LCR2 8/9/2004 FIV
The electrical working clearance for Panel LCR2 is not
per NEC 110. The conduits at the floor in front of the
panel, penetrate the floor in front of the plane of the
panel can.
CEC
3 Panel HN3 8/9/2004 FIV
The electrical working clearance for Panel HN3 may
not be per NEC 110. The transformer and flexible
conduits @ the floor must be 42" from the panel
(exposed live parts).
CEC
4 Panel LCR5 8/9/2004 FIV
The electrical working clearance for Panel LCR5 is not
per NEC 110. The adjacent panel can blocks the right
portion of the panel width within the 36" reqmt.
CEC
5 AHU 1 8/9/2004 FIV
The chilled water coil pull is blocked bythe header at
the coil.
B&K
Flanged connections have been provided in
the piping above the coil for piping removal for
coil pull.
JAH
9/20/04
6 RF 5A 8/9/2004 FIV
The relief duct is tapped into the back of the 90 degree
silencer.
B&K
PCA
Relief duct tap into 90o
silencer approved and
designed byM&I Systems.
JAH
9/20/04
7 RF 5Aand B 8/9/2004 FIV
The FSDs at the floor entering the return (see sheet
M406) are not accessible without dismantling a section
of the fabricated return plenum. An access door is not
shown to be installed.
B&K
PCA
Removable access panels have been provided
in the return plenum for access to FSDs.
JAH
9/20/04
Master Deficiency List
February 3, 2005
(latest deficiencies in bold text)

28. Document Installation
Box access

29. Document Installation
Incorrect coil piping

30. Document Installation
Valve access

31. Document Installation
Lack of welding on grease duct

32. Construction Services
• Acceptance Phase
– Start-up
– Functional testing
• Verify controls
• Simple to complex
• Single to integrated
• Coordinate w/ subs – controls, T&B
– Owner training
• Execute and monitor
• Systems training
– Final report/systems manual

33. Monitor Start-up
Construction filters not in place

34. The Field Team

35. Functional Performance Tests
(FPTs)
Mode Test Procedure Expected Response Pass Y/N/Note
Command the Chiller on by
the EMS WCM-4 to lead 1. CHW pump started by EMS
Note 3
2. CWisolation valve opens; CW pump starts (interlocked w/ CHP)
3. Cooling tower isolation valve opens and CT is enabled
4. Chiller enabled by EMS
5. Chiller starts when water flows are proven
6. Chiller controls on internal chiller LCHW stpt
7. Valve in CWR modulates to control chiller condenser pressure
Staging sequence WCM 1 >WCM 2 >WCM 3 >WCM 4
Tons = .0417*GPM*(CHWRT-CHWRST)
1. SCHW flow from EMS __________ GPM Load _______ tons Note 4&7
2. When lead chiller is at 90% full load amps, lag chiller#1 begins
start sequence after 15 minutes.
YES
Staging sequence WCM 1 >WCM 2 >WCM 3 >WCM 4
Tons = .0417*GPM*(CHWRT-CHWRST)
1. SCHW flow from EMS __________ GPM Load _______ tons Note 4&7
2. When the average amperage ofall operating chillers is above
90% full load amps, lag chiller#2 begins start sequence after 15
minutes.
YES
Open preheat valves to
increase the load above the
capacity of two chillers
Open preheat valves to
increase the load above the
capacity of one chiller

36. Functional Performance Tests

37. Construction Services
• Post Occupancy and Warranty
– Opposed season functional testing
• Peak summer
• Peak winter
– Warranty review
• Review building performance w/ owner & O&M staff
• Note any deficiencies
• Plan of action

38. Client Relationships 

39. Client Relationships
• WHO ARE THE CLIENTS?
– Owner? General Contractor? A/E
Consultants?..............Yes
– Does the client always hold the Cx contract?
• WHAT KIND OF CLIENTS?
– Participative or Non-Involved?
– Demanding or Relaxed?
– Sophisticated or Not?
– Clear on Cx Expectations or Not?
• HOW DO YOU HANDLE DIFFERENCES?

40. Client Relationships
• IMPORTANCE OF COMMUNICATION
– Enlistment of an advocate
– Prevent surprises
– Build a cooperative environment
– Reduce misunderstandings
– Speed resolution
– Must be clear, concise, factual, non-blaming
– Professional use of all forms:
• Verbal or written
• Cx documents

41. Client Relationships
• WHY DO WE DOCUMENT?
– Communication
– Set Expectations
– Record and track events and results
– Legacy
• WHAT MAKES OUR DOCUMENTATION
DIFFERENT?
– Independent Perspective
– Detail
– Resolution oriented rather than blame oriented

42. Client Relationships
• WHAT DEFICIENCIES DO YOU BRING TO
THE CLIENT?
– All? Cost impact ones? Design ones? Construction
ones? Long Term ones?
– Are all logged issues actually deficiencies?
• HOW DO WE GET RESOLUTION?
– Participate or pull away?
– Resolve during or after discovery?
– Get Client involved?
– Can we reduce the number or deficiencies or time it
takes to resolve them?

43. Client Relationships
• SUMMARY
– Communicate
– Be Professional
– Listen
– Communicate
– Document
– Participate
– Communicate