The Commissioning Process - Lawrence Berkeley National Laboratory

The Commissioning Process:In Search of aUniversal Definition and Application

Agenda■■Overview– The Current Reality– Defining Commissioning– The Commissioning ProcessCase Study– Pfizer B220

Why More Focus onCommissioning?■■■■■Challenges created by “speed to market” pushFocus on maximum building operationalefficiency– Documented lower life cycle costs/higher operatingefficiency through proper Cx– 8-10% reduction in Operation CostOwners feel that the construction costs areincreasing disproportionately with buildingperformanceHeightened focus on occupant satisfactionToday's building systems/new technologies aremore complex & interdependent

The Current Reality■■■Definitions and Expectations vary– Commissioning vs. validation– What systems should be included?Can become a “stepchild” of the design &construction process– Funding allocated – spent on other “priorities”Even R&D and process facilities do notalways take an “Integrated System Cx”approach

■The Current RealityLinear process with little collaborationOwnerdevelopsrequirementsA/E developstechnicalspecificationsBuilderimplementsseries of testsat the end ofthe projectFM/O&M stafftrainedafterwardsand givenmanuals

Defining CommissioningASHRAE: a qualityorientedprocess forachieving, verifying, anddocumenting that theperformance of facilitysystems and assembliesmeet defined objectivesand criteria.USDOE: a systematicprocess of ensuring thatall building systemsperform interactivelyaccording to the designintent and the owner’soperational needs.COMMISSIONINGDEFINITIONSNIBS: the systematicprocess of ensuring thatperformance of thefacility and its systemsmeet the functional andoperational needs of theowner and occupants.ISPE: well planned,documented, & managedeng'ing approach to start-up& turnover of facilities,systems, & equip. to End-User that results in a safe &functional env. that meetsestab'ed design req's &stakeholder expectations.

Defining Commissioning■Our consensus:– A well-planned, documented and managedapproach to the installation, start-up, turnover andverification of facilities, systems and equipment tothe end-user which results in a safe, productiveenvironment that meets the designers intent andthe owner’s quality expectations.

Commissioning Objectives■■■■■■Document Owner’s goals & requirementsEstablish “common success criteria”Keep project team focused on owner’s goals& success criteriaVerify and document that building systemsmeet owner’s intent & needTrain facilities personnel to properly operate& maintain the systemsIncrease operational efficiency

Design Phase■■■■■Work with Team to determinerequirements/Document design intent (BOD)Review Design Documents (SD, DD, CD)Develop Commissioning Plan and Schedulewith the TeamDevelop written protocolsDevelop Technical Specifications forincorporation into “buy-out” documents

Construction & Turnover Phase■■■■■■Develop commissioning sequencesReview submittalsSchedule, coordinate and document systemtesting (TAB, etc.)Perform additional functional performancetestingProvide O&M trainingCoordinate turn-over activities

During Operation■■■■Perform any required seasonal testing &trainingReview equipment and system performanceprior to warranty period expirationConduct a “Lessons Learned” sessionProvide trouble shooting support

The Commissioning Team■■■■Owner RepresentativesDesign ProfessionalsConstruction ManagerCommissioningAuthority/Agent■ Suppliers /Equipment Manufacturers■■O&M RepresentativesTrade Contractors

