Turn Over Packages, FAT and

Commissioning
San Francisco Bay Area Chapter
Commuter Conference May 13th 2008
Misha Anissimov, Genentech
Mike Britting, Hathaway Dinwiddie
Leo Santini, Hathaway Dinwiddie

FAT
Why do we need a Factory Acceptance Test?
Who Benefits, who are the stakeholders?
Who should be in charge, who should go?
Is it worth the cost?

Basic FAT

Establish what needs to be tested

Establish who needs to attend
Establish the schedule
Establish who will be responsible for
reporting and recording

Commissioning Basics for the Owner

Misha Anissimov, P.E.

M.E. 101, Inc.

What is Commissioning?

ASHRAE defines it as A quality-focused process for

enhancing the delivery of a project. The process focuses on
verifying and documenting that the facility and all of its
systems and assemblies are planned, designed, installed,
tested, operated and maintained to meet the Owners Project
Requirements.

TRANSLATION: The process of testing and challenging your

building systems in such a way as to find all of the problems
and mistakes before Building Turnover. Each problem found
during Commissioning = One less problem found by the User.

Establish the Team (the Cx agents support network)

The Owners Representative : should have a solid working knowledge

of Mechanical Systems design and function, and provide unbiased
information to upper management.

Commissioning Agent : Reviews Controls, Writes FPTs, executes

FPTs

Mechanical Engineer of Record : Owns the system design and

Sequence of Operation.

General Contractors MEP Coordinator : Will act as the enforcer in

helping resolve issues between subcontractors.

Mechanical Contractor Project Manager and Field Start Up Technician

Controls Contractor Project Manager, Design Engineer and FIELD

PROGRAMMER.

Step 1 : Establish Scope

. A detailed Commissioning (Cx) specification is needed to define

systems/parameters to be tested, trends to be run, documentation that
is required. Spend time achieving clarity in your own mind of exactly
what you want to accomplish.

If you are using a generic specification, supplement this with your own
building-specific attachment. What are some unique tests you want to
include? 72 hour trends of all building zones? A 5-day quality of life
check? A Cx agent Overview class for Facilities? Unusual systems
which may require special attention? 100% vs. 10% point to point?
Get Facilities Involved. All facilities engineers have pet peeves. Maybe
they hate variable primary chilled water systems. Include specific tests
in the scope to specifically address Facilities and User concerns.

Step 2: Choosing a Commissioning Agent

-

As always, word-of-mouth recommendations of Agents are a great

starting point. This is 100% Labor.less cost means less Cx activity.

PROPOSALS: Ask for sample Issues logs (what kind of problems did
they uncover in past jobs?), Ask for sample Functional Performance
Tests-FPTs (how are the tests written? Do the documents include
generous amounts of hard data like pressure/temperatures/flows, or
do the tests look too simplified pass/fail with no data recorded). Test
data acquired in the field is useful later in troubleshooting.

INTERVIEW: Meet the lead Cx Manager who would be assigned to your

project. Be sure you are getting an A list person, not a B list
person. Is he or she an effective leader? Do they take charge? Ask
them about a system you have had problems with in the past and how
they would test it.

Step 3: Preparation Preparation Preparation

-

THIRD PARTY OVERSIGHT: Be sure the contract and channels of

communication are established so that the Owner always gets the real
deal information from the Cx Agent. He is your person in the trenches
making sure everything works.

PLANNING: I like to start with dedicated Cx meetings early..right after 95%

CD Documents are issued. That means dedicated Commissioning Meetings
once a week, starting with a thorough document design review process

75% of Commissioning Problems are controls related. Start with a detailed

Controls Sequence of Operation Review by the Cx Agent, Mechanical
Engineer, and FACILITYS rep. You are building a Cx TEAM.

After SOO , Get the Controls Programmers involved. Ask for Logic Diagrams
to understand how the system will be programmed.

A Few Words about FPTs

Actively Review Functional Performance Tests especially key

tests. Focus on the Objectives and the Results you would
like to see.

