J-C3-WHS_Master_Cx_Plan_2016_Final_4-4-16.pdf

WASHINGTON HEADQUARTERS

SERVICES

MASTER

COMMISSIONING PLAN

Department of Defense

Washington Headquarters Services

Facilities Services Directorate

Standards & Compliance Division

Primary Point of Contact:

Wade Shankle, P.E.

WHS/FSD/MS/Standards & Compliance Division

Phone: 703-614-0137

Email: wade.l.shankle.civ@mail.mil

Secondary Point of Contact:

Ariam Kloehn, P.E.

Fire Protection Engineer & Acting Deputy Fire

Marshal

Office of the Pentagon Fire Marshal (OPFM) Phone: 703-692-1827 Email: ariam.c.kloehn.civ@mail.mil

Contract Number: HQ0034-16-R-00XX mailto:wade.l.shankle.civ@mail.mil mailto:ariam.c.kloehn.civ@mail.mil

WHS Master Commissioning Plan

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Revision History

The Commissioning Plan is a dynamic document that is updated throughout each phase of the project. Following represents the history of revisions made to the plan:

REVISION HISTORY

Description of Revision Pages Affected Date

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Table of Contents

Introduction

Commissioning Plan Overview

Commissioning Team

Commissioning Team Roles

Commissioning Scope of Work

Commissioning Project Phases

Commissioning Forms

Appendix A - Functional Performance Test Sample and Failure Rates

Appendix B – SOMM and O&M Data and Manual Requirements

Appendix C – Training Requirements

Appendix D – Acceptance Criteria

Appendix E – Definitions

Appendix F – Abbreviations and Acronyms

Appendix G –Sample Documentation – Pre-Functional Checklist and Functional Performance Test

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Introduction

Commissioning (Cx) is a systematic process that helps to ensure that building systems perform interactively according to the owner’s operational requirements and the design intent. Cx facilitates the transition from design through construction and into operations. At completion of the Cx process, all defined equipment and systems will have been started and tested in accordance with the contract requirements and verified operational relative to operational requirements and design intent.

The Cx plan defines the equipment and systems, commissioning requirements, and addresses the integration of commissioning into the overall project delivery process. This plan will serve as a guideline and is intended to assist members of the Project Team in applying a clear and consistent approach to commissioning during all phases of project delivery.

Commissioning Plan Overview

The purpose of the Cx Plan is to provide direction for the implementation of the Cx process. The Cx Plan is a management and communications tool that defines the scope, standards, processes, roles and responsibilities, expectations, and deliverables for the project. It is a dynamic document that is revised and refined as the phases of the project progress. The Cx Plan provides a detailed description of the Cx process and a description of the roles and responsibilities of key members of the Cx Team. It also identifies communication, and provides direction on scheduling, coordination and reporting. The plan addresses the following:

Cx Team: Defines the roles and responsibilities of the team members.

Cx Scope of Work: This describes in detail the scope of work, the contractual roles and responsibilities, identifies the equipment and systems to be commissioned, and defines the related Cx specification requirements.

Project Phases, Description, and Cx Sequence: This table identifies the key project phases and the major Cx activities associated with each phase.

Cx Forms: A sample of the checklist and testing forms to be completed.

The owner, design-build (DB) contractor, and Cx specialist (CS) contractor shall review the Cx Plan. The owner approved document will be distributed to the Cx Team for reference and action. As changes or modifications to the Cx Plan are identified by the team and approved by the Cx Program Manager (Cx PM) and the Cx Authority

(CA), the changes are recorded in the Revision History, incorporated into the Cx Plan and the Cx Plan is redistributed.

Commissioning Team

The Cx team, through coordinated action, is responsible for implementing the commissioning process. Cx team members are directly involved in the design, construction, testing, operations and maintenance processes and activities. Members of the Cx team include:

Commissioning Program Manager (Cx PM) o Commissioning Specialist, Mechanical, Electrical and Plumbing (CS-MEP) o Commissioning Specialist, Building Envelope (CS-BE) o Commissioning Specialist, Fire Protection (CS-FP)

Building Owner/Operator (BO) Team

Department of Defense Page 5 o Facilities Services Directorate (FSD) Standards and Compliance Division (SCD) o Facilities Configuration Management Branch (FCMB) o Building Management Office-Pentagon (PBMO), Mark Center (MC), or building manager at other DOD sites in the NCR

Government Design and Construction Management Team o FSD Engineering & Construction Management (ECM) o Commissioning Authority (CA) o Construction Manager (CM) o Design Coordinator (DC)

Design Build (DB) o DB Contractor (represented by the DB Commissioning Team Leader (DB-CTL) o DB Architect/Engineer (DB-AE) o DB Mechanical, Electrical, Fire Protection and Testing and Balance (TAB) Contractors (DB-MC, DB-EC, DB-FP, DB-TAB, DB-Controls)

Commissioning Team Roles

The general roles for members of the Cx team are as follows. Specific responsibilities of Cx team members during each phase of commissioning will be described in later sections of the Cx Plan.

