Appendix C - HC1028R0067.pdf

DISA Computing Services Page 1 of 57 Consolidated Closeout-Commissioning Facilities Engineering (CD521) Moderate Project Procedures DISA CSI 360-95-3 Version Date: 28 October 2011

Consolidated Closeout-Commissioning Volume 2

Moderate Project Procedures

Summary

This closeout-commissioning volume provides mandatory guidance for projects determined to be of “Moderate” project complexity IAW section 01 77 13 (Project Complexity) of the CSI 360-95-3 Facilities Standards.

“Moderate” projects generally involve the installation of multiple pieces of equipment or complete systems that require full functional performance testing, but minimal or no integrated systems testing.

“Moderate” projects generally do not (but may in some circumstances) follow a separate, formal design project or require the services of an A/E.

Examples of projects that would be determined by CD521 to be “Moderate” are shown below. Note that this is not intended to be a complete list.

⊗ Administrative Office Build-Out (may include minor construction, HVAC and electrical distribution, and generally changes the layout or use of a facility in a relatively major manner)

⊗ BAS Repair/Replacement

⊗ Fire Protection System Replacement (may include detection, alarm, and suppression systems)

⊗ Install Partial Facility BAS

⊗ Install Second Main Electrical Utility Feeder

⊗ Integrated Security System Upgrade

⊗ Raised Floor Equipment Technical Refresh (may include access floor, PDUs and distribution, CRACs, and IT rack realignment with master plan)

⊗ Raised Floor PDU Zoning

⊗ Replace Ceiling, Lighting, and Fire Suppression

⊗ Replace ten (10) CRACs

⊗ Roof Replacement

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DISA CSI 360-95-3 Version Date: 28 October 2011

TABLE OF CONTENTS

This document is organized in MasterFormat 2004 order. Requirements and specifications are discussed first, in 01 77 xx and 01 79 xx, with specific processes and responsibilities following in 01 91 xx and specialty subsections.

SUMMARY

00 70 00 EXECUTION AND CLOSEOUT REQUIREMENTS

01 77 00 Project Closeout Procedures

01 77 01 Applicability 01 77 05 Definitions 01 77 06 Project Complexity 01 77 10 Phased Completion of Projects 01 77 20 Requirements for Substantial Completion 01 77 21 Record Documents 01 77 22 General Requirements 01 77 23 Inspection Procedure for Substantial Completion 01 77 30 Requirements for Final Acceptance 01 77 33 Inspection Procedure for Final Acceptance 01 77 40 Required Project Record Documents 01 77 41 Record Documents

01 77 41.10 Maintenance of Record Drawings During Construction 01 77 41.20 Supplemental Drawings 01 77 41.30 Preparation of Final Record Drawings

01 77 42 Record Specifications 01 77 43 Operations & Maintenance (O&M) Manuals & Binders

01 77 43.10 Required Equipment Data 01 77 45 Record Documentation Submittals 01 77 47 Commissioning & Closeout Manual (CCM) 01 77 50 Conditions at Substantial Completion 01 77 60 Conditions at Final Acceptance

01 79 00 Demonstration and Training 01 79 10 Submittal Requirements 01 79 20 Training Responsibilities 01 79 30 Coordination 01 79 40 Instruction Program

01 91 00 Commissioning 01 91 13 General Commissioning Requirements 01 91 30 Definitions 01 91 08 Commissioning Tools & Equipment 01 91 10 Scheduling 01 91 40 Commissioning Team Roles and Responsibilities 01 91 41 Government Role and Responsibilities 01 91 43 Contractor’s Role and Responsibilities 01 91 44 TAB Vendor’s Role and Responsibilities 01 91 50 Commissioning Documentation Requirements 01 91 51 Equipment List 01 91 52 Request for Start-Up/Functional Performance Test Form

01 91 52.20 Request for Start-up 01 91 52.40 Request for Functional Performance Test

01 91 54 Prefunctional Checklist 01 91 60 Pre-Commissioning Meeting 01 91 65 Commissioning Progress Meetings 01 91 70 Commissioning Procedures 01 91 72 Initial Start-up

01 91 72.10 Start-up of Independent Devices 01 91 72.30 Start-up of Building Systems

01 91 74 Functional Performance Tests (FPTs) 01 91 74.20 FPT Objective and Scope 01 91 74.40 Development of FPT Procedures 01 91 74.50 FPT Requirements

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01 91 74.60 FPT Coordination and Scheduling 01 91 76 Integrated System Tests (ISTs)

01 91 76.20 IST Objective and Scope 01 91 80 Documentation and Non-Conformance 01 91 82 Non-Conformance 01 91 84 Disputes 01 91 90 Deferred Tests

20 08 00 Fire Suppression, Plumbing, & HVAC Systems Commissioning 20 08 20 Prefunctional Checklists 20 08 25 Minimum Prefunctional Checklist Procedures 20 08 50 Functional Performance Test (FPT) Procedures 20 08 55 Sample FPT Procedures 20 08 56 Sample FPT Acceptance Form 20 08 60 Seasonal & Deferred Testing 23 05 90 System Testing, Adjusting, and Balancing (TAB) for HVAC