Beware of Boiler Plate FPTs. Are the tests custom tailored to

your systems?

FPTs are common sense and are the battle plan of

Commissioning.

Step 4: Execution

The SOOs have been scrubbed, you know how the Control
Systems will be programmed, the Functional performance tests
have been created and reviewed by the Owner, you have adequate
staffing for all trades-contractors, and you have PGE power to all
systems! You are ready to start Cx activities!

Embrace PROBLEMS: The more you find now, the better.

Keep FACILITIES Involved: Witnessing tests is great facilities

training.and establishes a comfort level before turnover.

Cx is a coordinated team effort and delays WILL occur. Avoid the

temptation to accelerate Cx activitiesthis will result in errors. Cx
agents are not painters/sheetrockers, etc. Start with a REALISTIC
schedule and then ADD SOME EXTRA.

A Few Words About Scheduling

Substantial Completion Certificate of Occupancy does not

mean the Building is ready for User Move-In.

Ideal Move In Date should lag 4 8 weeks or so behind

substantial completion

Cx activity issues TAKE TIME to resolve. Simple Issues are

quick. Design Issues can take weeks.

Case Study: A simple Lab Building with a top notch team, with
Mechanical Engineering Owner oversight, and a thorough
review process is projected to have the Cx Issues resolved 3
4 weeks after substantial completion. THIS IS NORMAL.

Turn Over Packages

What is the Turn Over Package
(TOP)?
Why is the TOP essential for
successful Project completion?
What is needed for a TOP?

The Owners Perspective

Establish the requirements for contractor
turnover packages
Assign defined roles & responsibilities and
incorporate into the Contract Documents
Establish ongoing TOP meetings
Manage and support the turnover
plan/schedule throughout the Project

Case Study: Genentech TI Project

Leo Santini, MEP Coordinator

Hathaway Dinwiddie

Summary: The Contractors Perspective

Know your contract and specifications

Define and/or clarify all questionable items
Formalize the complete organization of the TOP
Team members buy-in
Provide a means of signing off and tracking
documents as the Project progresses
Develop an outline/schedule for key turn over
items
Follow through and execution - maintain visibility
and communication among all team members

Key Items in Turnover Package

O&Ms delivered to Facilities for SOPs

Seismic calcs, inspection & approval letters
Start-up data
BAS AT box programming data
VFD parameters data
Accurate BAS as-builts and control sequences
EH&S Binder
Sound consultant calculations, and reports

Other Turnover Items & Activities

Training & Coordination Equipment is
running. Coordinate days and times with Facilities
Final Punch List Final punch walks occur
weeks before substantial completion. Final punch
completion and Owner backcheck completed by
substantial completion date.
As Builts Architectural backgrounds freeze 30
days before substantial completion
Final Building Turnover Checklist
signature and date by Owner Project Engineering,
Facilities and Contractor

Building Turnover Checklist

MEP System Turn Over Checklists

TOP Manuals: Table of Contents

GENERAL DOCUMENTATION
Volume I:

SUBMITTALS
Volume II:

PROJECT SPECIFICATIONS
Volume III:

SYSTEMS DOCUMENTATION
Volume IV:

Volume VII:

A.
B.
C.
D.
E.
F.
G.

Project Directory
TOP Matrix
As-Builts Record Set CD
Master Punchlist
Warranty Letters
RFI Log w/Responses
O & M Manuals

A.
B.

Submittal Log
Approved Submittals

A.
B.
C.

Specification Listing
Record Specifications
Record Basis of Design (BOD)

DRY-SIDE HVAC
Central Air Handling
Economizer Return Air Fan
General Lab Exhaust
"H" Area Exhaust Fans
Radioisotope Exhaust Fans
Air Terminal Zones
IDF/MDF Backup AC Units
Mechanical Room, Boiler Room Exhaust Fans
Refrigeration Room Ventilation, Refigerant Leak
Detection, Purge & EPO
Bag In / Bag Out Filtration System

LABORATORY SUPPORT EQUIPMENT

D.I. Point of Use Polishers
Chemical Fume Hoods
Radioisotope Hoods
Bio Safety Cabinets

