MODULE #6 COMMISSIONING, VALIDATION, … and manufacturer/vendor subcontractors. ... Identify Required Testing MODULE 6 | COMMISSIONING, VALIDATION AND CERTIFICATIONS Zone Controls

MODULE #6 COMMISSIONING, VALIDATION, CERTIFICATIONS

MICHAEL WALSH | PRINCIPAL, R.G. VANDERWEIL ENGINEERS, LLP

274 Summer Street, Boston, MA 02210(T) 617-423-7423 (F) 617-423-7401

[email protected]

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MODULE 6 | COMMISSIONING, VALIDATION AND CERTIFICATIONS

Module 6 Agenda

1. Cx Scope of Work

2. Roles & Responsibilities

3. Containment Testing

4. CDC, USDA and NIH Submission Requirements

Commissioning


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What is Commissioning?

AIHA/ANSI Z9.14 Developed Specifically for BSL-3 Commissioning

BSL-3 Experienced Cx & Design Team Help Define Failure Testing


What is Commissioning?

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• When should you begin working on the commissioning and turnover process for a building?

Is it at this stage of the project?


Commissioning

Or at this stage of the project?


Commissioning

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Merrick & Company


Commissioning


Commissioning - OPR

To understand Owner requirements ASHRAE suggests Commissioning Agent (CxA) documents Owners Project Requirements

As design progresses, CxA reviews design then construction to ensure OPRare met

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Commissioning - Cx Plan

Initial commissioning plan (CxPlan) developed as early in project as possible

Understanding tests to be performed allows design team to address failure scenarios in design sequences rather than during testing and commissioning


Commissioning – Basis of Design

Design team documents HOW OPR is met.

CxA reviews BOD ensure design will meet owner requirements

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Commissioning - Submittals

In addition to the design team submittal review, CxA reviews actual equipment being provided to determine if manufacturers requirements will require adjustment to CxPlan

Information gathered for subsequent tasks


Commissioning O&M Manual

Contractor prepares Operations and Maintenance Manuals for Design Team and CxA review

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Commissioning – Record Documents

CxA reviews Record Documents to ensure matches adjustments made during commissioning


Commissioning

CxA prepares project training plan

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Commissioning – Systems Manual

Cx Team compiles project systems manual

Roles & Responsibilities


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Cx TEAM MEMBER RESPONSIBILITYDesign Architect and

Engineers (AE)General: Develop and maintain the Basis of Design (BoD) document throughout the design and construction processDesign Phase: Incorporate Cx specification sections prepared by the CxA in the total construction document package Review and incorporate Cx design review comments into the final contract documentsConstruction Phase: Review Cx Plan Attend the commissioning kickoff meeting and selected commissioning team meetings as needed. Review contractor submittals for compliance with contract documents. Support CM submittal review for commissioning issues Review, and approve the O&Mmanuals. Attend commissioning specific pre‐construction, planning, and coordination meetings as necessary. Provide construction punch‐lists. Review and comment on test and balance documentation. Review contractor's as‐built documents for completeness and accuracy. Provide clarifications on any design narrative and sequences documentation requested by the CxA. The designers shall assist

(along with the contractors) in clarifying the operation and control of commissioned equipment in areas where the specifications, control drawings or equipment documentation is not sufficient for writing detailed testing procedures.

Resolve Issue Log deficiencies associated with design items. Provide feedback and review of CVF’s, ST’s and IST documentation.Acceptance/Post‐Acceptance Phases: Witness testing of selected pieces of equipment and systems


Commissioning Roles and Responsibilities

Design Team Cx Responsibilities

Cx TEAM MEMBER RESPONSIBILITYCommissioning Authority

(CxA)General: Coordinates and directs the commissioning activities in a logical, sequential and efficient manner. Develops and maintains/updates the Cx Plan throughout the design and construction processDesign Phase: Review and comment on design documents to ensure commissioning activities are accommodated Review and comment on Basis of Design (BoD) and Owner’s Project Requirements (OPR) documents to ensure that the design is meeting the