Cx PM: Provides management and oversight of the Cx activities of the CS-MEP, CS-BE, and CS-FP on behalf of the Facilities Services Directorate (FSD). The Cx PM establishes Cx strategies and protocols and directs CS participation in the Cx process.

BO: Representative of PRLB and PBMO, MC, or building manager at other DOD sites in the NCR provides direction and guidance to the CxT on behalf of the BO. BO representatives provide input on

Operations and Maintenance (O&M) issues, witness the check-out, start-up and testing of selected systems and participate in dispute resolution.

CS: The CS-MEP, CS-BE, and CS-FP assist the CA with the execution of Cx tasks on behalf of the Cx

PM. Typical tasks performed by the CS include review of design and construction submittals, development of pre-functional checklists (PFCs) and functional performance tests (FPTs) used by the Cx team to verify systems meet performance requirements; witnessing conduction of FPTs by the DB Team and OGCs, recording and reviewing the results and makes recommendations to the CA and BO as appropriate; and maintaining the Cx deficiency log for the Cx team. The CS reviews project documents from a Cx perspective and makes recommendations to the CA and BO.

CA: Facilitates the Cx process on behalf of FSD. The CA is responsible for management and oversight of the Cx process. The CA coordinates the efforts of the Cx team members in the execution of Cx Tasks.

The CA coordinates dispute resolution and provides the final acceptance of Cx activities. The CA establishes communication norms and facilitates information flow for the Cx process.

DB-CTL: Facilitates the Cx process on behalf of the DB Team (DB-A/E, DB-M, DB-E, DB-FP and DB-

TAB) contractors. The DB-CTL ensures the DB Team integrates Cx into the construction process and schedules. The DB-CTL is responsible for the coordination of Cx activities with Other Government

Contractors (OGCs), e.g., Vertical Transportation contractor, and other members of the Cx Team.

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Commissioning Scope of Work

For building systems and equipment not included in the Cx Plan’s scope of Cx the DB will develop detailed, equipment and system specific testing procedures and submit to the CA for approval a minimum of 30 days prior to equipment/system start-up and checkout. Appendix A shows functional performance test sample and failure rates.

Commissioning Project Phases

The Cx process begins before the design phase, when design and operating intent are documented. The process continues through the design, construction, acceptance and warranty phases. Activities during these phases will include Cx focused design reviews, submittal reviews, development and implementation of pre-functional checklists, development of functional performance tests, systems installation and testing, System Operations and

Maintenance Manuals (SOMMs) compilation and delivery, training of building operations and maintenance personnel, the preparation and submission of final “as-built” documents and deferred and seasonal testing. The major phases of the Cx process are:

Design

Construction

Testing and Acceptance

Warranty and Deferred/Seasonal Testing

The methodology to be used for each phase is presented in the following table. The table also includes a synopsis of the Cx sequence associated with the phase.

Project Phase Description and Commissioning Sequence

PROJECT PHASE DESCRIPTION AND COMMISSIONING SEQUENCE

PHASE CX AUTHORITY CX SPECIALIST D-B CONTRACTOR

Design Phase:

DB Contractor develops initial Design Intent Documents (DIDs) consisting of concepts and ideas important to Owner.

These requirements can be performance based or very specific, depending on the level of importance to Owner. The basis of design (BOD) is developed with overall system descriptions and objectives of systems.

100% construction documents are prepared and issued.