Volume VIII:

"DIRTY" PROCESS UTILITIES

Laboratory Vacuum

Volume IX:
Volume X:
Volume XI:

"CLEAN" PROCESS UTILITIES

RO/DI Water System
Carbon Dioxide
Laboratory Compressed Dry Air

Volume XII:
Volume XIII:
Volume XIV:
Volume XV:
Volume XVI:

BUILDING UTILITIES
Domestic HW/CW
Natural Gas
Sanitary Waste & Vent
Lab Waste & Vent
Storm/Roof Drainage

Volume XVII:
Volume XVIII:
Volume XIX:
Volume XX:

FIRE/LIFE SAFETY SYSTEMS

Fire Alarm & HVAC Interface
Elevator Recall and Safety Sequences
Fire Sprinkler
Flammable Vapor Detection (LEL)

Volume V:

WET-SIDE HVAC
Preheat/Reheat - Boilers, Pumps
Condenser Water - Towers, Pumps
Refrigerated Water - Chillers, Pumps

Volume XXII:
Volume XXIII:
Volume XXIV:
Volume XXV:
Volume XXVI:

ELECTRICAL & SPECIALTY SYSTEMS

Normal Power Service & Distribution
Emergency/Standby Distribution
Grounding
Lighting & Lighting Control
Generator & ATS
UPS, Batteries
Security Including CCTV
FMS - Facility Management System

Volume VI:

CONTROLS SYSTEMS
BAS - Building Automation System

Volume XXVII:

ENVIRONMENTAL HEALTH & SAFETY

EH&S - Environmental Health & Safety

Volume VII:

LABORATORY SUPPORT EQUIPMENT

D.I. Point of Use Polishers
Chemical Fume Hoods
Radioisotope Hoods
Bio Safety Cabinets

Volume XXI:

APPENDICES
Appendix A:
Appendix B:
Appendix C:

Seismic Bracing Drawings, Calcs and Inspection

Sign-off - Mechanical/Plumbing Eqpt & Overhead
Balance Report - Air & Water
Commissioning Plan and Report

CENTRAL AIR HANDLING

GENERAL CONTRACTOR
MEP SIGN-OFF

GNE FACILITIES SIGN-OFF

SYSTEM DOCUMENTATION

GNE ENGINEERING SIGNOFF

TAB

SECTION

System Docs: TOP Matrix

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION
SECTION 3a - PIPING
A

Piping Specifications

Piping Documentation

SECTION 1-GENERAL
A System Overview
i.

Equipment List

ii.

BOD - Basis of Design

i.

Construction Drawings and/or P&IDs

ii.

Vendor Furnished Drawings

iii.

As-Built Drawings

C Punchlists/Mechanical Completion Letter

D Balance Report

E Startup/Commissioning Test Plan

i.

Commissioning Plan

ii.

Final Commissioning Report

Warranty

G Owner Training Documentation

ii.

Contractor/Vendor Supplied Equipment Submittals/Drawings

iii.

Equipment Prefunction Checklist

iv.

HEPA Filter Certification

v.

Seismic and/or Structural Calculations

vi.

Labeling Document

vii.

Recommended Spare Parts List

i.
ii.

Field Test Results

iii.

Contractor/Vendor Startup Reports

iv.

Hood Certifications (GNE)

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION

SECTION 3a - PIPING
A Piping Specifications

vii.

Pipe Brazing/Soldering Procedure(s)

Installation Documentation/Field Verification

Pressure Test Report

ii.

Flushing Report

iii.

Cleaning and/or Passivation Report

iv.

Sanitization Plan and Report

v.

Field QC Reports/Particulate Report

i.

Ductwork Submittal

ii.

Insulation Submittal

iii.

Shop Drawings

iv.

Seismic Details and Stamped Drawings

v.

Specialty Ductwork

Installation Documentation
i.

Ductwork Leak Tests

ii.