25 08 00 Building Automation System (BAS) Commissioning 26 08 00 Electrical Systems Commissioning

26 08 10 Coordination Between Testing Parties 26 08 11 Factory Start-ups 26 08 12 Independent Testing Agencies 26 08 20 Prefunctional Checklists 26 08 25 Minimum Prefunctional Checklist Procedures 26 08 26 Sample Prefunctional Checklist Procedures 26 08 50 Functional Performance Test (FPT) Procedures 26 08 54 Minimum FPT Procedures 26 08 55 Sample FPT Procedures 26 08 56 Sample FPT Acceptance Form 20 08 60 Seasonal & Deferred Testing

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DISA CSI 360-95-3 Version Date: 28 October 2011

00 70 00 EXECUTION AND CLOSEOUT REQUIREMENTS

01 77 00 Project Closeout Procedures

The purpose of the required project closeout procedure described herein is to ensure that projects, when completed and transitioned to their lifecycle sustainment phase, are complete and able to be supported as designed and constructed.

01 77 01 Applicability

The requirements of this document, “Consolidated Closeout-Commissioning Volume 2 – Moderate Project Procedures,” shall apply to all projects determined by CD521 to be “Moderate” in accordance with section 01 77 06 (Project Complexity).

01 77 05 Definitions

“As-Built” is an adjective that refers to completed Record Documents (see sections 01 77 21 & 01 77 40) showing the final conditions at the end of a project. The term “As-Built” shall not be used as a noun to replace the formal term Record Document.

Any reference to the term “As-Built” in a noun sense in any official or unofficial contract documentation or correspondence shall, without exception, be taken to mean Record Document as that term is defined below and used in this Standard.

“Building Automation System” (BAS) means the system and components associated with the Building Automation System (see section 25 XX xx (Integrated Automation Network Equipment)).

“Commissioning” is the planned structured process of assuring that all equipment, systems, and components modified or installed during a project are properly installed, tested, and have correct functional interactions with the surrounding (logical and/or physical) facility, equipment, and systems. Commissioning ensures that building systems have been installed, properly started, and consistently operated in strict accordance with the contract Technical Specifications, that all systems are complete and functioning in accordance with the contract Technical Specifications at Substantial Completion, that Contractor has provided the Government with adequate system documentation and training, and that every operational component performs as designed and intended, from individual subcomponent functionality to the functions of complete systems in all operational states, prior to the closeout of the project. Commissioning includes deferred and/or seasonal tests as approved by the Government.

A “Commissioning Consultant” or CC is a Government representative or contracted consultant who performs technical reviews of contract Technical Specifications, observes completion of construction, verifies equipment and system start-up by the Contractor (or their subcontractor), observes Prefunctional Checklists, Functional Performance Tests, & Integrated System Tests for compliance with the contract Technical Specifications, tracks deficiencies, and recommends solutions. A CC is typically external to the project, with no conflicts of interest with regards to other parties on the Commissioning Team. The CC may not be the A/E or the Contractor.

The CD521 project manager may be the CC.

The “Commissioning Plan” is the document prepared by Contractor and approved by the Government that provides the structure, schedule, and coordination plan for the commissioning process from the construction phase through the warranty period.

The Commissioning Plan must satisfy the Government’s Test Requirements.

http://en.wikipedia.org/wiki/Project_commissioning

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DISA CSI 360-95-3 Version Date: 28 October 2011

The “Commissioning Team” is the working group made up of representative(s) from the Architect/Engineer (A/E), Contractor, TAB (Test, Adjust, and Balance) contractor, BAS vendor, specialty subcontractors, specialty manufacturers and suppliers, CC, and CD521 project manager. The Contractor shall provide ad-hoc representation of subcontractors on the Commissioning Team as required for implementation of the Commissioning Plan. For certain scopes/disciplines and complexities of projects (see section 01 77 06), not all of these groups may be involved.

“Datalogging” means monitoring flows, current, status, pressures, et cetera of equipment using stand-alone dataloggers or the BAS (if acceptable for the specific project and data requirements).

“Deferred Tests” are authorized Functional Performance or Integrated System Tests performed after Substantial Completion due to partial occupancy, partial equipment acceptance, seasonal requirements, design, or other site conditions that prohibit the test from being performed prior to Substantial Completion.

A “Deficiency” is a condition of a component, piece of equipment, or system that is not in compliance with the contract Technical Specifications.

“Factory Testing” is the testing of equipment at the factory, by factory personnel with the CC present, if deemed necessary by the Government.

“Functional Performance Tests” (FPTs) are tests of dynamic function and operation of equipment and systems executed by the Contractor. Systems are tested under various modes, such as during low cooling or heating loads, high loads, component failures, unoccupied, varying outside air temperatures, life safety conditions, power failure, et cetera. Systems are run through all specified sequences of operation.