Conducts Cx coordination meetings

Coordinates Cx activities

Facilitates the development and review of design documentation

Works with DB to develop detailed Cx specifications

Develops Cx requirements for the contract documents

Reviews DIDs for completeness and clarity and provides comments to CA and BO

Reviews contract documents and provides comments/ recommendations to the CA and BO

Provides input in development of Cx specifications

Prepares sample Cx forms

Reviews design development submittals at each cycle and provide comments /recommendations to the CA and BO

Reviews DMEL

Updates Cx Plan

Develops DIDs

Prepares BOD documents

Prepares design and construction documents in compliance with the contract and RFP requirements

Incorporates Cx requirements into the construction specifications

Incorporates Cx activities into the master schedule

Prepares Design Master Equipment List (DMEL)

Construction Phase:

Phase of the project during which the facility is constructed and/or systems and equipment are installed and started.

Early in the Construction Phase all Cx requirements are reviewed by the

Coordinates Cx meetings

Approves construction phase Cx Plan

Provides copies of all construction meeting minutes, RFIs, CO’s, etc.

to the CS and BO

Provides copies of O&Ms, SOMMs, Training

Maintains Cx Plan

Facilitates Cx meetings and prepare minutes

Reviews contractor schedule and provides comments/ recommendations to CA and BO

Reviews DB submittals, e.g., shop drawings, product data, concurrent with and before approval by the DB-

Incorporates Cx activities into construction schedule

Prepares submittal register and submits for DD-AE review and approval, all submittals including product and O&M data in accordance with the contract requirements

Provides copies of all

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PROJECT PHASE DESCRIPTION AND COMMISSIONING SEQUENCE

PHASE CX AUTHORITY CX SPECIALIST D-B CONTRACTOR

Construction Team. DB contractor prepares initial Systems Operation and Maintenance Manuals (SOMMs) for review 120 days after 100% construction documents are approved. See Appendix 2 for SOMM and O&M requirements.

plans/materials to CS

Approves PFCs and FPTs

Develops procedure for handling warranty claims

AE. Provides recommendations to the CA and BO

Reviews O&Ms, SOMMs, and training plans/materials. Provides recommendations to the CA and BO

Observes and documents construction of Exterior Envelope Mockup and designated Air/ Moisture/Thermal Barrier field sample areas.

Develops project specific PFCs

Develops project specific FPTs and ISTs construction meeting minutes, RFIs, CO’s, etc. to the CA

Submits O&M manuals for non-system related products and equipment, initial SOMMs, O&M material for inclusion into the SOMMs to the CA and BO

Submits Training Plans and materials to the CA and BO.

Provides comments on PFCs and FPTs to CA and BO

Coordinates with CA for Exterior Envelope Mock-up and designated Air/Moisture/ Thermal Barrier field samples to be tested.

System Readiness: Pre- Functional checklists and Start-ups are conducted.

Contractor/vendors conduct equipment specific training. All systems are ready for FPTs. See Appendix 3 for training requirements.

Accepts completed PFCs

Develops criteria for determining that training was satisfactorily completed and oversees training

Recommends approval of training to the BO; BO has final “acceptance” authority for the training received.

BO witnesses PFCs and start-ups to greatest extent possible

Reviews completed PFCs

Reviews procedures and witnesses start-up and balancing activities periodically. Provides comments and/or recommendations to CA and

BO.

Maintains issues log

Witness Training

Completes 100% of PFCs and submits to the CS with other installation certification testing, start-up reports, certification, inspection reports, etc.

Conducts the equipment & system startup and proving

Completes controls point and calibration verifications

Completes Testing Adjusting and Balancing (TAB)

Completes equipment training sessions

Prepares final Master Equipment List

Testing and Acceptance Phase:

The facility and its systems and equipment are inspected, tested, and verified. DB finalizes “as-built” or record documentation. Approved Functional Completion marks the end of this phase. See Appendix 4 for acceptance criteria.

The BO witnesses and participates in the FPTs to the greatest extent possible. CA provides notification of testing to the BO (two week minimum).

Oversees deficiency resolution

Accepts commissioning

Witnesses/documents FPTs and provides documentation to CA. A copy of the test documentation will be available to the DB Team upon completion of each day of testing regardless of test status with a copy of the test documentation provided to the DB Team upon completion of each test regardless of test status.

Documents deficiencies and tracks deficiency resolution in the issues log

Witnesses/documents re-testing procedures as required

Reviews record documentation and provides comments/ recommendation to CA and BO

The DB Team coordinates and schedules FPTs with the CA, which are conducted by the DB Team using calibrated test instruments provided by the DB team.