intent of the OPR Develops Commissioning Specifications for bid and provide to AE for inclusion in the total design packageConstruction Phase: Develops Cx plan with design specific information and submit to OREP and AE for review Conducts initial Cx kick‐off meeting and co‐ordinates monthly/weekly/daily commissioning meetings thereafter. Shall make recommendations to CM for modification of the Construction Schedule to incorporate Cx activities. Obtains and reviews all applicable submittals for systems to be commissioned in order to develop CVs, STs and ISTs. Develops and submits CV, ST and IST test forms for review by CM, AE and OREP. Review and comment on Final Startup Reports Verifies completion of CV’s by CM (or SUB). Reviews specific equipment tests, start up procedures, and systems submittals / shop drawings Reviews the CM integrated construction schedule to ensure commissioning tests periods and dates are accurate. Perform site visits to observe component and system installations. Report any discrepancies with the BoD and contract documents Review TAB plan and provide input in execution. Recommend approval of air and water systems balancing by reviewing completed reports and by selected site observation. Maintains Issues Log based on field and testing observations. Coordinates testing observation by client and submits suggestions to Owner for resolution of conflicts relating to Cx activities. Reviews O&Mmanual for completeness and ensures changes made during the course of the project Verifies O&Mmanuals are submitted to the owner per contract requirements. Verifies training is scheduled and completed by CM (or SUB) prior to facility turnover. Reviews results of third party testing agencies.Acceptance/Post‐Acceptance Phases: Directs and executes ST’s and IST’s with the support of CM (or SUB) Provides final commissioning report Carry out and document any required “off season” or deferred ST and ISTs Revise commissioning report after “off season” ST and ISTs as needed



Commissioning Authority Responsibilities

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Cx TEAM MEMBER RESPONSIBILITYConstruction Manager (CM) General:

Coordinates subcontractors in support of commissioning activities. Designates representatives for all critical sub contractors associated with the commissioning process. This shall include representatives from Mechanical, Electrical, Plumbing, TAB, Controls/BMS, and manufacturer/vendor subcontractors. These team members shall be identified in the Cx Plan.

Ensure that all subcontractors and vendors execute their commissioning responsibilities according to the contract documents. Update/maintain project schedule to accommodate commissioning activities Provide access means (lifts, ladders, etc.) to support commissioning activitiesConstruction Phase: Attend the commissioning kickoff meeting and all commissioning team meetings. Coordinate attendance of SUBs. Integrates Cx activities into construction schedule. Provides CxA with submittals pertinent to the development and execution of CVs, STs and ISTs. Develops start‐up plans and incorporates into construction schedule, keeping CxA informed of any changes. Performs and documents equipment start‐ups. Rectifies any system or equipment deficiencies found during system start‐up.

Submits completed, signed, and dated start‐up reports to CxA. Review and sign‐off on Final Start‐up Reports Reviews the final CVs, STs, and ISTs for safety concerns, equipment and warranty protection, and general comments prior to their

execution. Submits review comments to CxA. Responsible for all subcontractors completing CVFs prior to the execution of ST and ISTs. Coordinates TAB agency in completion and documentation of test and balance work. Submits TAB report to CxA for review Clearly identifies any outstanding issues with associated piece of equipment or system prior to scheduling ST’s or IST’s. Support the CxA in resolution of issues recorded in the Issues Log. Submit training plan and coordinate the SUBs to provide the training of owner personnel as required by the contract documents Coordinate the submission of the O&M manuals, according to the contract documents, including clarifying and updating the

original sequences of operation to as‐built/as‐tested conditions. Produce final as‐built drawings and specificationsAcceptance/Post‐Acceptance Phases: Coordinates SUBs in execution of and witnesses ST and ISTs. Provide utilities and testing equipment necessary to complete associated STs and ISTs. Carry out / coordinate O&M staff training for effective, ongoing operations and maintenance of all systems.


Contractor/CM Responsibilities


Cx TEAM MEMBER RESPONSIBILITYOwner’s Representative (OREP) General:

Facilitate the coordination of the commissioning work by the CxA, and, with the CM and CxA, ensure that commissioning activities are being incorporated into the master schedule.

Develop and maintain the Owner’s Project Requirement (OPR) document throughout the design and construction process

Assign operation and maintenance personnel and schedule them to participate in commissioning team activities. Review and approve the final Cx Plan.Design Phase: Provide the OPR documentation to the CxA and Contractor for information and use. Provide the BoD document, prepared by the AE and approved by owner, to the CxA for use in developing the

commissioning plan, CVs, STs, and ISTs. Coordinate the resolution of non‐compliance and design deficiencies identified in all phases of commissioning.Construction Phase: Attend Cx meetings and approve/reject results of Cx efforts as required to ensure optimal performance of

systems as per Owner’s requirements and contract documents. Perform the normal review of contractor submittals. Reviews initial and final CVs, STs and ISTs. Provides approval and direction to move forward with Cx activities. Support the CxA in resolution of issues recorded in the Issues Log Engage owner’s personnel in witnessing of installation verification, system and integrated system testing. The

owner’s personnel shall be designated by the OREP for the specific Cx activities as deemed necessary. They shall include but not be limited to representatives from Facilities Maintenance Staff, Environmental Health and Safety Staff, BioSafety Staff, etc..

Acceptance/Post‐Acceptance Phases: Assist the CM in coordinating the training of owner personnel. Provide final acceptance of CVs, STs and ISTs. Provide final acceptance of equipment, systems and ultimately the project. Assist the CxA as necessary in the seasonal or deferred testing and deficiency corrections required by the

specifications.