Components are verified to be responding in accordance with contract Technical Specifications. FPTs are executed after start-ups and Prefunctional Checklists are complete.

“Functional Performance Test Procedures” are formal, written commissioning protocols and detailed test procedures and instructions in tabular and script-type format that fully describe system configuration and steps required to determine if the system is performing and functioning properly. The Contractor prepares these procedures to document FPTs.

“Integrated System Tests” (ISTs) are tests of dynamic function and operation of multiple systems. ISTs are tested under various modes, such as fire alarm and emergency situations, life safety conditions, power failure, et cetera. Systems are integrally operated through all specified sequences of operation. Components are verified to be responding in accordance with contract Technical Specifications. ISTs are executed after FPTs are complete and prior to Substantial Completion. ISTs provide verification that the integrated systems will properly function according to the contract Technical Specifications. **ISTs are not performed in “Moderate” complexity projects.

“Integrated System Test Procedures” are formal, written commissioning protocols and detailed test procedures and instructions in tabular and script-type format that fully describe system configurations and steps required to determine if the interacting systems are performing and functioning properly. The Contractor prepares these procedures to document ISTs. **ISTs are not performed in “Moderate” complexity projects.

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DISA CSI 360-95-3 Version Date: 28 October 2011

“Indirect Indicators” are indicators of a response or condition without direct physical linkage, such as a reading on a control system display reporting a damper to be 100 percent closed.

A “Manual Test” involves the use of hand-held instruments, immediate control system readouts or direct observation to verify performance (contrasted to analyzing trend data to make the “observation”).

“Overwritten Values” involves writing over a sensor value in control system to see response of a system (e.g., changing outside air temperature value from 52°F to 72°F to verify economizer operation). See also “Simulated Signal”.

“Prefunctional Checklists” are lists of static inspections and material or component tests that verify proper installation of equipment (e.g., belt tension, oil levels, labels affixed, gages in place, sensors calibrated, et cetera). Prefunctional refers to before FPTs; Prefunctional Checklists shall be completed prior to the beginning of FPTs in the commissioning process. Prefunctional Checklists must include the manufacturer’s start-up checklist(s). The Contractor shall sign Prefunctional Checklists as complete and submit with the Request for Start-Up/Functional Performance Test Form.

“Record Documents” are formal written or drawn documentation illustrating and/or otherwise documenting the conditions at the conclusion of a project. This documentation generally includes measurements, locations, quantities, test results, data submittals, and similar information that completely describes the work completed and the final condition(s) of the equipment, system(s), and/or facilit(ies) that were affected by the project, and allows for complete knowledge and understanding of those condition(s) for lifecycle and future project purposes. See also “As-Built.”

“Simulated Conditions” are those conditions created specifically to test component(s) and system(s) responses (e.g., applying heat to space temperature sensor to monitor response of a terminal unit).

“Simulated Signals” are those transmitted to components or systems artificially to induce responses. For example, disconnecting a sensor and using a signal generator to send voltage, amperage, resistance or pressure to transducer and/or direct digital control system to simulate a value to the BAS to test the system and component response.

“Start-up” means the activities where equipment is initially energized, tested and operated. Start-up is completed prior to FPTs.

An HVAC Testing, Adjusting, and Balancing (TAB) contractor may be engaged by the Contractor or Government to conduct specific functions as described in section 23 05 9X (System Testing, Adjusting, and Balancing (TAB) for HVAC). TAB responsibilities are detailed in individual project Technical Specifications.

“Test Requirements” are those specifying what systems, modes and functions, et cetera must be tested during a commissioning process. Test requirements are not detailed test procedures. Test requirements and acceptance criteria are specified in the contract Technical Specifications.

“Trending” refers to mathematic interpretation of data collection of monitoring point values using the BAS or dataloggers over a period of time.

01 77 06 Project Complexity

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DISA CSI 360-95-3 Version Date: 28 October 2011

CD521 projects will be categorized by CD521 into four (4) levels of complexity to determine when during the project specific deliverables will be required.

Determination of project complexity is accomplished solely by CD521.

This attachment, “Consolidated Closeout-Commissioning Volume 2 – Moderate Project Procedures,” will be used for all projects rated as “Moderate” IAW this section and related CD521 guidance.

Project Complexity Description Example

None Projects that do not require equipment start-up or formal commissioning.

Power whip installation. Furniture installation. Design (only) projects.

Minor facility renovations.

Engineering studies. Configuration management surveys.

Simple

Projects involving new equipment installations into existing systems, or minor systems without significant or complex interactions with other systems. Simple projects typically take less than three months to complete, not including product or component manufacturing and delivery lead times.

Addition of CRAC units to an existing chilled water loop. Installation of a pair of new PDUs to support a new zone. Installation of a leak detection system and connection to the facility BAS. Does not involve a separate or formal Design phase or an A/E.

Moderate

Projects involving simple and/or stand-alone systems, but that are large in scale or scope, or have significant interactions with other facility systems. Moderate projects typically take three months to one year to complete.