Submits Envelope Test Results and Report

Resolves testing issues

Coordinates and schedule re-testing

Completes and receives acceptance of commissioning by the CA prior to requesting acceptance of construction

Finalizes record documentation

Warranty and Deferred Testing Phase:

Includes occupancy of the building and can continue through the warranty period and at least into the opposite season from when it was initially tested.

Oversees deficiency resolution

Oversees warranty claims

Witnesses/documents FPTs and provides documentation to CA. A copy of the test documentation will be available to the DB Team upon completion of each test regardless of test status.

Documents deficiencies and tracks deficiency resolution

Witnesses/documents re-testing procedures as required

Prepares Final Cx Report

DB Team conducts deferred testing and finalizes associated documentation.

Responds to warranty calls

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Commissioning Forms

The following table represents typical forms and the purpose of the forms that will be utilized during the commissioning process:

COMMISSIONING FORMS

Form Purpose

Design Review Comment Utilized to document comments and track resolution at each design submission.

Comments are typically related to conformance to the RFP, design intent, commission-ability and O&M related requirements.

Meeting Minutes Forms include meeting agenda, meeting attendance sheet and meeting minutes.

Regular commissioning meetings will be held through the project. Meeting Items will be documented with responsible parties and due dates assigned. Meeting minutes will be distributed to the Cx Team.

Submittal Review Comment Utilized to document comments related to construction submittals per the submittal register including product data, shop drawings, O&M Data, SOMMs, training plans, and record documents as it relates to commissioning.

Master Equipment List (MEL) The master equipment list identifies all equipment subject to the commissioning process. The format of the MEL is defined in the SOMMs and is utilized to track the Cx process and provide baseline data for the computerized maintenance management system (CMMS), MAXIMO.

Field Reports Site observations will be conducted and documented periodically during the construction phase to assess progress of the work and conformance to the contract documents relative to commissioning.

Pre-Functional Checklists (PFCs) A PFC is prepared for each piece of commissioned equipment and is uniquely identified. PFCs provide a documented means to verify that the proper piece of equipment has been installed and checked out by the installing contractor and verified by the DB. PFCs include nameplate data, installation checks and startup and documentation checks.

Functional Performance Test (FPT) Procedures and Integrated Systems Tests (IST)

The intent of the functional performance test is to provide a functional demonstration of the control and operational sequences of the various systems within the performance criteria defined by the RFP and the design intent. This may include testing under various modes of operation such as, startup, normal operation, shutdown, power failure, fire alarm conditions and other building specific operations.

Issues Log Incomplete work or deficiencies discovered in PFCs, FPTs, or ISTs will be documented on the issues log. Issues will be corrected by the responsible contractors and re-tested or witnessed to produce satisfactory results prior to proceeding to the next stage of the Commissioning process.

Commissioning Report The final commissioning report summarizes the results of the commissioning process and discusses variances between design intent and the as-tested conditions and identifies any special operational or maintenance issues noted during commissioning. This report provides an evaluation of the systems operations and can serve as a future reference document during the operation of the facility systems.

The Pentagon utilizes a database application, the QuiCx Project Delivery System, to manage and track the commissioning process and documentation through all phases of the project. Commissioning team members may utilize this system as required in the performance of the commissioning activities for the project.

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Appendix A - Functional Performance Test Sample and Failure Rates