Owner Representative Responsibilities


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Testing & Certification


Standard Testing & Balancing

Air Systems

Water Systems

Containment System Testing

Duct Integrity

Standard Leakage Test

Pressure Decay Testing

Helium Leak Testing

Room Integrity

Testing and Certification

Identify Required Testing


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Duct Pressure Decay Test Hookup Detail


Must Understand Time Required for Testing

Due to Sensitivity of Tests, Cannot Relieve Test Gas into Room Since Affects Next Test


Containment Boundary Testing

Room Integrity

For BSL-3 Spaces

• Two part procedure

• Visual inspections

• Smoke test

• Not a pressure decay test

SAFETIES & CONTROLS




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Primary Containment Testing

Fume Hoods

Biological Safety Cabinets

HEPA Filter Housing Test

Pressure Decay Testing

HEPA Filter Installation Verification

Scan Testing




Zone Controls Testing

Normal Operation

Standby Power Operation

Failure Mode Testing

System Controls Testing

Normal Operation

Standby Power Operation

Failure Mode Testing




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COMPONENT VERFICATION (CV) TABLE

MECHANICAL COMPONENTS Sampling Rate Failure Limit

Air Handling Units (AHU‐1.1, AHU‐1.2) 100% 0%

BSL3 Exhaust Fans (EF‐1.1, EF‐1.2) 100% 0%

HEPA Filter Housings (BI/BO‐1A&1B,2A&2B,3A&3B,4A&4B) 100% 0%

Supply/Exhaust Valve Box Sound Attenuating Devices (SATT‐SVA1, SATT‐SVA2, SATT‐SVA3, SATT‐SVA4, SATT‐SVA5, SATT‐EVA1, SATT‐EVA2, SATT‐EVA3, SATT‐EVA4, SATT‐EVA5, SATT‐EVA6)

50% 10%

Steam PRV Stations (PRV‐1.1, PRV‐2.1, PRV‐2.2) 100% 0%

Steam Condensate Pumps (CP‐1.1, CP‐1.2) 100% 0%

Hot Water Unit Heater (UH‐2.1, UH‐2.2)

Steam Unit Heater (UH‐1.1, UH‐1.2, UH‐1.3, UH‐1.4) 100% 0%

Fan Coil Unit (FCU‐1.1, FCU‐1.2, FCU‐1.3)

Lab Area Supply Air Valve (SV‐A1, SV‐A2, SV‐A3, SV‐A4, SV‐A5) 100% 10%

Lab Area Exhaust Air Valve (EV‐A1, EV‐A2, EV‐A3, EV‐A4, EV‐A5, EV‐A6) 100% 10%

Biosafety Cabinets (BSCs) 100% 0%

Autoclaves 100% 0%

Bioseal Isolation Dampers 100% 0%

Building Automation System (BAS) 100% 0%

Domestic Cold/Hot Water Systems 50% 10%

Lab Cold/Hot Water Systems 50% 10%

Emergency Showers and Eyewash Stations 100% 0%

Lab Vacuum System 100% 0%

Lab Gas Systems (CO2) 100% 0%

Pure Water System 100% 0%

Fire Protection System 50% 10%

Control Valve (V‐1, V‐2, V‐3, V‐4, V‐5) 100% 0%

Hot Water Duct Coil (RHC‐A1, RHC‐A2, RHC‐A3, RHC‐A4, RHC‐A5) 100% 0%

Flash Tank (FT‐1, FT‐2) 100% 0%

Air Cooled Air‐Conditioning Unit (ACCU‐1, ACCU‐1) 100% 0%

Glycol Hot Water Pump (P‐1.1, P‐1.2) 100% 0%

Hot Water Pump (P‐2.1, P‐2.2) 100% 0%

Commissioning Example


CxA HVAC Component Verification

Containment DevicesVentilation EquipmentHeating EquipmentCooling Equipment

For Certification You Must -Document, Document, Document

ELECTRICAL COMPONENTSSampling Rate

Failure Limit

Automatic Transfer Switches 50% 10%

Emergency Power Generator 100% 0%

Transformers 100% 0%

UPS System 100% 0%

Fire Alarm Components 50% 10%

Lighting Control Devices 50% 10%

Distribution/Breaker Panels 50% 10%

Emergency Power Circuits 50% 10%

Normal Power Circuits 50% 10%

VFD Drives (for AHU’s, EF’s, Pumps) 50% 10%



CxA Electrical Component Verification

Main EquipmentSafety Devices (Breakers)Normal & Emergency Power

For Certification You Must -Document, Document, Document

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For Each Component Develop Specific Checklist


