Commissioning (Cx)Commissioning (Cx)EPWOG MeetingEPWOG Meeting

October 21, 2003October 21, 2003

Washington, D.C.Washington, D.C.

Team MembersTeam Members

Dwayne Colburn – PNNLDwayne Colburn – PNNL

Marty Fallier – BNLMarty Fallier – BNL

John Gertsen – BWXT Y-12John Gertsen – BWXT Y-12

Jim Whitcraft – Yucca Mt.Jim Whitcraft – Yucca Mt.

Tom Etheridge – ORNLTom Etheridge – ORNL

CommissioningCommissioning

What, Why, How Much ($)……What, Why, How Much ($)……

Commissioning GuidanceCommissioning Guidance

ApplicationsApplications

What is Commissioning?What is Commissioning?

……systematic process of ensuring that a building systematic process of ensuring that a building performs in accordance with the design intent, performs in accordance with the design intent, contract documents, and the owner's operational contract documents, and the owner's operational needs.needs.

……quality-assurance process that increases the quality-assurance process that increases the likelihood that a newly constructed building will likelihood that a newly constructed building will meet client expectations.meet client expectations.

……systematic process for achieving, verifying, and systematic process for achieving, verifying, and documenting that the facility and its systems, documenting that the facility and its systems, subsystems, and equipment are planned, designed, subsystems, and equipment are planned, designed, installed, and tested, and are capable of being installed, and tested, and are capable of being operated and maintained according to the Owner's operated and maintained according to the Owner's Project Requirements (OPR).Project Requirements (OPR).

When does Commissioning When does Commissioning Occur?Occur?

The process begins with developing the OPR The process begins with developing the OPR and extends through all phases of project and extends through all phases of project delivery and into operation and maintenance.delivery and into operation and maintenance.

……through all phases of a building project.through all phases of a building project. Commissioning can begin during pre-design, Commissioning can begin during pre-design,

design, construction or building start-up. The design, construction or building start-up. The process offers significantly greater and more process offers significantly greater and more cost effective benefits when it begins during cost effective benefits when it begins during pre-design or early design.pre-design or early design.

Commissioning Span of ControlCommissioning Span of Control

Commissioning

Test &

Balance

Start-up Testing

Benefits of CommissioningBenefits of Commissioning Fewer change orders during the construction Fewer change orders during the construction

processprocess Fewer call-backsFewer call-backs Long-term tenant satisfactionLong-term tenant satisfaction Lower energy billsLower energy bills Avoided equipment replacement costsAvoided equipment replacement costs Improved profit margin for building owners once the Improved profit margin for building owners once the

building is occupiedbuilding is occupied Assures building’s operational staff is properly Assures building’s operational staff is properly

trainedtrained Operations and maintenance manuals are compiled Operations and maintenance manuals are compiled

correctly at project turn-over.correctly at project turn-over.

Project documentation relevant Project documentation relevant to commissioningto commissioning

Commissioning PlanCommissioning Plan Quality Assurance Project PlansQuality Assurance Project Plans Construction Management PlansConstruction Management Plans Test & Inspection PlansTest & Inspection Plans Acceptance Test ProceduresAcceptance Test Procedures O&M ManualsO&M Manuals Training PlansTraining Plans Re-commissioning Management ManualRe-commissioning Management Manual

Building Systems to be Building Systems to be CommissionedCommissioned

Building envelope Building envelope Interior finish materialsInterior finish materials HVAC/mechanicalHVAC/mechanical ElectricalElectrical Life safetyLife safety PlumbingPlumbing Facility processesFacility processes

Cost ExpectationsCost Expectations

O&M cost savings O&M cost savings of 8%-20% over of 8%-20% over non-commissioned non-commissioned buildingsbuildings

Retro-Cx costs Retro-Cx costs range from 3%-5%range from 3%-5%

Commissioning Scope

Cost

Entire Building(HVAC, Controls, Electrical, Mechanical)