Description

Normal Systems

Sample FPT rate Failure Limit

Mechanical

TAB Verification 10% 10%

Air Terminal Units 20% 15%

CRAC Units 100% N/A

Radiant Heater 25% 0%

Air-Handling Units 100% N/A

Fan Coil Units 50% 0%

Exhaust Fans 33% 0%

Finned Tube 25% 0%

Unit Heaters 20% 0%

EMCS Head End including M&V 100% N/A

Fuel Oil System 100% N/A

Plumbing

Building Drinking Water System 100% N/A

Emergency Eyewash 100% N/A

Water Temp Mixing Valve 25% 0%

Domestic Hot Water System/Circ Pump 100% N/A%

Elevator Sump Pump 100% N/A

Lighting Interior Light Controls and Levels 25% 0%

Interior Egress Lighting Operation & Levels 100% N/A

Electrical Distribution

System

Electrical Generator/ATS 100% N/A

Network Transformers 100% N/A

Secondary Voltage Transformers 100% N/A

Grounding 100% N/A

Primary Switches 100% N/A

Primary Conductors 100% N/A

Network Protectors 100% N/A

Secondary Bus Duct 100% N/A

Circuit Breaker Switchgear/Switchboards 100% N/A

TVSS Equipment 100% N/A

UPS System 100% N/A

Secondary Feeder Conductors 10% 0%

Feeder Bus Way 25% 0%

Panel boards 10% 0%

Fire Protection and

Alarm

Fire Pump and Transfer Switch 100% N/A

Fire Alarm System 100% N/A

Wet Pipe Sprinkler System 100% N/A

Dry Pipe Sprinkler System 100% N/A

Building Envelope

Air Barrier Leakage-Wall (Joints & Openings) 100% N/A

Water/Moisture Barrier Leakage-Wall (Joints & Openings) 100% N/A

Water/Moisture Barrier Leakage-Roof) 100% N/A

Thermal Barrier IR Scan-Wall 100% N/A

Thermal Barrier IR Scan-Roof 100% N/A

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Appendix B – SOMM and O&M Data and Manual Requirements

The DB will develop System Operation and Maintenance Manuals (SOMM) detailing project-specific O&M requirements for facility systems as detailed in the RFP. To ensure format, organization and style compatibility, the SOMM developed for the Wedge 2-5 renovation project shall serve as the guide. The SOMM’s will be developed electronically until the format and content has been approved. The DB will then provide electronic and hard copy deliverables as required to meet contract requirements.

The Pentagon has developed a standard scheme for equipment and component labeling, which incorporates space/room number/designation as an integral component. Equipment and component labeling shall use approved equipment abbreviations to be consistent with the WHS MAXIMO equipment maintenance management system.

The DB shall submit their proposed labeling scheme for approval by the FFD operations staff.

The DB shall write and publish Operation and Maintenance Data packages, as detailed in RFP, using information from the plans and specifications, technical submittals, manufacturer’s recommended O&M procedures, OSHA lock out/tag out (LOTO) requirements, Pentagon maintenance criteria, and generally accepted O&M practices.

The DB will provide electronic and hard copy deliverables as required to meet contract requirements.

LOTO requirements developed and certified by original equipment manufacturers and/or suppliers shall be submitted as an integral part of the required O&M data. These manufacturers and/or suppliers shall also identify possible remote start-stop and other outside control initiation that can occur through their equipment components.

The DB shall further augment these requirements to address LOTO needs due to add-on components installed by those other than the original manufacturers and/or suppliers such as temperature control, EMCS, fire alarm, supervisory control and data acquisition (SCADA), physical security, and other proprietary control systems.

Equipment put into operation prior to its turnover to the Government must be operated and maintained by the DB in accordance with the project-specific design intent and manufacturer’s O&M requirements. This includes posting LOTO procedures in a protective plastic jacket fastened to the equipment operated and documenting adjustments made, consumable materials used (filters, lubricants, belts, chemicals, etc.), and maintenance performed. The DB shall provide a full record of this pre-turnover work, verifying and dating final replacement of consumables and system readiness for functional performance testing under the oversight of the CS.

The final electronic inventory, O&M Manuals, SOMMs, pre-turnover record, and LOTO data formats must follow the Pentagon Renovation Electronic Data Standards (EDS), be coordinated with the Government, and be capable of direct import into the FDMS. Hard-copy O&M information shall represent all data provided electronically, be in a format consistent with the O&M manuals to be provided, and be original documentation copies.

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Appendix C – Training Requirements

The DB will develop and implement a comprehensive project specific training program in accordance with the

RFP.

A Sample Training Plan is available for reference. The Sample Training Plan is intended to represent the level of rigor expected in the Training Session Plans to be submitted by the DB Contractor and Sub-Contractors. The

Training Sessions submitted by the Contractors shall be customized for this project and reflect all the commissioned equipment and systems. There may be project-specific equipment/systems that require training, which are not included in the Sample Training Plan. The minimum rigor shall include instruction on the following:

Materials, components, systems, and equipment

Installation requirements and O&M manual content

Operational requirements, features, functions, testing, and diagnostics

Identification systems

Automatic/manual control systems

Safety precautions and LOTO procedures

Hazards including Material and Safety Data Sheet information

Interactions/interfaces with other equipment and systems

Common failure modes and typical problems

Testing, adjusting, calibration, and balancing

Specialty tools, lubricants, fuels, etc.