Seismic Inspection reports & Sign-off

SECTION 4 - ELECTRICAL
A Electrical Specifications
B

Single Line Diagrams

Electrical Documentation

FAT Test Results

Welder Certification

Ductwork Specifications

B Test Reports

Weld Procedure(s)

vi.

Ductwork Documentation

A System Documentation
x

Seismic Details and Stamped Drawings

v.

Installation Guide and O&M Manuals

Specialty Piping / Plumbing Fixture Submittals

iv.

i.

iii.

SECTION 3b - DUCTWORK

SECTION 2 - EQUIPMENT

Piping Submittal
Valving Submittals

i.

B Drawings
x

i.
ii.

i.

Electrical Commodities Submittal

ii.

Seismic Details, Stamped Drawings and Inspection Reports/Sign-off

Electrical Equipment Checkout

i.

Ground System Testing

ii.

Transformer Testing/Reports
a. Tilt-Meter Testing
b. Insulation Resistance Test Report

iii.

Megger Testing
a. Switchgear/Switchboards

FMS - FACILITY
MANAGEMENT SYSTEM

SECURITY, INCLUDING
CCTV

UPS, PDU & BATTERIES

GENERATOR & ATS

EMERGENCY/STANDBY
POWER DISTRIBUTION

GROUNDING SYSTEM

LIGHTING & LIGHTING

CONTROL

NORMAL POWER SERVICE

& DISTRIBUTION

FIRE SPRINKLER

FLAMMABLE VAPOR
DETECTION SYSTEMS
(LEL, %O2)

ELEVATOR RECALL AND

SAFETY SEQUENCES

DOMESTIC HW / CW

FIRE ALARM SYSTEM AND

HVAC INTERFACE

LAB WASTE & VENT

STORM/ROOF DRAINAGE

NATURAL GAS

SANITARY WASTE & VENT

LABORATORY
COMPRESSED AIR

CARBON DIOXIDE

RO/DI WATER
PURIFICATION

LABORATORY VACUUM

REFRIGERATED WATER CHILLERS, PUMPS, ETC.

VBSE'S - VENTILATED
BALANCE SAFETY
ENCLOSURES

PREHEAT-REHEAT
BOILERS, PUMPS

CONDENSER WATER TOWERS, PUMPS

BIO SAFETY CABINETS

BAG IN / BAG OUT

FILTRATION SYSTEM

CHEMICAL FUME HOODS

IDF/MDF BACKUP AC
UNITS

RADIOISOPTOPE HOODS

AIR TERMINAL ZONES

D.I. POINT OF USE

POLISHERS

RADIOISOTOPE EXHAUST
FANS

BAS - BUILDING
AUTOMATION SYSTEM

GENERAL LAB EXHAUST

"H" AREA EXHAUST FANS

Equipment List
Basis of Design (BOD)

SYSTEM DOCUMENTATION

MECHANICAL ROOM,
BOILER ROOM EXHAUST
FANS
REFR ROOM VENTIL,
REFRIGERANT LEAK
DETECTION, PURGE, EPO

CENTRAL AIR HANDLING

ECONOMIZER RETURN AIR

FAN

i.
ii.

TAB

SECTION

TOP VOLUME NO.

Master TOP Matrix

SECTION 1-GENERAL
A

System Overview

Drawings

x
x

i.

Construction Drawings and/or P&IDs

ii.

Vendor Furnished Drawings

iii.

As-Built Drawings

Punchlists/Mechanical Completion Letter

Balance Report

Startup/Commissioning Test Plan

Warranty

i.

Commissioning Plan

ii.

Final Commissioning Report

G Owner Training Documentation

x
x

SECTION 2 - EQUIPMENT
A System Documentation
i.

Installation Guide and O&M Manuals

ii.

Contractor/Vendor Supplied Equipment Drawings/Submittals

iii.

Equipment Installation Checklist (Including Identification)

iv.

HEPA Filter Certification

v.

Seismic and/or Structural Calculations

vi.

Labeling Document

vii.

Recommended Spare Parts List

Test Reports
i.

FAT Test Results

ii.

Field Test Results

iii.

