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 VII: LABORATORY SUPPORT EQUIPMENT
Volume I: A. Project Directory D.I. Point of Use Polishers
B. TOP Matrix Chemical Fume Hoods
C. As-Builts Record Set CD Radioisotope Hoods
D. Master Punchlist Bio Safety Cabinets
E. Warranty Letters
F. RFI Log w/Responses "DIRTY" PROCESS UTILITIES
G. O & M Manuals Volume VIII: Laboratory Vacuum

SUBMITTALS "CLEAN" PROCESS UTILITIES

Volume II: A. Submittal Log Volume IX: RO/DI Water System
B. Approved Submittals Volume X: Carbon Dioxide
Volume XI: Laboratory Compressed Dry Air
PROJECT SPECIFICATIONS
Volume III: A. Specification Listing BUILDING UTILITIES
B. Record Specifications Volume XII: Domestic HW/CW
C. Record Basis of Design (BOD) Volume XIII: Natural Gas
Volume XIV: Sanitary Waste & Vent
SYSTEMS DOCUMENTATION Volume XV: Lab Waste & Vent
Volume IV: DRY-SIDE HVAC Volume XVI: Storm/Roof Drainage
Central Air Handling
Economizer Return Air Fan FIRE/LIFE SAFETY SYSTEMS
General Lab Exhaust Volume XVII: Fire Alarm & HVAC Interface
"H" Area Exhaust Fans Volume XVIII: Elevator Recall and Safety Sequences
Radioisotope Exhaust Fans Volume XIX: Fire Sprinkler
Air Terminal Zones Volume XX: Flammable Vapor Detection (LEL)
IDF/MDF Backup AC Units
Mechanical Room, Boiler Room Exhaust Fans ELECTRICAL & SPECIALTY SYSTEMS
Refrigeration Room Ventilation, Refigerant Leak Volume XXI: Normal Power Service & Distribution
Detection, Purge & EPO Emergency/Standby Distribution
Bag In / Bag Out Filtration System Grounding
Volume XXII: Lighting & Lighting Control
Volume V: WET-SIDE HVAC Volume XXIII: Generator & ATS
Preheat/Reheat - Boilers, Pumps Volume XXIV: UPS, Batteries
Condenser Water - Towers, Pumps Volume XXV: Security Including CCTV
Refrigerated Water - Chillers, Pumps Volume XXVI: FMS - Facility Management System

Volume VI: CONTROLS SYSTEMS ENVIRONMENTAL HEALTH & SAFETY

BAS - Building Automation System Volume XXVII: EH&S - Environmental Health & Safety

Volume VII: LABORATORY SUPPORT EQUIPMENT APPENDICES

D.I. Point of Use Polishers Appendix A: Seismic Bracing Drawings, Calcs and Inspection
Chemical Fume Hoods Sign-off - Mechanical/Plumbing Eqpt & Overhead
Radioisotope Hoods Appendix B: Balance Report - Air & Water
Bio Safety Cabinets Appendix C: Commissioning Plan and Report
System Docs: TOP Matrix

GNE FACILITIES SIGN-OFF

GNE ENGINEERING SIGN-

CENTRAL AIR HANDLING

GENERAL CONTRACTOR
SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION

SECTION 3a - PIPING

MEP SIGN-OFF
SECTION

A Piping Specifications
TAB

OFF
B Piping Documentation
SYSTEM DOCUMENTATION
i. Piping Submittal
ii. Valving Submittals
iii. Specialty Piping / Plumbing Fixture Submittals
iv. Seismic Details and Stamped Drawings
v. Weld Procedure(s)
SECTION 1-GENERAL vi. Welder Certification
vii. Pipe Brazing/Soldering Procedure(s)
A System Overview
C Installation Documentation/Field Verification
i. Equipment List x
i. Pressure Test Report
ii. BOD - Basis of Design x
ii. Flushing Report
B Drawings
iii. Cleaning and/or Passivation Report
i. Construction Drawings and/or P&IDs x
iv. Sanitization Plan and Report
ii. Vendor Furnished Drawings x
v. Field QC Reports/Particulate Report
iii. As-Built Drawings x
SECTION 3b - DUCTWORK
C Punchlists/Mechanical Completion Letter x
A Ductwork Specifications x
D Balance Report x
B Ductwork Documentation
E Startup/Commissioning Test Plan
i. Ductwork Submittal x
i. Commissioning Plan x
ii. Insulation Submittal x
ii. Final Commissioning Report x
iii. Shop Drawings
F Warranty x
iv. Seismic Details and Stamped Drawings x
G Owner Training Documentation x
v. Specialty Ductwork x