SYSTEM TEST (ST) TABLE

MECHANICAL SYSTEM TESTS Sampling Rate Failure Limit

Chilled Water System N/A N/A

Hot Water System N/A N/A

Steam System N/A N/A

Air Handling Units (AHU‐1.1, AHU‐1.2) 100% 0%

BSL3 Exhaust Fans (EF‐1.1, EF‐1.2) 100% 0%

VFD (for fans and pumps) 100% 0%

Lab Area Supply Air Valve (SV‐#) 100% 0%

Lab Area Exhaust Air Valve (EV‐#) 100% 0%

Biosafety Cabinets (BSCs) 100% 0%

Autoclaves 100% 0%

Building Automation System (BAS) 100% 0%

Domestic Cold/Hot Water Systems 50% 10%

Lab Cold/Hot Water Systems 50% 10%

Emergency Showers and Eyewash Stations 100% 0%

Lab Gas Systems (CO2) 100% 0%

Pure Water System 100% 0%

Fire Protection System 50% 10%

Containment TAB Verification 100% 0%

Non‐Containment TAB Verification 50% 10%

BSL‐3 Boundary Integrity Testing 100% 0%

ELECTRICAL SYSTEM TESTSSampling Rate

Failure Limit

Fire Alarm System 50% 0%

Lighting Control System 50% 10%

UPS System 100% 0%

Emergency Power Generator 100% 0%


Once components are confirmed to be operating properly, each system can then be tested.

Operational tests must be done on normal power and standby power

System Failure Tests are Also Performed


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INTEGRATED SYSTEM TEST (IST) TABLE

INTEGRATED SYSTEM TEST Sampling Rate Failure Limit

Lab Module (Note 1) N/A N/A

Emergency Power Failure N/A N/A


Finally Integrated System Tests are Performed

How does failure of one system affect another??

Should non-BSL-3 systems shut down on BSL-3 supply air failure?

Should non-BSL-3 systems shut down on BSL-3 exhaust air failure?




All testing and results must be included in submission to certifying agency. Typically included in the Design Intent Document

No specifics on how to document.

Video of tests have been used in the past.

Before testing must clearly identify pass-fail criteria (“e.g. airflow shall not be reversed”)

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Submit Appropriate Checklist


BMBL 5th Edition BSL-2

BMBL 5th Edition BSL-3

Submit Appropriate Checklist


ABSL-2 with NIH Req’mts

ABSL-3 with NIH Req’mts

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Updated Standards


Always check for current updated requirements

Due to timing of projects, new requirements may affect design:

BMBL 4th Edition:“Consideration should be given to installing an HVAC control system to prevent sustained positive pressurization of the laboratory.”

BMBL 5th Edition:“The laboratory shall be designed such that under failure conditions the airflow will not be reversed.”

Sample Cx Issues

Upon BSL-3 System Failure – Reverse Airflow 45 Seconds• Cause: Temporary Loss of Exhaust Header Static• Resolution: Close Supply Valves In Lab, Pressurize Clean Corridor• Note: Must Not Make Lab Too Negative on Supply Closure

Loss of Exhaust Header Static Pressure• Cause: Failed Fan Isolation Damper Closes Too Slow• Resolution: Consider Backdraft Damper• Note: Must Meet Code for Isolation with Fan Offline

Upon BSL-3 System Failure – Reverse Airflow• Cause Signal Delay Between Fan Failure and Room Response • Hard Wire Signal to Pressurize Clean Corridor

Upon Startup Large Negative Pressure in Labs• Cause: Supply and Exhaust Valve Actuator Speeds Did Not Match• Resolution: Slow Down Ramping of Fans and Exhaust Valves to Match Supply


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• Commissioning Is Planned Verification of System Performance

• For BSL-3, Falure Testing Should be Identified Early in Design to Ensure Component Performance Can be Specified

• Failure Testing Not Identified During Design May Have Unintended Consequences (Duct, Ceiling or Wall Damage)

MODULE 4 | MECHANICAL, ELECTRICAL, PLUMBING CONSIDERATIONS I

Tradeline Takeaways

Questions?


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MODULE #6 COMMISSIONING, VALIDATION, CERTIFICATIONS

MICHAEL WALSH | PRINCIPAL, R.G. VANDERWEIL ENGINEERS, LLP

274 Summer Street, Boston, MA 02210(T) 617-423-7423 (F) 617-423-7401

[email protected]

Date:

Session:

Presenters:

Metrics

Tools

Resources

Innovative Ideas

Proofs

Date:

Session:

Presenters:

Metrics

Tools

Resources

Innovative Ideas

Proofs

Date:

Session:

Presenters:

Metrics

Tools

Resources

Innovative Ideas

Proofs

Date:

Session:

Presenters:

Metrics

Tools

Resources

Innovative Ideas

Proofs