0.5%-1.5% of total construction cost

HVAC and Automated Control System

1.5%-2.5% of mechanical system cost

Electrical Systems 1.0%-1.5% of electrical system cost

Energy Efficiency Measures

$0.23-$0.28 per square foot

Commissioning GuidanceCommissioning Guidance

Web-based information:Web-based information: http://www.eere.energy.gov/buildings/operate/buildingcommissioning.cfmhttp://www.eere.energy.gov/buildings/operate/buildingcommissioning.cfm

http://216.98.139.76/docs/ch-complete.pdfhttp://216.98.139.76/docs/ch-complete.pdf http://www.eere.energy.gov/femp/techassist/bldgcomgd.htmlhttp://www.eere.energy.gov/femp/techassist/bldgcomgd.html http://buildings.lbl.gov/hpcbs/Element_5/02_E5.htmlhttp://buildings.lbl.gov/hpcbs/Element_5/02_E5.html http://www.rebuild.org/attachments/guidebooks/http://www.rebuild.org/attachments/guidebooks/

commissioningguide.pdfcommissioningguide.pdf http://www.peci.org/cx/http://www.peci.org/cx/ http://www.ornl.gov/~webworks/cppr/y2001/rpt/101847.pdfhttp://www.ornl.gov/~webworks/cppr/y2001/rpt/101847.pdf http://www.energy.state.or.us/bus/comm/Newcx.pdfhttp://www.energy.state.or.us/bus/comm/Newcx.pdf http://www.bcxa.orghttp://www.bcxa.org http://www.fm.emory.edu/http://www.fm.emory.edu/

Commissioning ProcessCommissioning Process

Develop an overall commissioning Develop an overall commissioning strategystrategy

Begin early in pre-design processBegin early in pre-design process Designate a Cx Agent (Cx-A)Designate a Cx Agent (Cx-A)

A/E acquiredA/E acquired Construction contractor acquiredConstruction contractor acquired Independent (Owner acquired)Independent (Owner acquired)

Form a commissioning teamForm a commissioning team

Commissioning Agent RoleCommissioning Agent Role

Represents the “Owner “ as an objective advocateRepresents the “Owner “ as an objective advocate Develops the Cx PlanDevelops the Cx Plan Develops contract language for the A/E and Develops contract language for the A/E and

Construction contractsConstruction contracts Guides the Cx processGuides the Cx process Introduces standards/strategies early in designIntroduces standards/strategies early in design Ensures implementation of selected measuresEnsures implementation of selected measures Verifies minimum targets have been metVerifies minimum targets have been met Completes final Cx reportCompletes final Cx report

Commissioning ApplicationsCommissioning Applications

Oak Ridge National LaboratoryOak Ridge National Laboratory 33rdrd Party Development Party Development Russell Laboratory (Vivarium) Russell Laboratory (Vivarium) JICS/ORCASJICS/ORCAS Research Support CenterResearch Support Center

Nuclear Facility ORR applicationsNuclear Facility ORR applications Other case studiesOther case studies

http://216.98.139.76/docs/ch-complete.pdfhttp://216.98.139.76/docs/ch-complete.pdf http://www.peci.org/cx/overviews.htmlhttp://www.peci.org/cx/overviews.html

Others?Others?

Examples: ORNL 3Examples: ORNL 3rdrd Private Private Developer FacilitiesDeveloper Facilities

Cx Agent reports to owner/occupantCx Agent reports to owner/occupant Other parties: Developer; A/E; ConstructorOther parties: Developer; A/E; Constructor Cx approach - http://www.peci.org/cx/Cx approach - http://www.peci.org/cx/ Cx covers from 90% design through post-Cx covers from 90% design through post-

occupancy “re-Cx” period (1 year of O&M)occupancy “re-Cx” period (1 year of O&M) Cx-A performs QA-audit oversight of Cx-A performs QA-audit oversight of

construction & LEED certification docsconstruction & LEED certification docs Excellent MEP contractorsExcellent MEP contractors

Examples: ORNL 3Examples: ORNL 3rdrd Private Private Developer FacilitiesDeveloper Facilities

Cx Plan:Cx Plan: Integrated testingIntegrated testing System component verification against specSystem component verification against spec Upset testing plan (emergency/failure mode)Upset testing plan (emergency/failure mode) Dynamic and flexibleDynamic and flexible

Flood problem where Cx-A became critical integrator of Flood problem where Cx-A became critical integrator of problem correctionproblem correction

Cx reportCx report Complete documentation of all tests, manuals, Complete documentation of all tests, manuals,

training and performance expectationstraining and performance expectations

Examples: ORNL Russell Laboratory Examples: ORNL Russell Laboratory (Vivarium = “Mouse House”)(Vivarium = “Mouse House”)

Cx requirement of Design Build ContractCx requirement of Design Build Contract Cx-A a former TAB contractor (1Cx-A a former TAB contractor (1stst Cx project) Cx project)

Cx Plan – 3 phasesCx Plan – 3 phases1.1. Design review and installation verificationDesign review and installation verification