SECTION 2 - EQUIPMENT C Installation Documentation

i. Ductwork Leak Tests x
A System Documentation
ii. Seismic Inspection reports & Sign-off x
i. Installation Guide and O&M Manuals x

ii. Contractor/Vendor Supplied Equipment Submittals/Drawings x SECTION 4 - ELECTRICAL

iii. Equipment Prefunction Checklist x A Electrical Specifications

iv. HEPA Filter Certification B Single Line Diagrams

C Electrical Documentation
v. Seismic and/or Structural Calculations x
i. Electrical Commodities Submittal
vi. Labeling Document x
ii. Seismic Details, Stamped Drawings and Inspection Reports/Sign-off
vii. Recommended Spare Parts List x
D Electrical Equipment Checkout
B Test Reports
i. Ground System Testing
i. FAT Test Results
ii. Transformer Testing/Reports
ii. Field Test Results x
a. Tilt-Meter Testing
iii. Contractor/Vendor Startup Reports x
b. Insulation Resistance Test Report
iv. Hood Certifications (GNE) iii. Megger Testing

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION a. Switchgear/Switchboards

SECTION 3a - PIPING
A Piping Specifications
Master TOP Matrix

ECONOMIZER RETURN AIR

NORMAL POWER SERVICE

"H" AREA EXHAUST FANS

FIRE ALARM SYSTEM AND

SANITARY WASTE & VENT
RADIOISOTOPE EXHAUST

REFRIGERATED WATER -
CENTRAL AIR HANDLING

DETECTION, PURGE, EPO

GENERAL LAB EXHAUST

RADIOISOPTOPE HOODS

STORM/ROOF DRAINAGE

ELEVATOR RECALL AND

BOILER ROOM EXHAUST

CHEMICAL FUME HOODS

CHILLERS, PUMPS, ETC.

LABORATORY VACUUM

UPS, PDU & BATTERIES

MANAGEMENT SYSTEM
EMERGENCY/STANDBY
BIO SAFETY CABINETS

SECURITY, INCLUDING
POWER DISTRIBUTION
CONDENSER WATER -

AUTOMATION SYSTEM
AIR TERMINAL ZONES

LIGHTING & LIGHTING

VBSE'S - VENTILATED

DETECTION SYSTEMS

GROUNDING SYSTEM
SAFETY SEQUENCES
MECHANICAL ROOM,

REFRIGERANT LEAK

IDF/MDF BACKUP AC
REFR ROOM VENTIL,

FILTRATION SYSTEM

FLAMMABLE VAPOR
LAB WASTE & VENT

GENERATOR & ATS

DOMESTIC HW / CW
TOP VOLUME NO.

PREHEAT-REHEAT

BALANCE SAFETY

COMPRESSED AIR
BAG IN / BAG OUT

HVAC INTERFACE
D.I. POINT OF USE

CARBON DIOXIDE
BOILERS, PUMPS

FIRE SPRINKLER
TOWERS, PUMPS

& DISTRIBUTION
BAS - BUILDING

NATURAL GAS

FMS - FACILITY
ENCLOSURES

PURIFICATION

LABORATORY
RO/DI WATER
POLISHERS

(LEL, %O2)

CONTROL
SECTION

UNITS
FANS

FANS

CCTV
TAB

FAN
SYSTEM DOCUMENTATION

SECTION 1-GENERAL
A System Overview
i. Equipment List x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

ii. Basis of Design (BOD) x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

B Drawings
i. Construction Drawings and/or P&IDs x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

ii. Vendor Furnished Drawings x x x x x x x x x x x x x x x x x x x x x x x

iii. As-Built Drawings x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

C Punchlists/Mechanical Completion Letter x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

D Balance Report x x x x x x x x x x x x x

E Startup/Commissioning Test Plan

i. Commissioning Plan x x x x x x x x x x x x x x x x x x x x x x x x x x x x

ii. Final Commissioning Report x x x x x x x x x x x x x x x x x x x x x x x x x x x x