Rezoning and replacement of all PDUs in a datacenter space. Facility-wide security system upgrades or replacements. Roof replacements.

Major build-outs inside existing facilities. May involve a formal

Design phase and may require an A/E.

Complex

Major projects involving large and/or complex systems, multiple systems of moderate complexity, major construction, and similar.

Complex projects generally take longer than one calendar year to complete.

Installation of an upgraded chiller plant. Installation of an upgraded facility-wide UPS and generator system. Construction of a new facility. Involves a formal Design phase and generally requires an A/E.

Timelines for projects are based on the amount of time estimated as necessary to complete a project from Notice to Proceed (NTP) until Final Acceptance.

Project Complexity O&M Binder Structure Due Date

All Individual O&M Manuals Delivered

Not Used

None N/A N/A N/A Simple N/A Final Acceptance N/A

Moderate NTP +60 COMM -60 N/A Complex NTP +90 COMM -90 N/A

For the purposes of this table, NTP is the formal written Notice to Proceed delivered by the Contracting Officer to the Contractor for the “build” portion of a design-bid-build project or the overall NTP for a smaller project. (Some contracting offices provide NTPs only through the execution of a contract modification.) COMM is the scheduled beginning date of the formal commissioning process.

http://en.wikipedia.org/wiki/Design-bid-build http://en.wikipedia.org/wiki/Design-bid-build

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DISA CSI 360-95-3 Version Date: 28 October 2011

01 77 10 Phased Completion of Projects

Depending upon the design and nature of any given project, the closeout procedures related to completion and acceptance may be either a single period of time for the entire project, or a series of periods for individual portions or phases of the project that are to be certified as substantially complete at different dates.

If the project is to be accepted in phases then project closeout requirements shall pertain to each separately accepted portion or phase of the project.

01 77 20 Requirements for Substantial Completion

Substantial Completion and Final Acceptance (section 01 77 30) may, but are not required, to be combined so long as the requirements of both sections are completely met. This is typically only done on very simple projects where intensive review by CD521 against the design documents is not expected to be required.

01 77 21 Record Documents

Record Documents for project closeout include, but are not necessarily limited to, the following documents, which are required at Substantial Completion:

• Record Drawings.

• Record Specifications.

• Operating and Maintenance (O&M) Manuals & Binders.

• Record Approved Submittals and Samples.

• Material Safety Data Sheet (MSDS) Binder.

• Completed Punch Lists.

• Completed CCM.

01 77 22 General Requirements

Prior to requesting CD521 to schedule a Substantial Completion inspection, the Contractor shall complete the following and list known exceptions in the request.

• For the progress payment request coincident with the period of time anticipated for substantial completion, the Contractor's payment request should reflect a minimum of 95% completion for all applicable work.

• The Contractor shall submit to CD521 a complete copy of the most current punch list covering the portion(s) of the project claimed as substantially complete. The punch list shall indicate dates of Contractor re-checks and schedule for completion of work items remaining. All items remaining outstanding on the punch list shall include a projected date of completion and/or correction with an explanation of why such item is not presently completed.

• The Contractor shall submit to A/E and CD521 for review the full set of marked-up design drawings and marked-up design specifications as described later in this section.

• The Contractor shall submit to CD521 for review the preliminary copies of Operating and Maintenance (O&M) Manuals as described later in this section.

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DISA CSI 360-95-3 Version Date: 28 October 2011

• The Contractor shall provide access to Contractor’s copy of the CCM for review by CD521. The CCM must be up-to-date before the Contractor requests the Substantial Completion inspection.

• The Contractor shall obtain and submit any necessary releases enabling CD521's full and unrestricted use of the project and access to services and utilities, including (where applicable) operating certificates, and similar releases.

• The Contractor must deliver tools, spare parts, extra stocks of materials, and similar physical items to CD521.

If CD521 intends to occupy project upon substantial completion acceptance, the Contractor shall make provisions for final changeover of locks or similar access-restrictive devices with CD521 personnel. Upon written directive from CD521 for convenience in completing punch list activity, CD521 may waive the final changeover of locks until final acceptance.

The Contractor must complete instructing and training CD521 personnel for all systems and equipment serving the areas claimed as substantially complete, for which CD521 training was not completed in association with system demonstrations and inspections. Refer also to sections 01 79 00 (Demonstration and Training) and 01 91 00(General Commissioning Requirements).

The Contractor must complete the initial clean up requirements as described later in this section for the entire portion of the project claimed as substantially complete.

The Contractor shall touch up and otherwise repair and restore marred exposed finishes.

01 77 23 Inspection Procedure for Substantial Completion

Refer to section 01 43 00 (Quality Assurance) for additional specific guidance.

The Contractor shall ensure the work is ready for inspection and/or re-inspection. If the work is found not to be as stated in the Contractor’s punch list or the items have not been substantially corrected/completed, the inspection will be terminated.

01 77 30 Requirements for Final Acceptance

Prior to requesting CD521 to schedule Final Inspection for the project, the Contractor shall complete the following:

• The Contractor shall submit a copy of the Substantial Completion punch list including evidence that each item has been completed or otherwise resolved.

