Commissioning: Making it Work For You - SAME DC Post · Commissioning: Making it Work For You ... McDonough Bolyard Peck (MBP) July 15, 2004. What is Commissioning ASHRAE Guideline

Commissioning: Making it Work For You

Presented by

Jim ColemanEngineering Economics, Inc. (EEI)

Doug WrennMcDonough Bolyard Peck (MBP)

July 15, 2004

What is Commissioning

ASHRAE Guideline 1-1996.

The PROCESS of of ensuring that systems are designed, installed, functionally tested, and capable of being operated and maintained to perform in conformity with the design intent… it begins with planning and includes design, construction, start-up, acceptance and training, and can be applied throughout the life of the building.

What is Commissioning

The Department of Energy“Building Commissioning involves the

DOCUMENTING the owner’s goals and needs for a facility and then ensuring that those goals are met.”

Why We Need Commissioning

Owner Satisfaction is Down50% of Buildings Suffer Control Problems40% Suffer HVAC Problems85% of Claims Involve HVAC Systems15% Have Missing Equipment

What Commissioning AchievesEnergy Savings of 20 to 50 PercentMaintenance Savings of 15 to 35 PercentReduction of Claims 2 to 10 PercentReduction of Trouble Shooting Costs

Source: Building Owners and Managers Association (BOMA) cost data for Office Buildings.

Oregon Dept of Energy: between $0.11/SF/yr and $0.35/SF/yr.

The Cost of Commissioning

0.5-1.5% of total construction costs1.5-2.5% of mechanical system costs.1.0-1.5% of electrical system costs.$0.23-$0.28/SF

Program Phase

Post Bid Award Phase

Design Phase

Construction Phase

Acceptance Phase

Functional Performance Phase

Post Acceptance Phase

Operation & Maintenance Training

Warranty Phase

The Commissioning Process

Commissioning

Program Phase

Design Phase


Develop Commissioning TeamDocument Design Intent

Program Phase

Program Phase

Design Phase


Develop Commissioning ScheduleDevelop Commissioning SpecificationPlan Review Comments

Design Phase


Commissioning Plan, Expanded to be job specific.

Submittal ReviewDevelop a Commissioning Schedule (by entire

construction team)Set up Deficiency Reporting Procedures

Post Bid Award Phase (Early Construction)

Design Phase

Construction Phase

Post Award Phase


Coordination DocumentationInstallation ObservationStatic Testing; DALT, Piping Pressure Tests,

Ground TestsDocument Changes


Design Phase

Construction Phase

Construction Phase


Start Up Observation and InspectionBuilding Automation Testing: “Point to Point

Verification”.Testing Adjusting and Balancing Review


Design Phase

Construction Phase

Construction Phase


Deficiency ReportingAs Built DocumentsO&M ManualsTAB Reports


Design Phase

Construction Phase

Construction Phase


Point to Point TestingTAB Accuracy VerificationControl System FunctionIntersystem Functions

Construction Phase

Acceptance Phase

Acceptance Phase


Deficiency Reporting and CorrectionsVerification ReportFinal Test ReportsFinal Deficiency ListCertificate of Readiness to Begin Functional

Testing

Construction Phase

Acceptance Phase

Acceptance Phase


The ability of the system to produce the effect in accordance with the final design intent.

“The Functional Performance Tests are the heart of the Commissioning process, but they are also the most difficult and time consuming.”

Acceptance Phase


Warranty Phase



Owner’s Maintenance Staff Documentation of 11 Month Operations.

Off Season TAB Testing

Acceptance Phase


Warranty Phase

Warranty Phase


Acceptance Phase



Warranty Phase

Final Commissioning Report.Prepare Re-commissioning Plan



Done throughout the entire Commissioning Process.

Integrated and Coordinated with the Contractor’s Specified Training Requirements.