Contractor Startup Reports

iv.

Hood Certification

x
x

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION

SECTION 3a - PIPING
A

Piping Specifications

Piping Documentation

i.

Piping Submittal and Material Certifications

ii.

Valving Submittals and Material Certifications

iii.

Specialty Piping / Plumbing Fixture Submittals and Material Certifications

iv.

Seismic Details and Stamped Drawings

v.

Weld Procedure(s)

vi.

Welder Certification

Pipe Brazing/Soldering Procedure(s)

vii.
C

i.

Pressure Test Report and Drawings

x
x

Installation Documentation/Field Verification

ii.

Flushing Report and Drawings

iii.

Cleaning Report and Drawings

iv.

Sanitization Plan and Report

v.

Field QC Reports

Ductwork Specifications

Ductwork Documentation

i.

Ductwork Standards

ii.

Insulation Data

x
x

SECTION 3b - DUCTWORK
A

TOP Manuals: Review Sheet

GENENTECH BLDG 46, 47, 48
TOP REVIEW SHEET
N AME :
D ATE :
S YSTEM /S COPE :

REVIEW SHEET
SECTION

COMMENTS

RESPONSIBLE

CORRECTED

Turn Over Schedule

ID

Task Name

Responsible

8
S

1
2

BUILDING 47 TURNOVER
SPARE PARTS IDENTIFIED & TURNED OVER

Spare Parts Identified by Facilities

GNE

Pricing Submitted to GNE for Approval

GNE

Order Spare Parts

Therma, REI, H

Spare Parts Turned Over to GNE

Therma, REI, H

FINAL PUNCHLIST (REFER TO PROJECT SCH)

Final Punchlist Walkthrough

Issue Final Punchlist

10

Make Corrections & Backcheck

11
12
13
14
15

Final Punchlist Complete

P&W, GNE
P&W, GNE
All Subs, HD, P&W, GN
P&W, GNE

BALANCE REPORT
Issue Balance Reports for TOP (Preliminary)

Therma

Issue Final Balance Reports

Therma

COMMISSIONING PACKAGE

16

Executed System Protocols Complete

AEI

17

Provide Final Commissioning Overview Package

AEI

18

AS-BUILTS, BOD, & SPECS RECORD SET

19

Final as-built, BOD & Specs Submitted to P&W

20

Other As-Builts Submitted to HD

21

Siemens Issue BAS as-builts

22

P&W Compile and Issue Record Set for TOP

Therma, REI, Siemens Security

Siemens FLS
BFP, Walker FMS
Siemens BAS
P&W

Mar 24, '08

M W F

Mar 31, '08

Apr 7, '08
S T T S M W F

Apr 14, '08

Apr
S T T S M

Turn Over Schedule - Continued

ID
23
24
25

Task Name

Responsible

WARRANTY LETTERS
Submit warranty letters

ALL SUBS

TOP MANUALS

26

Submit Remaining TOP System Installation Docs

27

Submit Start-up & Testing Docs

28

Facilities & Engineering TOP Binder Review

29

Make TOP Revisions

30

TOP Substantially Complete

31

Insert Remaining Docs

32

RO/DI Piping Sanitization Reports

33

D.I. Point-of-use Polisher Docs

34

Final Balance Report

35

Final Commissiong Package & Presentation

36

As-Built Record Set

37

Mar 31, '08

Apr 7, '08
S T T S M W F

EH&S Binder & Section 7 EH&S Docs

38

System Training (See Training Schedule)

39

Certificate of Occupancy (Refer to Project Schedule for ac

40

Permit Binder Submitted

Therma, REI, Siemens, BF

Thyssen Krupp, Walker FMS, HD
Therma, REI, Siemens, Walker FM
GNE
Therma, REI, Siemens, BF
Thyssen Krupp, Walker FMS, HD

Therma
Therma/HD
Therma
AEI
P&W
GNE, HD
Therma, REI, Siemens, GNE, H
HD
All Subs, HD

Apr 14, '08

Apr 21, '08
S T T S M W F

Ap
S

Q&A