• The Contractor must submit final Record Drawings and Specifications, bound original signature hard copy warranties, and all approved submittals and Operating and Maintenance (O&M) Manuals as described later in this section. This includes specific warranties, maintenance agreements, product certifications and similar documents. CD521 must approve closeout Record Documentation in writing prior to issuance of final payment.

• The Contractor must transmit the completed CCM to CD521. The CCM shall be complete, acknowledging receipt of all bench stock, spare parts, training/demonstration, test reports and any other requirements of the contract Technical Specifications.

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• The Contractor must submit updated O&M information developed or discovered during the commissioning process, if applicable.

• The Contractor must complete final cleaning requirements including touch-up of marred surfaces.

01 77 33 Inspection Procedure for Final Acceptance

When the Contractor has completed the work required in the Substantial Completion punch list and has complied with the close-out requirements in this section and elsewhere in the contract Technical Specifications, then the Contractor must provide written notice to CD521 that the project is ready for Final Inspection.

01 77 40 Required Project Record Documents

01 77 41 Record Documents

The Contractor shall not use original Record Documents for construction purposes.

The Contractor must protect original Record Documents from deterioration and loss in a secure location, and adhere to any security requirements set forth in the contract Technical Specifications. The Contractor must provide access to Record Documents for CD521 reference or review during normal working hours.

The Contractor must furnish Record Drawings made from the design drawings, or subsequent updates thereof, annotated as noted below with actual final (“as-built”) conditions. Specific Record Drawing requirements are described in section 01 78 39 (Project Record Documents). Record drawing information must be professionally drafted.

Record Drawings must show all changes in the work relative to the original design documents, and must show additional information of value to CD521's records but not indicated in the original contract Technical Specifications.

Submissions of Record Documents must include marked-up copies of design drawings and Technical Specifications, including newly prepared drawings if applicable or necessary to achieve CD521’s intended result, and design/shop drawings including all changed conditions issued through addenda and/or change orders.

Record Documents must include marked-up product data submittals, field records for variable and concealed conditions such as excavations and foundations, and miscellaneous record information on work that was recorded only schematically or not recorded at all.

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DISA CSI 360-95-3 Version Date: 28 October 2011

Certain individual sections of the Technical Specifications may indicate specific requirements, which may clarify requirements of this section. When a conflict may be perceived to exist in requirements between Technical Specifications and/or mandatory reference documents, the more restrictive (i.e., more expensive) requirement will prevail. There is no intent, however, to require more sets of Record Drawings than indicated herein.

The Contractor shall bear all costs associated with obtaining original contract Technical Specifications and design drawings, any subsequent revised or updated versions thereof, drafting “as-built” information, reproduction, or other related work.

01 77 41.10 Maintenance of Record Drawings During Construction

During progress of the work, the Contractor shall maintain a redline set of Record Drawings (along with the Record Technical Specifications) and the shop drawings in the construction office. The Contractor must update these drawings weekly, at a minimum, with mark-ups of actual installations that vary from the work as originally shown. The Contractor shall include all drawings issued as addenda, clarifications, and/or change orders.

Use of electronic redline drawings using the requirements of section 01 78 39 (Project Record Documents) is strongly recommended in order to reduce the time and costs associated with creation of the final Record Drawings.

The Contractor must fully and accurately mark-up whatever drawing(s) is most compatible for showing actual physical condition, and must reference all other appearances of this work to the updated sheet. The Contractor must include

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DISA CSI 360-95-3 Version Date: 28 October 2011 cross-references to the official change number on the updated redline sheet and all additional redline sheets where the work is shown.

Redlines, whether electronic or manual, should use separate colors and styles to distinguish between changes for different categories of work at the same general location, in order to reduce confusion and difficulty in drafting the final Record Drawings.

The Contractor must mark-up important additional information, which was either shown schematically only or omitted from the original drawings. The Contractor must give particular attention to information on concealed work that would be difficult to identify, measure, or record at a later date.

On redline drawings, the Contractor must record alternative numbers, change order numbers and similar identification for any change. This information shall not be transferred to the final Record Drawings.

The Contractor shall maintain and have available for review in conjunction with the regular project progress meetings, a current set of the marked-up redline drawings and specifications marked with "as-constructed" information.

Availability for review and acceptability of both the format and the content, is a prerequisite condition for certification of the monthly pay requests by CD521.

01 77 41.20 Supplemental Drawings

The use of shop drawings as supplements to the Record Drawings is required for all items in which the larger scale employed on the shop drawings is needed to show the work in sufficient detail for CD521’s future use. For the purposes of this section, this means that additional Record Drawings may be necessary based on the work content of a project, and these must be delivered by the Contractor as additional Record Drawings. When marked-up shop drawings are included in the Record Drawing deliverables, the Contractor must mark-up and cross-reference on the Record Drawings the corresponding location(s) and new drawings as applicable.