Work with Maintenance Personnel to Develop Maintenance Programs



War Stories

War stories tell the Cx tale bestWar stories tell the Cx tale bestOne of the most important abilities of a One of the most important abilities of a CxA is conflict resolutionCxA is conflict resolutionIt doesn’t matter what your technical skill It doesn’t matter what your technical skill level is, if you can’t communicate and get level is, if you can’t communicate and get along with others on the project you will along with others on the project you will never forge a union to focus on the never forge a union to focus on the important project goalsimportant project goals

What Cx is Up Against

ScenarioScenarioLarge showcase project for a large and Large showcase project for a large and prestigious clientprestigious clientProject delivery is CM with Multiple Project delivery is CM with Multiple Prime Contracts, including MechanicalPrime Contracts, including MechanicalCxA works directly for OwnerCxA works directly for OwnerMechanical Contractor has worked on Mechanical Contractor has worked on many projects for the Ownermany projects for the Owner

What Cx is Up AgainstWe made a checklist of specification requirements We made a checklist of specification requirements including O&M Manuals and Trainingincluding O&M Manuals and TrainingMech. Contractor submits an O&M Manual that is Mech. Contractor submits an O&M Manual that is FAR from meeting the specificationsFAR from meeting the specificationsWe review Manual and recommend rejection and We review Manual and recommend rejection and give specific sections of specifications not metgive specific sections of specifications not metEngineer agrees with our findings and rejects Engineer agrees with our findings and rejects O&M ManualsO&M ManualsNo word back from Mech. Contractor for No word back from Mech. Contractor for sometime sometime –– we could not get an answer in Cx we could not get an answer in Cx MeetingsMeetings

What Cx is Up AgainstFind out that Mech. Contractor has made an appeal to the Find out that Mech. Contractor has made an appeal to the Owner that his O&M Manuals should be accepted and that Owner that his O&M Manuals should be accepted and that he should not be held responsible or meeting specification he should not be held responsible or meeting specification requirements for O&M Manuals or Trainingrequirements for O&M Manuals or TrainingThe reason? They have never been required to meet the The reason? They have never been required to meet the specification requirements on this before and that they are specification requirements on this before and that they are delivering the same quality of manual the Owner has delivering the same quality of manual the Owner has always accepted in the past. Furthermore, they bid the always accepted in the past. Furthermore, they bid the project based upon “local prevailing practices”.project based upon “local prevailing practices”.The fact is, no one had been requiring the enforcement of The fact is, no one had been requiring the enforcement of the specifications and yet the Owner complains they have the specifications and yet the Owner complains they have not been getting good O&M information or training not been getting good O&M information or training –– and and they haven’t!they haven’t!

What Cx is Up AgainstThis dispute climbed the ladder of the Owner’s This dispute climbed the ladder of the Owner’s facility department facility department –– everyone was aware that this everyone was aware that this was a watershed decision by the Owner and would was a watershed decision by the Owner and would set the course for future projects.set the course for future projects.The Owner decided that the specifications would The Owner decided that the specifications would be enforced and the contractor was obligated be enforced and the contractor was obligated –– by by the contract he signed the contract he signed –– to meet the requirements to meet the requirements of the specifications.of the specifications.If this had not turned out this way, the If this had not turned out this way, the effectiveness of any future commissioning efforts effectiveness of any future commissioning efforts would be limited at best.would be limited at best.

What Cx is Up AgainstThe CxA should not only represent the Owner, he should The CxA should not only represent the Owner, he should represent the best long term interests of the O&M staff.represent the best long term interests of the O&M staff.The first cost of most buildings only represents 20% of the The first cost of most buildings only represents 20% of the building’s life cycle costs. The other 80% is from building’s life cycle costs. The other 80% is from operation and maintenance costs. It only makes sense that operation and maintenance costs. It only makes sense that we need to pay a lot of attention to the 80% as well as the we need to pay a lot of attention to the 80% as well as the 20%.20%.Effective commissioning can only occur if the CxA has the Effective commissioning can only occur if the CxA has the unwavering support of the Owner. The Owner is the only unwavering support of the Owner. The Owner is the only one who cares about the 80%.one who cares about the 80%.