F Warranty x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

G Owner Training Documentation x x x x x x x x x x x x x x x x x x x x x x x x x

SECTION 2 - EQUIPMENT
A System Documentation
i. Installation Guide and O&M Manuals x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

ii. Contractor/Vendor Supplied Equipment Drawings/Submittals x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x

iii. Equipment Installation Checklist (Including Identification) x x x x x x x x x x x x x x x x x x x x x x x x x x x

iv. HEPA Filter Certification x x

v. Seismic and/or Structural Calculations x x x x x x x x x x x x x x x x x x x x

vi. Labeling Document x x x x x x x x x x x x x x x x x x x x

vii. Recommended Spare Parts List x x x x x x x x x x x x x x x x x x x x x x

B Test Reports
i. FAT Test Results x

ii. Field Test Results x x x x x x x x x x x x x x x x x x x x x x x x x x

iii. Contractor Startup Reports x x x x x x x x x x x x x x x x x x x x x x x x

iv. Hood Certification x x x x

SECTION 3 - EQUIPMENT TESTING/INSTALLATION VERIFICATION

SECTION 3a - PIPING
A Piping Specifications x x x x x x x x x x x x x

B Piping Documentation
i. Piping Submittal and Material Certifications x x x x x x x x x x x x x

ii. Valving Submittals and Material Certifications x x x x x x x x x x

iii. Specialty Piping / Plumbing Fixture Submittals and Material Certifications x x x x x x x x x

iv. Seismic Details and Stamped Drawings x x x x x x x x x x x

v. Weld Procedure(s) x x x x

vi. Welder Certification x x x x

vii. Pipe Brazing/Soldering Procedure(s) x x x x x x x

C Installation Documentation/Field Verification

i. Pressure Test Report and Drawings x x x x x x x x x x x x x

ii. Flushing Report and Drawings x x x x x

iii. Cleaning Report and Drawings x x x

iv. Sanitization Plan and Report x x

v. Field QC Reports x x

SECTION 3b - DUCTWORK
A Ductwork Specifications x x x x x x x x

B Ductwork Documentation
i. Ductwork Standards x x x x x x x x

ii. Insulation Data x x x

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 Mar 24, '08 Mar 31, '08 Apr 7, '08 Apr 14, '08 Apr
S M W F S T T S M W F S T T S M
1 BUILDING 47 TURNOVER
2 SPARE PARTS IDENTIFIED & TURNED OVER
3 Spare Parts Identified by Facilities GNE
4 Pricing Submitted to GNE for Approval GNE
5 Order Spare Parts Therma, REI, H
6 Spare Parts Turned Over to GNE Therma, REI, H
7 FINAL PUNCHLIST (REFER TO PROJECT SCH)
8 Final Punchlist Walkthrough P&W, GNE
9 Issue Final Punchlist P&W, GNE
10 Make Corrections & Backcheck All Subs, HD, P&W, GN
11 Final Punchlist Complete P&W, GNE
12 BALANCE REPORT
13 Issue Balance Reports for TOP (Preliminary) Therma
14 Issue Final Balance Reports Therma
15 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 Therma, REI, Siemens Security
Siemens FLS
20 Other As-Builts Submitted to HD BFP, Walker FMS
21 Siemens Issue BAS as-builts Siemens BAS
22 P&W Compile and Issue Record Set for TOP P&W
Turn Over Schedule - Continued
ID Task Name Responsible
Mar 31, '08 Apr 7, '08 Apr 14, '08 Apr 21, '08 Ap
S T T S M W F S T T S M W F S
23 WARRANTY LETTERS
24 Submit warranty letters ALL SUBS
25 TOP MANUALS
26 Submit Remaining TOP System Installation Docs Therma, REI, Siemens, BF
Thyssen Krupp, Walker FMS, HD
27 Submit Start-up & Testing Docs Therma, REI, Siemens, Walker FM
28 Facilities & Engineering TOP Binder Review GNE
29 Make TOP Revisions Therma, REI, Siemens, BF
Thyssen Krupp, Walker FMS, HD
30 TOP Substantially Complete
31 Insert Remaining Docs
32 RO/DI Piping Sanitization Reports Therma
33 D.I. Point-of-use Polisher Docs Therma/HD
34 Final Balance Report Therma
35 Final Commissiong Package & Presentation AEI
36 As-Built Record Set P&W
37 EH&S Binder & Section 7 EH&S Docs GNE, HD
38 System Training (See Training Schedule) Therma, REI, Siemens, GNE, H
39 Certificate of Occupancy (Refer to Project Schedule for ac HD
40 Permit Binder Submitted All Subs, HD
Q&A