Commissioning (Cx)

EPWOG Meeting
October 21, 2003
Washington, D.C.
 Team Members

Dwayne Colburn – PNNL

Marty Fallier – BNL
John Gertsen – BWXT Y-12
Jim Whitcraft – Yucca Mt.
Tom Etheridge – ORNL
 Commissioning
 What, Why, How Much ($)……

 Commissioning Guidance

 Applications
 What is Commissioning?

 …systematic process of ensuring that a building

performs in accordance with the design intent,
contract documents, and the owner's operational
needs.
 …quality-assurance process that increases the
likelihood that a newly constructed building will
meet client expectations.
 …systematic process for achieving, verifying, and
documenting that the facility and its systems,
subsystems, and equipment are planned, designed,
installed, and tested, and are capable of being
operated and maintained according to the Owner's
Project Requirements (OPR).
 When does Commissioning
Occur?
 The process begins with developing the OPR
and extends through all phases of project
delivery and into operation and maintenance.
 …through all phases of a building project.
 Commissioning can begin during pre-design,
design, construction or building start-up. The
process offers significantly greater and more
cost effective benefits when it begins during
pre-design or early design.
 Commissioning Span of Control

Commissioning

Test & Start-up

Testing
Balance
 Benefits of Commissioning
 Fewer change orders during the construction
process
 Fewer call-backs
 Long-term tenant satisfaction
 Lower energy bills
 Avoided equipment replacement costs
 Improved profit margin for building owners once the
building is occupied
 Assures building’s operational staff is properly
trained
 Operations and maintenance manuals are compiled
correctly at project turn-over.
 Project documentation relevant
to commissioning
 Commissioning Plan
 Quality Assurance Project Plans
 Construction Management Plans
 Test & Inspection Plans
 Acceptance Test Procedures
 O&M Manuals
 Training Plans
 Re-commissioning Management Manual
 Building Systems to be
Commissioned
 Building envelope
 Interior finish materials
 HVAC/mechanical
 Electrical
 Life safety
 Plumbing
 Facility processes
 Cost Expectations
 O&M cost savings Commissioning
Scope
Cost

of 8%-20% over Entire Building 0.5%-1.5% of total

non-commissioned (HVAC, Controls, construction
Electrical, cost
buildings Mechanical)

 Retro-Cx costs HVAC and

Automated
1.5%-2.5% of
mechanical
range from 3%-5% Control System system cost

Electrical Systems 1.0%-1.5% of

electrical
system cost
Energy Efficiency $0.23-$0.28 per
Measures square foot
 Commissioning Guidance
 Web-based information:
 http://www.eere.energy.gov/buildings/operate/buildingcommissioning.cfm
 http://216.98.139.76/docs/ch-complete.pdf
 http://www.eere.energy.gov/femp/techassist/bldgcomgd.html
 http://buildings.lbl.gov/hpcbs/Element_5/02_E5.html
 http://www.rebuild.org/attachments/guidebooks/commissioninggui
de.pdf
 http://www.peci.org/cx/
 http://www.ornl.gov/~webworks/cppr/y2001/rpt/101847.pdf
 http://www.energy.state.or.us/bus/comm/Newcx.pdf
 http://www.bcxa.org
 http://www.fm.emory.edu/
 Commissioning Process
 Develop an overall commissioning
strategy
 Begin early in pre-design process
 Designate a Cx Agent (Cx-A)
 A/E acquired
 Construction contractor acquired
 Independent (Owner acquired)
 Form a commissioning team
 Commissioning Agent Role
 Represents the “Owner “ as an objective advocate
 Develops the Cx Plan
 Develops contract language for the A/E and
Construction contracts
 Guides the Cx process
 Introduces standards/strategies early in design
 Ensures implementation of selected measures
 Verifies minimum targets have been met
 Completes final Cx report
 Commissioning Applications
 Oak Ridge National Laboratory
 3rd Party Development
 Russell Laboratory (Vivarium)
 JICS/ORCAS
 Research Support Center
 Nuclear Facility ORR applications
 Other case studies
 http://216.98.139.76/docs/ch-complete.pdf
 http://www.peci.org/cx/overviews.html
 Others?
 Examples: ORNL 3rd Private
Developer Facilities
 Cx Agent reports to owner/occupant
 Other parties: Developer; A/E; Constructor
 Cx approach - http://www.peci.org/cx/
 Cx covers from 90% design through post-
occupancy “re-Cx” period (1 year of O&M)
 Cx-A performs QA-audit oversight of
construction & LEED certification docs
 Excellent MEP contractors
 Examples: ORNL 3rd Private
Developer Facilities
 Cx Plan:
 Integrated testing
 System component verification against spec
 Upset testing plan (emergency/failure mode)
 Dynamic and flexible
 Flood problem where Cx-A became critical integrator of
problem correction
 Cx report
 Complete documentation of all tests, manuals,
training and performance expectations
 Examples: ORNL Russell Laboratory
(Vivarium = “Mouse House”)
 Cx requirement of Design Build Contract
 Cx-A a former TAB contractor (1st Cx project)
 Cx Plan – 3 phases
1. Design review and installation verification
2. Operational & Functional testing/training
3. Interoperability testing (failure modes)/training
 Cx Report – complete documentation
 Success key – Owner principal engineer
 Examples: ORNL JICS/ORCAS
(State of Tennessee Funded Facilities)
 Cx-A contracted with ORNL (Landlord)
 Other parties: TN; A/E(2); Builder
 Cx Tasks
1. Design reviews
2. Systems/components verification
3. Specific operations/functions testing
4. Start-up and warranty validation (10 months)
5. Training and documentation
 Examples: ORNL JICS/ORCAS
(State of Tennessee Funded Facilities)
 Cx-A Deliverables
1. Design comments
2. Cx plan per phase of work
3. Cx construction contract specification
4. Testing documentation
5. O&M manuals
6. Warranty period
reports/testing/verification
7. Final Cx report
 Examples: ORNL Research Support
Center (RSC)
 Cx-Agent is internal ORNL staff
 A/E tasked with Cx-plan development
 Subcontracted to Cx- Specialty firm
 Identified systems to be Cx-ed
 Identified roles/responsibilities of Cx Team
 Cx-Team
 PM, Construction Field Representative
(CFR), Design Disciplines, Constructor
 Cx-PM has lead role as Cx-Agent
 Examples: ORNL Research Support
Center (RSC)
 Process
 System readiness checklist completed by
constructor prior to validation testing
 Verification testing performed by constructor or
manufacturer
 Testing witnessed by CFR
 All checklists and testing results documented in
Cx report
 System training performed after testing (video-
taped)
 Cx-report filed with LEED certification package
 Examples: Nuclear Facility ORR Applicability

 DOE-O-425.1C delineates minimum “core requirements” for

operational readiness
 Cx provides a systematic approach to addressing the “CRs”
from design through construction up to the ORR/A
 Approach:
 Ensure Cx planning requirements include ORR/A CRs (i.e.
Cx-A contract)
 Make ORR/A CRs part of Cx plan
 Build the ORR/A documentation record as the project
progresses
 Benefits
 Avoids 3-6 month assembly of “proof” documentation
 Strengthens the O&M aspects of the process
 Acquaints staff with ORR/A requirements
 Conclusions on Cx …
 A growing expectation of facility delivery and
management process
 Integrated across the planning, engineering design,
construction and operational disciplines
 Adds cost to initial delivery of facilities but results in
reduced operational and maintenance costs
 Requires advanced planning
 Can be tailored to project budget and can be
delivered in various ways
 Supports other requirements such as LEED
certification and ORRs