Use of such shop drawings is particularly applicable to ductwork and electrical shop drawing layouts. Use of shop drawing supplements is acceptable provided the following conditions are met:

• The applicable supplemental sheet must be placed in the drawing set directly behind the appropriate Record Drawing which it supplements (or as otherwise required in section 01 78 39 (Project Record Documents) based on content), with appropriate reference notes on both the applicable Record Drawing(s) and all other affected drawings.

• The Contractor must retain a copy of all marked-up shop drawings for inclusion with the Record product submittals.

• The supplemental document must be identified as a "Supplementary Record Drawing" and must be numbered with an extension to the Record Drawing it supplements in a manner acceptable to CD521.

01 77 41.30 Preparation of Final Record Drawings

See section 01 78 39 (Project Record Documents) for detailed requirements and guidance.

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DISA CSI 360-95-3 Version Date: 28 October 2011

In association with Contractor’s request for Substantial Completion inspection, the Contractor must submit the marked-up site copy of the design/shop drawings to CD521 for review.

Following review of the marked-up redline drawings and supplemental drawings, and upon acceptance that the marked-up information is accurate and complete, the Contractor shall proceed with preparation of a full set of professionally drafted Record Drawings in electronic format made from the design drawing files.

All redline and marked-up shop/design (but not Record) drawings shall bear the official project name and number.

Once the final Record Drawings are complete, the Contractor shall transmit them to the CD521 for Final Acceptance, which shall occur within sixty (60) calendar days of Substantial Completion.

The Contractor shall ensure that all drawings issued as addenda, clarifications and/or change orders are incorporated into the Record Drawing set and fully shown on the applicable Record Drawing. If supplemental sheets are used, the Contractor must follow the requirements outlined above for supplemental shop drawing sheets.

01 77 42 Record Specifications

During progress of the work, the Contractor must maintain and update one Record copy of the contract Technical Specifications at the job site, including addenda, change orders and similar modifications issued during construction, indicating all significant variations between the actual work and the text of original specifications.

This redline copy of the Technical Specifications may be either paper or electronic.

The Contractor must give particular attention to substitutions, selection of options, and similar information on work where the exact products used are not clearly identified or readily discernable in the original specifications. When applicable, the Contractor must cross-reference related Record Drawing information and product data.

It is not necessary to re-type an entire section if modified, but it is mandatory that all changes to specified materials, installation, warranty, et cetera be clearly and fully marked within the applicable specification section in a manner acceptable to CD521.

The Contractor should review with CD521 any changes to assure an acceptable procedure early in the construction phase.

The Contractor must neatly transcribe and post all marked-up information to a "clean" copy of the Technical Specifications, ensuring that similar types of information are annotated in like fashion throughout the Technical Specifications.

In association with the Contractor’s request for Substantial Completion inspection, the Contractor must submit the marked-up site copy of the Technical Specifications to CD521 for review.

Once the marked-up specifications are found acceptable, the Contractor will proceed with preparation of the final Record Documentation specifications. The final Record Documentation copy of the Technical Specifications shall be submitted in electronic format in MS Word .docx format with tracked redline changes from the original, and in final (complete) Adobe Acrobat .pdf format.

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DISA CSI 360-95-3 Version Date: 28 October 2011

01 77 43 Operations & Maintenance (O&M) Manuals & Binders

The delivery of O&M information to CD521 shall be pushed to as early in the project as feasibly possible to allow for a more organized transition to lifecycle services at the conclusion of the project. Traditionally, O&M information has been bound into large hard-copy binders and submitted following the completion of the project. This traditional approach does not allow adequate development of O&M work orders or of service contracts to support the equipment as it enters lifecycle.

The material and equipment data required by this section must include all data necessary for the proper installation, removal, normal operation, emergency operation, startup, shutdown, maintenance, cleaning, adjustment, calibration, lubrication, assembly, disassembly, repair, inspection, trouble-shooting, and warranty service of the equipment or materials.

Paper-based O&M records continue to remain an acceptable backup medium, but they shall only be used to augment the primary electronic O&M records required.

O&M Binders for CD521 projects shall be submitted in Adobe Acrobat .pdf format.

Binders are compendium tomes of individual equipment/system O&M Manuals, which contain operating, maintenance, troubleshooting, and similar detailed instructions for each subcomponent installed or changed by the project. Additional O&M information may be included in the O&M Binders, as appropriate and necessary.

For the purposes of this Standard, O&M Manuals are the manufacturer-provided instructions that come with the equipment, or similar. They are typically generic in nature. The O&M Binder is the compendium of all O&M Manuals and other O&M information necessary to perform lifecycle services on all equipment and systems installed, upgraded, or otherwise modified during a project.