Components of Cx ProcessA good Cx process should include the following A good Cx process should include the following elementselements

Know what the Owner needs and expects from Know what the Owner needs and expects from the buildingthe buildingRepresent the Owner’s long term interests to Represent the Owner’s long term interests to help assure a building that meets his functional help assure a building that meets his functional requirements and can be operated and requirements and can be operated and maintained successfullymaintained successfullyBe sure the O&M staff has the right training Be sure the O&M staff has the right training and toolsand toolsContinue involvement in building, where Continue involvement in building, where possible, to make benefits persistentpossible, to make benefits persistent

Little Things Can Mean a LotThe most important asset a Cx firm can have, other than The most important asset a Cx firm can have, other than good people, is a large database of “lessons learned”. good people, is a large database of “lessons learned”. These are mistakes/problems/issues that others have paid These are mistakes/problems/issues that others have paid for. The CxA should bring this asset to every project.for. The CxA should bring this asset to every project.The earlier you can prevent or catch a problem, the less it The earlier you can prevent or catch a problem, the less it costs to correct. Problems caught in design phase are costs to correct. Problems caught in design phase are inexpensive to correct.inexpensive to correct.The earlier a CxA becomes involved in a project, the more The earlier a CxA becomes involved in a project, the more value it has to the project.value it has to the project.For the benefits to occur, someone has to listen to the CxA For the benefits to occur, someone has to listen to the CxA and the CxA needs to explain why a recommendation is and the CxA needs to explain why a recommendation is important.important.

Understanding

Knowledge Application

Feedback

Little Things Can Mean a LotTriple Duty Valves vs. Shutoff, Check Valve and Flow Triple Duty Valves vs. Shutoff, Check Valve and Flow Measurement deviceMeasurement device

For TDVs to be able to work as a means to measure For TDVs to be able to work as a means to measure hydronic flow, they must be properly sizedhydronic flow, they must be properly sizedContractors find it least expensive to install line sized Contractors find it least expensive to install line sized valvesvalvesThe shutoff valve frequently requires a tool to The shutoff valve frequently requires a tool to open/close/adjustopen/close/adjustTDVs are expensiveTDVs are expensiveFlow measurement devices, such as a venturi, allow Flow measurement devices, such as a venturi, allow excellent flow measurement performanceexcellent flow measurement performanceYou don’t want to balance flow at pumps by imposing You don’t want to balance flow at pumps by imposing additional pressure resistanceadditional pressure resistance

Little Things Can Mean a LotWe flagged this problem in design reviewWe flagged this problem in design review

The Engineer changed the details on the plans to call for separaThe Engineer changed the details on the plans to call for separate te componentscomponentsThe Mech. Contractor was very late in submitting on this. When The Mech. Contractor was very late in submitting on this. When submittal was made, the Mech. Contractor argued that the Owner’ssubmittal was made, the Mech. Contractor argued that the Owner’sdesign standards allowed TDVs and that they needed to use them ddesign standards allowed TDVs and that they needed to use them due ue to a time restriction. The Engineer approved the submittal.to a time restriction. The Engineer approved the submittal.We saw the submittal and flagged this as an issue. We pointed oWe saw the submittal and flagged this as an issue. We pointed out ut that if they were going to accept the TDVs they at least needed that if they were going to accept the TDVs they at least needed to to require proper sizingrequire proper sizingAbout 6 weeks later we visited the job site and found TDVs on thAbout 6 weeks later we visited the job site and found TDVs on the e floor floor –– line sized and not anywhere close to time it would be installedline sized and not anywhere close to time it would be installedWe pointed this out to the Engineer and asked for him to look upWe pointed this out to the Engineer and asked for him to look up the the pressure drop of valves pressure drop of valves –– they were only about 20% of the minimum they were only about 20% of the minimum required pressure drop required to read flowrequired pressure drop required to read flowStill Still –– no one required the contractor to make a changeno one required the contractor to make a changeLater, TAB Contractor (who had backed Mech. Contractor on TDV Later, TAB Contractor (who had backed Mech. Contractor on TDV sizing) stated that they could not read system gpmsizing) stated that they could not read system gpm

VAV Lab Hood Controls

VAV Lab Hood Controls

Humidifier Controls

Cx as a Scheduling AidMechanical schedule on a large projectMechanical schedule on a large project