Legend:D = DevelopR = ReviewA = ApproveE = ExecuteCommissioningAgentResponsibilitiesDesign CPA -RFP for Commissioning Agent Services -Design Documents• Schematic DocumentsR• Design Documents• Construction DocumentsDevelop Commissioning ScheduleDDevelop Estimate For FullCommissioning Plan IncludingDImplementation CostsPre-construction Services• EstimatingR• Scheduling• Buy OutDefinitive CPARDevelop Project Specific CommissioningD & EPlanPre-Delivery Inspection (PDI) Plan D & EPre-Delivery Inspection (PDI) Report D & EFactory Acceptance Test (FAT) Plan D & EFactory Acceptance Test (FAT) Report D & EConstructionRImplement Commissioning PlanE(perform tests)Steady State (“Burn In”)RDeliverables• Commissioning Report• As-Built Drawings• O & M / Turn OverD & EDocuments• Warranties• ManualsTrainingD & E• Facilities Management/UsersFinal Commissioning Summary Report D & EPost-Acceptance Commissioning -Legend:D = DevelopR = ReviewA = ApproveE = ExecuteOwner’s ProjectManagerFacility ManagerArchitect/EngineerCommissioningAgentOwner Stakeholders(Users, EHS, etc.)ConstructionManager (Builder)Design CPA D R R - R -RFP for Commissioning Agent Services D & E D R - D RDesign Documents• Schematic DocumentsA R D R R R• Design Documents• Construction DocumentsDevelop Commissioning Schedule D D D D D DDevelop Estimate For FullCommissioning Plan IncludingA D R D R RImplementation CostsPre-construction Services• EstimatingA R R R R D & E• Scheduling• Buy OutDefinitive CPA D & E R R R R RDevelop Project Specific CommissioningD & A D R D & E D RPlanPre-Delivery Inspection (PDI) Plan A A R D & E R RPre-Delivery Inspection (PDI) Report A A R D & E R RFactory Acceptance Test (FAT) Plan A A R D & E R RFactory Acceptance Test (FAT) Report A A R D & E R RConstruction R & A R & A R R R EImplement Commissioning PlanR A R E E E(perform tests)Steady State (“Burn In”) R A & E R R A & E RDeliverables• Commissioning Report• As-Built Drawings• O & M / Turn OverR & A R & A D & E D & E R D & EDocuments• Warranties• ManualsTrainingR A & E R D & E R D & E• Facilities Management/UsersFinal Commissioning Summary Report A A R D & E R RPost-Acceptance Commissioning R D & E - - D & E -

Case Study – Pfizer B220■■■■■■600,000 SF800-plus Occupants$50 Million-plus M/E/P Systems7,000-plus Fan / Pump Horsepower65 VFDs450 Lab Hoods

Lab Compressed Air■■Field testing revealed a susceptibility to lossof cooling waterSystem was modified to ease maintenanceand reduce downtime during maintenance

Lab Vacuum Systems■■■Field testing revealed a problem withexhaust backpressure that caused safety tripshutdowns at higher loadsSystem has modified to meet design criteriaUsers wanted a deeper, higher volumevacuum that the system could not provideeven though design criteria was clear

Chilled Water■■■■6600 tons – 14,000 GPM @ 42FSystem automatically diverts to “free cooling”mode at 47F outside air and isolates fromthe campus supplyTesting revealed need for rapid transition tomaintain space temperatures; campussystem required a slow transition so as not toimpact chillersSequence of operation was modified toprotect the campus system with minimalimpact to control

Steam Systems■■■■■■140,000 #/HR – Five PRVsTesting saw excessive AHU tripping on lowtemperature detectors in the 1 st heating seasonControl strategies had to be modified to allow for acompromise between time to control at startup & tightcontrol in steady state operationResearch also indicated the need for additional driptraps, which helped solve the problemProblem was solved in the 1 st season rather thanlingeringInformation provided to designers re existing steamsupply did not prove out

Manifolded Air Handlers■■■3 Units - >150,000 CFM deliveredPressure relief doors caused problems withpressure controls and related safetiesTesting revealed a need to modify controlstrategies to suit both a rapid startup (e.g.restarting 1 unit after PM) and steady statecontrol

Vivarium Controls■■■Each room (>100)– individual T/RH/dPUser introduced a 30 day “burn-in”requirement that was not part of the originalCommissioning program and not in thescheduleCombined accuracies of related controls(AHU through local) meant a practical limiton humidity available for many rooms thatwas not anticipated

Manifolded Lab ExhaustSystems■■■7 fans / > 400,000 CFMField testing indicated problems with theautomatic restart (one or more fans)sequenceSequence was revised to improve reliabilityand revise the automatic backup (runningbackup is now “rested”)

Lessons Learned■■■■Phased occupancy of a Commissionedbuilding means retesting and disruption tooccupants of the earlier phasesAccurate information on the existing utilitiesto serve the building is critical to successfuloperationLab hood flow measurement needs toaccount for accuracies of available controls& test equipmentUsers must clearly understand the designcriteria – so that there are no surprises atoccupancy & systems do what they need todo