Within a set number of calendar days of the Notice to Proceed (NTP) with construction, the Contractor shall submit to CD521 the proposed format, content and tab structure for all O&M Binders for CD521’s review and approval. Due dates are based on the design-bid-build acquisition process, and are from NTP for the “build” portion of the project. See the tables in section 01 77 06 (Project Complexity) for the deadlines for each project

The tab structure for O&M Binders shall follow MasterFormat 2004 specification format as accepted by the Construction Specification Institute. The Contractor shall make revisions and corrections to O&M Binder format and content as reasonably requested by CD521. After CD521 approves the proposed format, content, and tab structure for the O&M Binders, the Contractor shall create and deliver to CD521 initial electronic tabbed Binders within twenty-one (21) calendar days. The Contractor shall transmit to CD521 updates to the content of the electronic O&M Binders in a timely manner (see below) as the work progresses, and the Binders shall be 100% complete for Substantial Completion.

O&M documents in the electronic O&M Binders shall include, but are not limited to, approved submittals, manufacturer’s operating and maintenance instructions, brochures, shop drawings, performance curves and data sheets annotated to indicate equipment actually furnished (e.g. identifying impeller size, model, horsepower, etc), procedures, wiring and control diagrams, records of factory and field tests and device/controller settings and calibration, program lists or data compact discs, maintenance and warranty terms and contact information, spare parts listings, http://en.wikipedia.org/wiki/Design-bid-build http://www.csinet.org/masterformat http://www.csinet.org/

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DISA CSI 360-95-3 Version Date: 28 October 2011 inspection procedures, emergency instructions, and other O&M documentation that may be useful to CD521.

All electronically submitted documents must include a complete, hyperlinked table of contents.

The Contractor shall submit to CD521 each individual O&M Manual document within fourteen (14) calendar days of the document’s availability to facilitate inspections, testing, commissioning planning, maintenance & lifecycle services planning, and similar by the Contractor and CD521. All O&M Manuals shall be made completely available not less than the number of days prior to the scheduled commissioning date for the project noted in the tables in section 01 77 06 (Project Complexity). Note that the final compendium O&M Binder containing this information is not required to be delivered until the inspection for Substantial Completion (although it may be submitted earlier to satisfy both requirements simultaneously).

The requirements of this section are separate, distinct and in addition to product submittal requirements that may be established by other sections of the project Technical Specifications. Owner's manuals, manufacturer's printed instructions, parts lists, and other submittals required by other sections of the Specifications may be included in the O&M Manuals provided that they are approved and are formatted in a manner consistent with the requirements of this section.

Test data and commissioning data included in the O&M Manuals need not be duplicated in the CCM and vice versa. Test data not pertaining to a particular device or piece of equipment (such as domestic water pipe pressure test reports) must be inserted in the CCM.

Equipment is defined as any mechanism, mechanical, electrical or electronic device, or any combination thereof, which is made up of two (2) or more working parts to perform a particular function.

When an item of equipment is a packaged unit furnished by one manufacturer and the package as furnished contains proprietary items of equipment obtained from other sources, the Contractor must include copies of equipment data for each item of such equipment as if each item of equipment had been separately furnished.

Any equipment, material, or system which requires periodic and/or recurring inspection or maintenance in order to remain in fully functional operating condition during that equipment, material, or system lifecycle requires the delivery of O&M data.

01 77 43.10 Required Equipment Data

Description of Equipment. Refer also to equipment list requirements of section 01 91 00 (General Commissioning Requirements).

• A complete description of each equipment item in the following order:

basic descriptive terminology first, followed by modifying words describing the model, size and weight, flow rate, amperage, voltage, material, et cetera, as applicable, plan designation, if any, and package serial number.

• Part Number. Manufacturer's and supplier's part number.

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DISA CSI 360-95-3 Version Date: 28 October 2011

• Quantity. Total quantity of this equipment item installed under the project.

• Specification Paragraph Reference. State the specification section, paragraph, and page number under which the item of equipment was procured.

• Source. Manufacturer's name and address and supplier's name and address.

• Serial Number. Complete manufacturer's serial number(s) or other identity symbol(s) as applicable.

• Location. State the name of the system and/or sub-system in which each like item of equipment is installed and state the physical location of each like item of equipment by identifying the columnar grid intersections, as shown on the facility drawings, near which the item is located and also state the building, floor, and room or space title as applicable (see section 01 67 00 (Facility and Device Labeling and Identification)).

Parts Lists. The Contractor must clearly identify every part in the item of equipment with the proper manufacturer's name, part nomenclature and number, supply source, and list price.

Recommended Spare Parts. The Contractor must furnish a list of recommended spare parts (see section 01 93 24 (Bench Stock)) and critical spare parts (see section 01 93 25 (Critical Spares)) for each equipment item that CD521 will likely need within a 60-month (five calendar year) period to support and operate that item of equipment. The quantities of spare parts recommended must be based upon the quantity of like equipment items installed under the project. The Contractor must prepare the recommended spare parts list for each equipment item and must include the following information for each part.

• Part Description. Complete descriptive nomenclature plus manufacturer's complete model and part number, and list price cost for each part.

• Quantity Per Assembly. Quantity of listed part that occurs in the item of equipment.

• Quantity of Equipment Items. Quantity of like equipment items installed under the project.