11stst Floor Mech RoughFloor Mech Rough--In by XX/XX/XXIn by XX/XX/XX11stst Floor Mech Completion by YY/YY/YYFloor Mech Completion by YY/YY/YYSame for other floorsSame for other floors

CxA can help keep project on schedule by backwards CxA can help keep project on schedule by backwards scheduling with specific milestone dates for specific tasks scheduling with specific milestone dates for specific tasks and by preand by pre--planning with CM/GC system testing sequenceplanning with CM/GC system testing sequenceThe milestone dates give an early warning alarm when the The milestone dates give an early warning alarm when the building mechanical systems are falling behind schedulebuilding mechanical systems are falling behind scheduleWhen contractors have to flood project near completion the When contractors have to flood project near completion the contractor’s efficiency is reduced and quality control contractor’s efficiency is reduced and quality control problems increaseproblems increase

ASHRAE Guideline 0Will define the commissioning process for all disciplines under Will define the commissioning process for all disciplines under NIBS Total Building Cx StandardNIBS Total Building Cx StandardASHRAE Guideline 1 will be the HVAC Cx StandardASHRAE Guideline 1 will be the HVAC Cx StandardEven though these are described as Guidelines, Court cases have Even though these are described as Guidelines, Court cases have already defined them as level of due diligencealready defined them as level of due diligenceNIBS Standard will include Electrical, Plumbing, Fire NIBS Standard will include Electrical, Plumbing, Fire Protection, Building Envelope, Roofing, etcProtection, Building Envelope, Roofing, etcASHRAE Guideline 0 has just completed second, and final, ASHRAE Guideline 0 has just completed second, and final, public draft reviewpublic draft reviewWe believe that this will be the prevailing commissioning We believe that this will be the prevailing commissioning standardstandardBCA Cx Certification (CCP) based on Guideline 0 and AEE BCA Cx Certification (CCP) based on Guideline 0 and AEE will probably change from PECI to this standard for their will probably change from PECI to this standard for their certification program (CBCP)certification program (CBCP)

ASHRAE Guideline 0Stresses importance of Owner hiring CxA very early in the Stresses importance of Owner hiring CxA very early in the processprocessCxA to document Owner’s Project Requirements (OPR) CxA to document Owner’s Project Requirements (OPR) early early –– even before hiring the Design Teameven before hiring the Design TeamThe Basis of Design is the design team’s response to the The Basis of Design is the design team’s response to the OPROPROPR + BoD = Design IntentOPR + BoD = Design IntentGreater focus on O&M issues during designGreater focus on O&M issues during designPrePre--functional Checklists become Construction Checklistsfunctional Checklists become Construction ChecklistsAcceptable means of sampling is definedAcceptable means of sampling is definedRequired Commissioning documentation requirements is Required Commissioning documentation requirements is better definedbetter defined

LEED™ Certification Programs

LEED NC (2.2 coming)LEED NC (2.2 coming)LEED EBLEED EBLEED CSLEED CSLEED CILEED CILEED AGLLEED AGLLEED HLEED H

Wise Old Sayings

If you keep doing what you’ve been doing If you keep doing what you’ve been doing then you’re going to keep getting what then you’re going to keep getting what you’ve been getting. you’ve been getting.

Summary

Commissioning is a process that can provide Commissioning is a process that can provide substantial benefits to the functionality and long substantial benefits to the functionality and long term operation and maintenance of a facilityterm operation and maintenance of a facilityCommissioning should be incorporated as early in Commissioning should be incorporated as early in the process as possiblethe process as possibleLearn the lessons from past problem projects and Learn the lessons from past problem projects and change what you’ve been doing so you can change change what you’ve been doing so you can change what you’ve been gettingwhat you’ve been getting

Summary

There is always resistance to changeThere is always resistance to changeOnly building owners can drive a change to Only building owners can drive a change to industry practices and prevent building by industry practices and prevent building by “local prevailing practices”“local prevailing practices”The commissioning process can help The commissioning process can help everyone involved in the building design everyone involved in the building design and construction processand construction process