2.2. Operational & Functional testing/trainingOperational & Functional testing/training

3.3. Interoperability testing (failure modes)/trainingInteroperability testing (failure modes)/training

Cx Report – complete documentationCx Report – complete documentation Success key – Owner principal engineerSuccess key – Owner principal engineer

Examples: ORNL JICS/ORCASExamples: ORNL JICS/ORCAS(State of Tennessee Funded Facilities)(State of Tennessee Funded Facilities)

Cx-A contracted with ORNL (Landlord)Cx-A contracted with ORNL (Landlord) Other parties: TN; A/E(2); BuilderOther parties: TN; A/E(2); Builder Cx TasksCx Tasks

1.1. Design reviewsDesign reviews

2.2. Systems/components verificationSystems/components verification

3.3. Specific operations/functions testingSpecific operations/functions testing

4.4. Start-up and warranty validation (10 months)Start-up and warranty validation (10 months)

5.5. Training and documentationTraining and documentation

Examples: ORNL JICS/ORCASExamples: ORNL JICS/ORCAS(State of Tennessee Funded Facilities)(State of Tennessee Funded Facilities)

Cx-A DeliverablesCx-A Deliverables1.1. Design commentsDesign comments2.2. Cx plan per phase of workCx plan per phase of work3.3. Cx construction contract specificationCx construction contract specification4.4. Testing documentationTesting documentation5.5. O&M manualsO&M manuals6.6. Warranty period Warranty period

reports/testing/verificationreports/testing/verification7.7. Final Cx reportFinal Cx report

Examples: ORNL Research Support Examples: ORNL Research Support Center (RSC)Center (RSC)

Cx-Agent is internal ORNL staffCx-Agent is internal ORNL staff A/E tasked with Cx-plan developmentA/E tasked with Cx-plan development

Subcontracted to Cx- Specialty firmSubcontracted to Cx- Specialty firm Identified systems to be Cx-edIdentified systems to be Cx-ed Identified roles/responsibilities of Cx TeamIdentified roles/responsibilities of Cx Team

Cx-TeamCx-Team PM, Construction Field Representative PM, Construction Field Representative

(CFR), Design Disciplines, Constructor(CFR), Design Disciplines, Constructor Cx-PM has lead role as Cx-AgentCx-PM has lead role as Cx-Agent

Examples: ORNL Research Support Examples: ORNL Research Support Center (RSC)Center (RSC)

ProcessProcess System readiness checklist completed by System readiness checklist completed by

constructor prior to validation testingconstructor prior to validation testing Verification testing performed by constructor or Verification testing performed by constructor or

manufacturermanufacturer Testing witnessed by CFRTesting witnessed by CFR All checklists and testing results documented in All checklists and testing results documented in

Cx reportCx report System training performed after testing (video-System training performed after testing (video-

taped)taped) Cx-report filed with LEED certification packageCx-report filed with LEED certification package

Examples: Nuclear Facility ORR ApplicabilityExamples: Nuclear Facility ORR Applicability

DOE-O-425.1C delineates minimum “core requirements” for DOE-O-425.1C delineates minimum “core requirements” for operational readinessoperational readiness

Cx provides a systematic approach to addressing the “CRs” Cx provides a systematic approach to addressing the “CRs” from design through construction up to the ORR/Afrom design through construction up to the ORR/A

Approach:Approach: Ensure Cx planning requirements include ORR/A CRs (i.e. Ensure Cx planning requirements include ORR/A CRs (i.e.

Cx-A contract)Cx-A contract) Make ORR/A CRs part of Cx planMake ORR/A CRs part of Cx plan Build the ORR/A documentation record as the project Build the ORR/A documentation record as the project

progressesprogresses BenefitsBenefits

Avoids 3-6 month assembly of “proof” documentationAvoids 3-6 month assembly of “proof” documentation Strengthens the O&M aspects of the processStrengthens the O&M aspects of the process Acquaints staff with ORR/A requirementsAcquaints staff with ORR/A requirements

Conclusions on Cx …Conclusions on Cx …

A growing expectation of facility delivery and A growing expectation of facility delivery and management processmanagement process

Integrated across the planning, engineering design, Integrated across the planning, engineering design, construction and operational disciplinesconstruction and operational disciplines

Adds cost to initial delivery of facilities but results in Adds cost to initial delivery of facilities but results in reduced operational and maintenance costsreduced operational and maintenance costs

Requires advanced planningRequires advanced planning Can be tailored to project budget and can be Can be tailored to project budget and can be

delivered in various waysdelivered in various ways Supports other requirements such as LEED Supports other requirements such as LEED

certification and ORRscertification and ORRs