Preventive and predictive maintenance

Contractor-furnished spare parts and extra materials

Recommended “attic stock” inventory not furnished by Contractor

Procurement information for replacement parts

Cleaning needs, surface care, and accompanying procedures

Warranty terms and conditions, points of contact, material return procedures, effective dates, expiration times, and extension options

Maintenance agreements and other similar continuing commitments

Additional training required by other project specification sections.

If SOMMs are to be utilized for training materials, they must be submitted and approved prior to being used for training.

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Appendix D – Acceptance Criteria

The acceptance criteria for functional performance tests (FPT) will generally be as follows, unless more specifically indicated within individual FPTs:

Capacity performance will be as specified, plus or minus 5 percent, but may be defined as plus 10 percent and zero percent if deemed necessary by the CS.

Efficiency where specifically indicated in the documents shall be plus or minus 5 percent. Where inferred from manufacturer’s catalogued data, criteria shall be plus or minus 10 percent.

Balancing-related criteria will be plus 5 percent and zero percent for water, and plus 10 percent and zero percent for air.

Accuracy and repeatability on sensing devices shall be as specified for the devices. The Contractor’s test and balance subcontractor working with the CS shall provide independent validation and professional judgment in passing or failing the devices. The coordination of multiple and related sensors is important.

Sequence-related criteria will be as explicitly specified in the documents.

Base-mounted pumps with coupled shafts shall have these shafts aligned with their respective motor shafts to within 0.001 inches in both the parallel and angular directions.

Test instruments shall have had a certified calibration within the last 12 months. Sensors installed inside a unit at the factory with calibration certification provided specific to those devices do not require field calibration. Measurement tolerances shall in general be as follows unless specified to be more stringent:

Tolerances for Standard Applications

Sensor Required Tolerance (+/-)

Cooling coil, chilled and condenser water temps 0.22°C

Relative humidity 1.1%

Hot water coil and boiler water temp 0.83°C

Outside air, space air, duct air temperatures 0.22°C

Watt-hour, voltage & amperage 1% of Design

Pressures; air, water and gas 3% of Design

Air flow rates 10% of Design

Water flow rates 4% of Design

Relative humidity 4% of Design

Oxygen or CO2 monitor 0.1% pts

CO monitor 0.01% pts

Natural gas and oil flow rate 1% of Design

Steam flow rate 3% of Design

Barometric pressure 0.34 kPa

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Appendix E – Definitions

Acceptance Phase: The phase of the project in which the facility and its systems and equipment are inspected, tested, and functional performance verified.

Approval: The acceptance by the approving authority of the Contractor submitted documents and test results.

Contractor: As used herein, a general reference to the applicable installing party and can therefore refer to the

DB, subcontractors, or vendors. The exceptions will be the EMCS Contractor and the Vertical Transport

Contractor, who will be referred to specifically as such.

Commissioning (Cx): A proactive, systematic, and rigorous process of assuring by documentation, functional testing, and training, from the design phase through the completion of the warranty period that all building facility systems perform interactively in accordance with the design documentation and intent, and in accordance with the

Government’s operational needs. This process judges correct performance of both individual systems and systems operating interactively according to the project design intent.

Commissioning Plan: The document which describes the organization, scheduling, allocation of resources, documentation, roles and responsibilities for performance verification of the facility and its systems and equipment.

Deficiency: An installation or condition that is not in conformance with the construction documentation or the design intent.

Design Criteria: The factors included in the design of a facility prescribed by the RFP and/or determined by the

Designer as necessary in order to meet the requirements of the Government.

Designer of Record (DOR): The Architect, Engineer or other professional who produces the design solution to meet the Governments requirements.

Design Intent: The methodology employed by the Designer or Record to meet the Design Criteria.

Documents: The written, drawn, pictorial, graphic, and other reference information that defines the design, construction, and performance requirements for this project. Typical documents include: contracts, Cx Plan and procedures, Basis of Design, Design Intent Document, construction plans and specifications, change orders, construction schedule.

Energy Management and Control System (EMCS): The computer based control and building automation system. This system will be installed, tested, and verified under the EMCS contract. EMCS includes the direct digital control of Heating, Ventilating, and Air-Conditioning (HVAC) systems; monitoring of an independent fire and life safety system; monitoring of building security systems and status; and other functions as described in the

EMCS specification.

Equipment (Commissioned): Energy consuming products and materials that are installed in a facility typically requiring operations and maintenance.

Failure: A formal action, taken by a person with authority to declare that some aspect of the commissioning process does not meet defined requirements, causing subsequent activities not to proceed.

Fine Tuning: The operational specific adjustments made during and after commissioning so as to optimize system performance.

Functional Completion: A milestone that marks the completion of the Acceptance Phase and successful completion of all Functional Performance Tests.

Functional Performance Testing (FPT): The detailed and thorough testing of the building systems and their interactions with the building components and other building systems. FPT is conducted by the DB, witnessed by the CS and relevant members of the Cx team, and is to be performed after the DB has completed Pre-Functional

Checklists and is convinced the system is ready to be declared functionally complete.

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Integrated System: Consist of multiple systems operating in conjunction with one another to provide an operational entity.

Party: Person, company, or organizational entity.

Pre-Functional Checklist (PFC): Includes all requirements for installation and start-up completed by the

Contractors and verifies system readiness for FPT’s.

Request for Information (RFI): Questions submitted by the Contractor to request clarifications to the contract documents and to confirm and/or document contract intent or field changes.

Shop Drawings: Documents prepared by the Contractor illustrating in detail their interpretation of the requirements of the Contract Documents for shop or on-site fabrication of various components, equipment, etc.

System: Consist of multiple equipment operating in conjunction with one another to provide an operational entity.

System Operation and Maintenance Manuals (SOMMs): Provides future operating staff the information needed to understand and optimally operate and maintain the commissioned systems.

Start-up: Typically used to refer to the Quality Control prescribed static testing or checkout of systems and equipment components to ensure that they are complete, properly installed, and ready for dynamic testing. Start-up is documented in, or attached to, the Pre-Functional checklist.

Trending: Monitoring and recording a time-series history of parameters, typically using EMCS, but occasionally using independent microprocessor-based digital data loggers. The latter are used when (i) data independent of

EMCS is required; and/or (ii) points are to be monitored that are not monitored by the EMCS.

TAB: Acronym for testing, adjusting and balancing work.

Verification: The process by which reported results are checked for completeness, accuracy and validity.

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Appendix F - Abbreviations and Acronyms

ACU Air Conditioning Unit

AHU Air Handling Unit

BAS Building Automation System

BO Building Owner or By Others

CA Commissioning Authority

CAV Constant Air Volume

CCV Cooling Coil Valve

CDs Construction & Contract Documents

CS Commissioning Specialist

CUH Cabinet Unit Heater

Cx Commissioning

CxT Commissioning Team

DAE Designer, Architect, and Engineer

DB Design-Build

DB-AE DB Architect-Engineer Firm

DB-EC DB Electrical Subcontractor

DB-FP DB Fire Protection Subcontractor

DB-MC DB Mechanical Subcontractor

DB Team DB Design Build Team

DeCx De-Commissioning

DID Design Intent Document

Docs Documents

EA Exhaust Air

EF Exhaust Fan

EMCS Energy Management & Control System

EPA Environmental Protection Agency

FAP Fire Alarm Panel

FCMB Facilities Configuration Management

Branch

FCU Fan Coil Unit

FDMS Federal Database Management System

FFD Federal Facilities Division

FPT Functional Performance Tests

FSD Facilities Services Directorate

GFCI Govt Furnished/Contractor Installed

HVAC Heating, Ventilating, & Air Cond.

IAQ Indoor Air Quality

IEQ Indoor Environmental Quality

JSP Joint Service Provider

LOTO Lock out/Tag out

MEP Mechanical, Electrical, Plumbing

MC Mark Center

MSDS Manufacturer’s Safety Data Sheet

NOI Notice of Intent

NTP Notice to Proceed

O&M Operation and Maintenance

OA Outside Air

OGC Other Government Contractor

OSA Outside Air

PBMO Pentagon Building Management Office

PC Pre-functional Checklist

POC Point of Contact

PHCV Preheat Coil Valve

RA Return Air

RFI Request for Information

RTU Roof Top Units

SCADA Supervisory Control & Data Acquisition

SD Smoke Detectors

SOMM System Operation & Maintenance

Manual

SOP Standard Operating Procedure

Subs Subcontractors

TAB Testing Adjusting and Balancing

TU Terminal Unit

UPS Uninterruptible Power System

VAV Variable Air Volume

VTC Vertical Transport Contractor

WHS Washington Headquarters Service

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Appendix G – Sample Documentation –

Pre-Functional Checklist and Functional Performance Test

Pre-Functional Checklist

Panelboard

Fan Powered Induction Unit (FPIU)

Functional Performance Test

Fan Powered Induction Unit (FPIU)

Pre-Functional Checklist – WHS Cx Projects Contract HQ0034-16-R-00XX Name Panelboard Document # System Name Tag # Section # Description Discipline Electrical Master Checklist Develop Date 14-Dec-15

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 17

Equipment Data Location Data

Equipment Type Building Name

Manufacturer Floor #

Model # Room #

Serial # Area Served

Vendor Parent Equipment

Nameplate Data Specified Submitted Installed Ctr CQC Cx Comment #

7.1 Panelboard - Data

Continuous Current Rating

NEMA Enclosure

Qty of Circuit Breakers

V/PH/Wire

Comments:

Inspection Items Ctr CQC Cx Comment #

7.1 Panelboard - Inspections

Compare equipment nameplate data with drawings and specifications.

Inspect physical and mechanical condition.

Inspect anchorage, alignment, grounding, and required area clearances.

Verify the unit is clean and all shipping bracing, loose parts, and documentation shipped inside cubicles have been removed.

Verify that fuse and circuit breaker sizes and types correspond to drawings and coordination study as well as to the circuit breaker’s address for microprocessor-communication packages.

Inspect bolted electrical connections for high resistance using one of the approved methods

Attempt closure on locked-open devices. Attempt to open locked-closed devices.

Verify appropriate lubrication on moving current-carrying parts and on moving and sliding surfaces.

Inspect insulators for evidence of physical damage or contaminated surfaces.

Verify correct barrier and shutter installation and operation.

Exercise all active components.

7.1 Panelboard - Grounding Systems - Inspections

Verify ground system is in compliance with drawings, specifications, and NFPA 70 article 250

Inspect bolted electrical connections for high resistance using one of the approved methods.

Inspect anchorage.

Tag # Section # Description Discipline Electrical Master Checklist Develop Date 14-Dec-15

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 18

Inspection Items

Ctr

CQC

Cx Comment #

7.6.1.1 Circuit Breakers, Air, Insulated- Case/Molded-Case - Inspections

Compare equipment nameplate data with drawings and specifications.

Inspect anchorage and alignment.

Verify the unit is clean.

Operate the circuit breaker to insure smooth operation.

Inspect bolted electrical connections for high resistance using one of the approved methods

Inspect operating mechanism, contacts, and arc chutes in unsealed units.

Perform adjustments for final protective device settings in accordance with the coordination study.

Documentation Ctr CQC Cx Comment #

7.1 Panelboard - Electrical Tests

Perform insulation-resistance tests on each bus section, phase-to-phase and phase-to-ground, for one minute.

Perform a dielectric withstand voltage test on each bus section, each phase-to-ground with phases not under test grounded, in accordance with manufacturer’s published data. The test voltage shall be applied for one minute.

7.6.1.1 Circuit Breakers, Air, Insulated- Case/Molded-Case - Electrical Tests

Perform insulation-resistance tests for one minute on each pole, phase-to-phase and phase-to- ground with circuit breaker closed, and across each open pole.

Perform a contact/pole-resistance test.

Determine long-time pickup and delay by primary current injection.

Determine short-time pickup and delay by primary current injection.

Determine ground-fault pickup and time delay by primary current injection.

Determine instantaneous pickup by primary current injection.

Perform minimum pickup voltage tests on shunt trip and close coils in accordance with manufacturer’s published data.

7.6.1.1 Circuit Breakers, Air, Insulated- Case/Molded-Case - Electrical Tests

Perform insulation-resistance tests for one minute on each pole, phase-to-phase and phase-to- ground with circuit breaker closed, and across each open pole.

Perform a contact/pole-resistance test.

Tag # Section # Description Discipline Electrical Master Checklist Develop Date 14-Dec-15

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 19

Documentation

Determine long-time pickup and delay by primary current injection.

Determine short-time pickup and delay by primary current injection.

Determine ground-fault pickup and time delay by primary current injection.

Determine instantaneous pickup by primary current injection.

Perform minimum pickup voltage tests on shunt trip and close coils in accordance with manufacturer’s published data.

Type

Contractor

Name Company Sign Off Date

Cx Rep

Mechanical Contractor

Electrical Contractor

CM/COR

CxS

CxA

Prepared By

Final Completion Date

Name Fan Powered Induction Unit Document # System Name Tag # FPIU-M-010 Section # