MECHATRONICS AND INSTRUMENT SERVICING MANAGEMENT LEVEL IV

DEJEN TVET COLLEGE

LEARNING MODULE 14 Logo of TVET Provider

TVET PROGRAM TITLE: Mechatronics and Instrument Servicing Management level IV

MODULE TITLE: Commissioning Mechatronics systems
MODULE CODE: ELE MIS4 M14 0814
NOMINAL DURATION: 20hrs

MODULE DESCRIPTION:
This module covers the knowledge, skills and attitudes necessary to undertake the
commissioning of Mechatronics systems.

LEARNING OUTCOMES:
At the end of the module the trainee will be able to:
LO1: Plan and prepare to undertake commissioning process
LO2: Commission Mechatronics systems
LO3: Test commissioned Mechatronics systems

MODULE CONTENTS:
LO1: Plan and prepare to undertake commissioning process
1.1 OH & S policies and procedures
1.2 Commissioning procedures
1.3 Selection & use of proper tools & equipment
LO2: Commission Mechatronics systems
2.1 Check Mechatronics systems
2.2 Perform Commissioning procedures
LO3: Test commissioned Mechatronics systems
3.1 Test the commissioned Mechatronics systems according to procedures
3.2 Report on the commissioning process

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LO1: Plan and prepare to undertake commissioning process

1.1 OH & S policies and procedures
Your Company Name is committed to the goal of providing and maintaining a healthy
and safe working environment, with a view to continuous improvement. This goal is only
achievable by adherence to established objectives striving to exceed all obligations under
applicable legislation, and by fostering an enthusiastic commitment to health, safety and
the environment within Your Company Name.
In particular:

 ƒ Management, working in cooperation with the Joint Health and Safety

Committee, will strive to take all reasonable steps to reduce workplace hazards to as
low as reasonably achievable.
 Supervisors and managers are held accountable for the health and safety of all
employees under their supervision. This includes responsibility for applicable
training and instruction, appropriate follow up on reported health and safety
concerns, and implementation of recommended corrective action. This
accountability is integrated into
the performance appraisal system.

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 Supervisors, workers and visitors are expected to perform their duties and
responsibilities in a safe and healthful manner, and are accountable for the Health
and Safety of themselves and others.
 Your Company Name is committed to providing all necessary training and
instruction to ensure that appropriate work practices are followed on the job, and to
promote their use off the job.
 if necessary, Your Company Name will take disciplinary action where individuals
fail to work in a healthy and safe manner, or do not comply with applicable
legislation or corporate policies and procedures.
Occupational Health and Safety in Workplaces
Duties of Workers
One of your most important responsibilities is to protect your Health and Safety as
well as that of your co-workers. This booklet will discuss some of your duties under
the occupational Health and Safety legislation and help you to make your
workplace safer and healthier.
What the law requires
Workplaces under the jurisdiction are governed by your provincial legislation.
The legislation places duties on owners, employers, workers, suppliers, the self
employed and contractors, to establish and maintain safe and healthy working
Conditions. The legislation is administered by your provincial legislation. Your officials
are responsible for monitoring compliance.
Your Responsibilities

You must also comply with the legislation. You have responsibilities to:
 ƒ protect your own Health and Safety and that of your co-workers;
 ƒ not initiate or participate in the harassment of another worker; and
 ƒ co-operate with your supervisor and anyone else with duties under the
legislation.
Your Rights
The legislation gives your three rights:

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 ƒ The right to know the hazards at work and how to control them;
 ƒ The right to participate in Occupational Health and Safety
 ƒ The right to refuse work which you believe to be unusually dangerous.
You may not be punished for using these rights. An employer can be required to legally
justify any action taken against a worker who is active in Health and Safety.
Your Right To Know
The Act requires your employer to provide you with all the information you need to
control the hazards you face at work. For example, chemicals at the workplace must be
listed. You are entitled to review this list. Your employer must train you to safely handle
the chemicals you will work with. If you are inexperienced, you must receive an
orientation which includes;
 What to do in a fire or other emergency;
 ƒ First aid facilities;
 ƒ Prohibited or restricted areas;
 ƒ Workplace hazards; and
 ƒ Any other information you should know.
You must also be supervised closely by a competent supervisor.
Your Right To Participate
You have the right to become involved in occupational Health and Safety. The legislation
encourages employers and workers to work together to maintain a healthy and safe
workplace. Employers at workplaces with (ten or more – consult your provincial act)
workers must set up an occupational health committee of employer and worker
representatives.
Committees Have Duties To:
 ƒ Regularly inspect the workplace;
 ƒ Conduct accident investigations;
 ƒ Deal with the Health and Safety concerns of employees;
 ƒ Investigate refusals to work;
 ƒ Meet at least (four times a year – consult your provincial act); and return
minutes of each meeting to the Division

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1.2 Commissioning procedures

 What is Commissioning
Commissioning is a “quality-oriented process for achieving, verifying and
documenting whether the performance of a building’s systems and assemblies
meet defined
objectives and criteria.” This internationally established definition is quite close to
the definition used by ASHRAE (the American Society of Heating, Refrigerating,
and Air Conditioning Engineers), that stipulates that Commissioning is “ the
process of ensuring that systems are designed, installed, functionally tested and
capable of being operated and maintained to perform in conformity with the
design intent.” In practice one can differentiate 4 types of commissioning which
are describe
 Initial commissioning begins during design and continues through construction
and
occupancy. It helps ensure that the performance of the new building or major
retrofit meets owner’s expectations.
 Retro commissioning is the first time commissioning is implemented in an
existing building in which a documented commissioning process was not
previously implemented.
 Re commissioning is another type of commissioning that occurs when a building
that has already been commissioned undergoes another commissioning process.
Most buildings experience degradation in performance that, if left untreated, will
reduce occupant productivity and energy efficiency, often well before comfort
complaints trigger a response.
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Lifetime commissioning or ongoing commissioning is a commissioning process
conducted continually for the purposes of maintaining, improving and optimizing
the performance of building systems initial or re/retro commissioning.
Through this process, a necessary improved coordination between design, construction
and occupancy will occur and permit to reach financial, comfort and performance
benefits, as described here:

 Reduced life-cycle costs

in the long term, the projected life-cycle costs of buildings and facilities will be reduced
as a result of the integrated efforts of the designer and the building operators to meet
commissioning requirements. It will contribute to reduce construction costs while
ensuring a more efficient use of energy over the years.
 Cost effective maintenance
Involvement of O&M staff in commissioning, plus the training and documentation
provided, is the basis for more effective operation, maintenance and management
throughout the life of the facility.
 Occupant satisfaction
The primary and immediate beneficiaries of a properly designed, constructed and
commissioned facility are the occupants. They will enjoy the advantages of living or
working in an improved indoor environmental quality that’s comfortable and safe and in
surroundings that meet their everyday needs. Further benefits will accrue to the
Owner/Investor as a result of having satisfied tenants in a quality building that complies
with the requirements of the investment plan. Also, when building quality is translated
into higher productivity and reduced absenteeism of the occupants, the overall savings
become even more significant.
 Quality assurance
The Owner/Investor is assured that a quality facility and a "surprise-free"
product/environment have been provided. There will be fewer system deficiencies at
building turnover. This will be achieved by ensuring that:
 the Contract Documents include all commissioning specifications,
 the requirements of these specifications will be met

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 fully documented tests and inspections will prevent minor errors from developing
into serious operational flaws

A. Sequence of testing: Commissioning shall proceed from lower to higher levels of

Complexity. For each discrete subsystem or system, testing at the lower level shall be
completed prior to starting the next higher level of tests. In general, the order of testing,
from lowest to highest is as follows:
1. Static tests (e.g. duct leakage tests, meggar tests). These tests or standard construction
testing requirements as part of the Quality Control Services. The Owner’s Representative,
CA
(Commissioning Agent) and Prime Contractor may witness the initial static tests to
establish the standard for testing and the acceptance criteria. The Contractors shall then
be responsible for conducting future tests in accordance with this standard. The Owner’s
Representative and/or the CA may observe future tests.
2. Component installation verification (e.g. motors, actuators, sensor calibration, etc.) and
start-up utilizing checklists developed by the CA.
3. System Balancing
4. System functional performance tests
5. Intersystem functional performance tests
B. Retesting: Contractor shall repeat, at no additional cost to the Owner, the complete
functional test procedure for each test in which acceptable results are not achieved and
the failed test is due to the Contractor’s action or nonconformance to contract
requirements. Repeat tests until acceptable results are achieved. Compensate the Owner
for direct costs incurred as the result of tests repeated to achieve acceptable results, if the
requirement for retesting is a direct result of the Contractor’s action or non-conformance
to contract requirements.
C. Correction of deficiencies

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1. Contractor shall correct functional performance test deficiencies promptly and
coordinate the scheduling of the retest with the CA.
2. Corrections during functional performance tests are generally prohibited to avoid
consuming the time of personnel waiting for the test, but not involved in making the
correction. Exceptions shall be allowed if the cause of the failure is obvious and
corrective action can be completed in a timeframe acceptable to the CA. If corrections are
made under this exception, the failure shall be noted on the functional performance test
data form. A new functional performance test data form, marked “retest,” shall be
initiated after the correction has been made. The entire functional performance test
procedure shall be repeated.
COORDINATION
A. Commissioning Team:
1. Members of the Commissioning Team (CT) shall consist of:
a. Commissioning Agent (CA)
b. Owner’s Representative(s) (OR)
c. Design Professional (A/E)
d. Prime General Contractor (GC)
e. Prime HVAC Contractor (MC)
f. Prime Plumbing Contractor (PC)
g. Prime Electrical Contractor (EC)
h. Test and Balance Sub-Contractor (TAB)
i. Controls Sub-Contractor (CC)
j. Prime Contractor Installation Sub-Contractors
k. Equipment Suppliers and Vendors
B. Installation verification and start-up documentation.
1. The Prime Contractor is responsible for installation in accordance with
applicable code, plans, specifications and industry standards and practices.
Quality Control Services includes inspection and testing requirements by the Contractor.
The commissioning program utilizes installation verification and start-up checklists for
equipment included in the program. The documentation of installation and start-up shall
be

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included in the requirements of the Quality Control Services and all Contractors shall be
responsible for completing their sections of these checklists.
C. Functional Performance Testing.
1. Once the installation verification and start-up checks have been completed and all
deficiencies identified have been corrected, a functional operational demonstration of the
equipment shall be performed. The CA shall develop a functional performance testing
protocol and then witness
the operational testing activities as the Contractor demonstrates the operation. The OR
may elect to also witness activities on a case-by-case basis.
D. Training.
1. As specified the technical sections of this specification, Prime Contractors are
responsible for coordinating and providing training to the building operators. The CA
shall work with the Owner’s Facility Management Department to define the areas of
focus for the training and develop the training plan. It shall be the Prime Contractors’
responsibility to prepare the training sessions in accordance with the training plan and
execute the training sessions utilizing qualified and experienced instructors and in
accordance with the training plan.
E. Meetings.
1. Participate in regularly scheduled commissioning meetings. In order to coordinate the
commissioning activities, the CA shall conduct regular commissioning meetings. These
would typically follow a project progress meeting.
F. Management:
1. The Owner shall provide the services of the CA. The CA directs and coordinates
commissioning activities and reports to OR. All members of the Commissioning Team
work together to fulfill contracted responsibilities and objectives of the Contract
Documents.
G. Scheduling:
1. In cooperation with the CA, the Prime Contractors shall integrate commissioning
activities into the master construction schedule. This integration of commissioning
activities, in general terms, shall be developed early in the project and then refined as the
project progresses.

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2. Scheduling issues shall be resolved at monthly commissioning meetings. The CA shall
provide an initial schedule of primary commissioning events at the commissioning kick-
off meeting. As construction progresses, more specific activities and milestones shall be
incorporated into the master construction schedule.
3. There shall be at least one commissioning scheduling meeting for all commissioning
team members to integrate key commissioning activities (i.e. equipment start-ups and
functional testing) with critical construction milestones. Participants shall include both
the Contractor Project Managers and the key on-site representatives. This meeting
typically
occurs about two months prior to equipment start-ups and can take up to a day.
4. Prime Contractors shall provide written timely notice to OR of any changes in date,
time, location or anticipated duration of start-up and test activities. For the purpose of this
paragraph written notice shall be received by OR a minimum of 72 hours in advance to
be considered timely. Prime Contractor shall reimburse Owner for actual costs incurred
by the Owner as the result of failure to provide timely notice, per preceding paragraph, of
changes in date, time, location, or anticipated duration of start-up and test activities.
FUNCTIONAL PERFORMANCE TESTING
A. Objectives and Scope:
1. the objective of Functional Performance Testing is to demonstrate each system is
operating according to the A/E Basis of Design as defined in the Contract Documents.
Functional Performance Testing facilitates bringing systems from a state of substantial
completion to full dynamic operation. Additionally, during Functional Performance
Testing, areas of deficient
performance are identified and corrected the improving operation and functionality of
systems.
2. Each system shall be operated through all modes of operation (seasonal, occupied,
unoccupied, warm-up, cool-down, part- and full-load, etc.) where there is a specified
system response. Verifying each sequence in the specified sequence of operation is
required including responses to conditions such as power failure, freeze condition, low oil
pressure, no flow, equipment failure, etc.
3. The Contractor that is responsible for the dynamic operation of a system shall

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demonstrate comprehensive functionality of that system. All Contractors that have
contributed to the installation of the same system shall not be required to directly
participate in the functional testing activity but shall be required to be immediately
available for reconciliation of
issues that fall within their scope and responsibility during testing.
A. Participation:
1. CA shall coordinate and witness functional performance tests after successful start up,
documentation of systems and equipment installation, and pre-requisite testing (e.g.
leakage tests, testing and balancing, etc.) have been completed and documentation
forwarded to CA. The CA shall coordinate with the Prime Contractor to ensure that
commissioning
milestones do not impact construction milestones and to ensure that the commissioning
activities are completed prior to Substantial Completion. The Contractor shall generally
execute test by manipulation of systems or equipment, provision of supporting equipment
or materials (lifts, ladders, specialty test equipment, etc.), and on spot remediation of
minor identified deficiencies.
2. The participation of the roofing contractor is specified in Division 7 commissioning
requirements. Provided the installation verification and start-up documentation was
properly completed by the Installation Contractor, the involvement of HVAC installation
sub-contractors during the functional performance testing is minimal except as noted
herein and in Division 15 – HVAC. The primary HVAC contractors involved in the
functional performance testing are the Controls Sub-Contractor and the Test, Adjust and
Balance Sub-Contractor. The anticipated levels of involvement for these two contractors
are defined in Division 15 - HVAC. The involvement of the Plumbing Prime Contractor
and installation subcontractors for systems included in the Commissioning Program shall
also be defined in Division 15 Plumbing and Fire Protection. The involvement of the
Electrical Prime Contractor and installation subcontractors for systems included in the
Commissioning Program shall
be defined in Division 16 - Electrical.
B. Detailed Test Forms: CA shall prepare detailed functional performance test (FPT)
protocols for functionally testing systems. These shall be developed during the

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construction phase and completed during the acceptance phase. The protocols shall be
reviewed with the involved parties (e.g. installation contractor, controls contractor, test
and balance contractor, etc.) at least four weeks prior to the scheduled testing to ensure
the involved parties clearly understand the procedures, level of involvement and scope of
testing prior to the actual system operational demonstration.
C. Completeness: All systems must be completed and ready for FPT. Submission of fully
completed installation verification and start-up checklists, including manufacturer’s rep
start-up forms is a prerequisite to proceeding with functional testing.
D. Test Documentation: CA shall witness functional testing of systems. CA shall record
test results on the forms developed for the testing. CA shall Pass or Fail the testing and
record the date and time of the test. Deficiencies shall clearly be indicated when the test
is failed. When all related testing is completed successfully, CA shall recommend
acceptance of the system or component.

E. Deficiencies and Re-testing: When deficiencies are identified during testing,

depending on their extent or magnitude, they can be corrected during the test and the
testing can continue to successful completion without significant delay. More significant
deficiencies shall require failure of the test and re-testing. Deficiencies of this magnitude
shall result in an action item on the System Functional Performance Test Discrepancy
Report. The Prime Contractor shall then subsequently track the resolution of the
deficiency via the Discrepancy Report. All tests shall be repeated until successful
completion.
F. Sampling: Some types of identical equipment (e.g. air terminal devices, smoke
detectors, etc.) shall be tested using a sampling strategy.
G. Failure Limit on Sample Tests: An acceptable failure limit shall be established for
each type of equipment where sampling is used. This limit indicates the maximum
percentage of tested devices that may have any test that fails before an entirely new
sample must be tested. This is based on the concept that if many failures occur, it is a
result of inadequate start-up. When the maximum number of failures is reached, testing
on that sample shall be terminated and re-testing shall be scheduled.
1. Where sample tests involve multiple systems, the maximum failure limit shall apply

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per system.
2. All work necessitated by sample failures shall be at no cost to the Owner
3. If a sampling strategy is conducted, the acceptance criteria shall be a maximum of ten
percent failure rate for total parameters that are sampled, provided the system
components being tested are not part of a life safety system (e.g. smoke detectors,
emergency lighting, etc.). For life safety systems there shall be a zero failure rate. At the
point a device fails on a
life safety system, the testing shall be terminated until the Contractor has rechecked and
confirmed proper operation of all devices.
H. Opposite Season Testing: Testing procedures shall be repeated and/or conducted as
necessary during appropriate seasons. "Opposite season" testing is primarily for
environmental systems and shall be required where scheduling prohibits thorough testing
in all modes of operation. The CA shall schedule the opposite season testing during the
warranty period to coincide with a design day condition when possible. Typically, trend
logs will be reviewed by the CA during the opposite season operation. If a review of
these logs generates concerns then follow-on opposite season testing shall be performed
to identify and correct deficiencies.
I. Acceptance Criteria: Acceptance criteria for construction installation tests (e.g. duct
leakage tests, pipe pressure tests, pipe cleaning, electrical acceptance testing, etc.) are
very important. The acceptance criteria where applicable shall be specified in the
individual technical specification sections. Documentation of the testing is to be provided
to the CA prior to FPT

1.3 Selection & use of proper tools & equipment

Proper tools and equipment are essential for the effective operation of any civil Works
site. Equipping the electrical construction site with the correct tools and equipment plays
an essential role in achieving timely and good quality results. For every electrical
construction activity there is an optimal combination of tools, equipment and labour.
Depending on the nature and content of the works, the technical staff needs to know
which tools to use and how to effectively combine them with manual labour. Once on
site, equipment requires trained operators and supervisory staff who are proficient in its

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operation and maintenance. Faulty equipment is a common reason for delays on
construction sites. A major responsibility of the project management is to ensure that
tools and equipment are maintained in a good condition and are readily available when
required for the various work activities.
Quality of Tools
Hand tools are the main instruments used by the workers to carry out the activities
involved in constructing a machine using labour-based work methods.
It is therefore important that project staff know how to select and maintain the tools since
they have a significant influence on the work outputs. Hand tools are used much more
intensively on labour-based construction work than in electrical machine. Many tools
commonly used for electrical work are not strong enough for use on construction sites
and will quickly break if used intensively. It is therefore essential that the tools used on a
electric works project are properly designed to stand the quality wear and tear of a
construction site.

LO2: Commission Mechatronics systems

2.1 Check Mechatronics systems
Mechanical systems are increasingly integrated with actuators, sensors and digital
Electronics.

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For designing Mechatronics systems the interplay for the realization of functions in the
mechanical and electronic part is crucial. Compared to pure mechanical realizations, the
use of amplifiers and actuators with electrical auxiliary energy has already led to
considerable simplifications, as can be seen from watches, electrical typewriters and
cameras. A further considerable simplification in the mechanics resulted from
introducing microcomputers in connection with decentralized electrical drives, e.g., for
electronic typewriters, sewing machines, multi-axis handling systems and automatic
gears.

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A primary energy flows into the machine and is then either directly used for the energy
consumer in the case of an energy transformer or converted into another energy form in
the case of an energy converter. The form of energy can, for example, be electrical,
mechanical (potential or kinetic, hydraulic, pneumatic) chemical or thermal. The primary
energy flow originates from an energy source or energy supply and can be manipulated
by an actuator. The energy consumer is in many cases an energy sink or/and an energy
storage. Machines are mostly characterized by a continuous or periodic (repetitive)
energy flow. For other mechanical processes like mechanical elements or precision
mechanical devices, piecewise or intermittent energy flows are typical.
The energy flow is generally a product of a generalized flow and a potential (effort).
Information on the state of the mechanical process can be obtained from measured
generalized flows, like speed, volume or mass flow, electrical current or potentials like
force, pressure, temperature and voltage. These measured signals are then the basis for
information processing in a digital computer operating under real-time conditions.
Together with reference variables, the measured variables are therefore the inputs for an

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information flow through the digital electronics resulting in manipulated variables for the
actuators or in monitored variables on a display. Hence, the mechanical–electronic
system can be considered as consisting of a feed forward energy flow and a feedback
information flow. Presently a development is taking place to integrate the mechanical
systems, the actuators, sensors and microelectronics, forming an inseparable overall
system

2.2 Perform Commissioning procedures

 RELATED DOCUMENTS
Drawings and general provisions of the Contract, including General and Supplementary
Conditions and other Division 1 Specification Sections, apply to this Section.
 SUMMARY
 ABBREVIATIONS
 COORDINATION
 COMMISSIONING GENERAL PROCESS

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 RESPONSIBILITIES

LO3: Test commissioned Mechatronics systems

3.1 Test the commissioned Mechatronics systems according to procedures
The purpose of these tests is to ensure that all components and systems are in a
satisfactory and safe condition before start up. Preliminary adjustment and setting of
equipment at this stage shall also be carried out at the same time to pave way for the
coming functional performance tests.
Before carrying out any test, the Contractor shall ensure that the installation complies
with all relevant statutory requirements and regulations. The T & C works shall also
comply with all site safety regulatory requirements.
3.2 Report on the commissioning process
Definition
Commissioning report today deals with an important aspect of commissioning activity.
In any industry and business today, every body is expected to write a commissioning
report on what he/she performed in commissioning. Because it is in the main means of
communication between suppliers and receiving agents.
In commissioning report, people express what they performed, analysed, the procedure
and material used, summaries of work and some recommendations.
Thus, commissioning report writing is a process of producing reports, which comprises
of the above components.
Any body who produces commissioning report should know how to communicate with
people to get reliable data, interpret data, analyse data and it is expected to know what
medium of communication used to exchange data, how to document this data and
generate the final report about the occurrence. So commissioning report writing is a
practical repetitive activity of employees as part of jobs in commissioning activities.
Purpose of commissioning report writing
Commissioning report writing has three basic purpose:
 To inform (receive and transfer items, activities done, procedures used, result of
work)

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 To instruct (give directions for performing duties, provide commissioning
support, descriptions of items…. etc)
 To persuade (to tell reason why does follow rules/procedures, convince work to
be done, to inform bottlenecks of the process).
Types Of Report
There are many ways to classify commissioning reports using subject matter,
functions, frequency of issuance, type and formality of formats, …but, traditionally
there are two descriptive categories
 Informational report and
 Analytic report
The Informational Report
Presents information with out criticism, evolution and recommendation.
It provides
This brochure is intended especially for persons who play a part in their organization in
setting up and implementing a reporting procedure and integrity policy. This applies to
public and private organizations. Integrity professionals are involved, such as compliance
and ethics officers and integrity coordinators. But this brochure is also useful for HRM
and Legal Affairs employees, managers and board members and members of the works
council. Employer organizations, sector associations, umbrella and professional
organizations will also find it useful.
They are an obvious point of contact for their members and can ‘translate’ new
legislation and general frameworks, such as this brochure, into the specific frameworks in
which their members operate.
Employees can only claim legal protection for disadvantage if they report an abuse in the
correct manner. Therefore, in your procedure indicate:
• where employees can report suspicions of abuses internally;
• when they can or even should make a report externally.
If a person makes a false or deceitful report, he or she cannot claim protection against
disadvantage.

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