• Shelf Life. Storage life of part, in months, if the part has limited life.

• Recommended Quantity. Quantity of parts that CD521 will need to support the installed quantity of equipment in which the part appears for a period of twelve (12) months.

• Source for Part. Name, address, website address, and phone number of three (3) technically acceptable suppliers for the part.

Normal Operating Instructions. The Contractor must furnish normal operating instructions with sufficient detailed information to permit a journeyman mechanic to adjust, start-up, operate and shut down the equipment. Special start-up precautions must be noted as well as other action items required before the equipment is put into service.

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DISA CSI 360-95-3 Version Date: 28 October 2011

Emergency Operating Procedures. The Contractor must furnish a detailed description of the sequence of action to be taken in the event of a malfunction of the unit, either to permit a short period of continued operation or emergency shutdown to prevent further damage to the unit and to the system in which it is installed.

Preventative Maintenance. The Contractor must furnish detailed information to cover routine and special inspection requirements, including but not limited to, field adjustments, inspections for wear, adjustment changes, lubrication points, frequency and specific lubrication type required, cleaning of the unit and type solvent to use, and such other measures as are applicable to preventative maintenance program.

Predictive Maintenance. The Contractor shall furnish detailed information on manufacturer recommended predictive techniques, frequencies, and thresholds, if available. If not applicable, so state explicitly.

Calibration. The Contractor must furnish detailed data on what to calibrate, how to calibrate, when to calibrate and procedures to enable checking the equipment for reliability or indications as well as data for test equipment, special tools and the location of test points. If not applicable, so state explicitly.

Scale and Corrosion Control. The Contractor must furnish detailed information covering the prevention of and removal of scale and corrosion. If not applicable, so state explicitly.

Troubleshooting Procedures. The Contractor must furnish detailed information and procedures for detecting and isolating malfunctions and detailed information concerning probable causes and applicable remedies.

Removal and Installation Instructions. The Contractor must furnish detailed information concerning the logical sequence of steps required to remove and install the item including instructions for the use of special tools and equipment.

Disassembly and Assembly Instructions. The Contractor must furnish detailed illustrations and text to show the logical procedure and provide the instructions necessary to disassemble and assemble the unit properly. The text shall include all checks and special precautions as well as the use of special tools and equipment required to perform the assembly or disassembly.

Repair Instructions. The Contractor must furnish detailed repair procedures to bring the equipment up to the required operating standard including instruction for examining equipment and parts for needed repairs and adjustments, and tests or inspections required to determine whether old parts may be reused or must be replaced.

System Drawings. The Contractor must furnish detailed drawings, where applicable, that clearly show wiring diagrams, utility service diagrams, control diagrams, system schematics, pneumatic and fluid flow diagrams, etc., which pertain to the unit function. System drawings must show major pieces of equipment, such as chillers, boilers, heat exchangers, pumps, air handlers, tanks, switchgear, et cetera, as meaningful to the project. Fluid flow and direction and valves with their valve tag identification numbers must be clearly noted on drawings. Drawings must show modifications to another manufacturer's standard unit when it is incorporated into the assembly or package unit.

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DISA CSI 360-95-3 Version Date: 28 October 2011

• The requirements of this paragraph are separate, distinct, and in addition to similar requirements that may be established by other sections. Where such system diagrams are required for submittal by other specification sections, the same diagrams will be acceptable for inclusion herein, so long as the diagrams used were approved during the submittal phase and are reproduced for clarity and to fit the size format of the O&M Manuals.

• System drawings may, for purpose of clarity, be prepared upon a major subsystem basis.

• System drawings, except where integrated into Record Drawings, are intended to be included in O&M Binders and other O&M documentation, and are not subject to the requirements of section 01 78 39 (Project Record Documents).

Special Tools and Test Equipment: The Contractor must furnish a detailed list of the special tools and test equipment needed to perform repair and maintenance for each equipment item. The list must contain the special tool and test equipment part number, size, quantity, price, manufacturer's name and address, and name and address of three (3) technically acceptable suppliers for the tools and test equipment.

Warranties and Guarantees: The Contractor must include, within the tabbed section for each system, equipment item, or material, an executed copy of the specified warranty/guarantee with warranty effective dates covering that particular system, equipment item, or material.

• The Contractor must include both the manufacturer's warranty as specified and the installing Contractor's guarantee for workmanship and system operation.

• This copy of the particular warranty/guarantee is in addition to the Final Acceptance deliverable requirement for original (hard copy) signature copies of all project warranties and guarantees bound together separately.

• As clarification, it is intended that at Final Acceptance the Contractor provide CD521 with a separate hard copy binder containing all original (signature hard copy) project warranties and guarantees. The Contractor must also provide, at Substantial Completion, a (soft) copy of the appropriate warranty in the same section as the equipment (or system) data furnished in individual tabbed sections of the O&M Binder for convenient reference.

Training of Owner/Operator Personnel: The Contractor must furnish documentation of owner/operator personnel training regarding operation of particular systems within the tabbed section for that particular system.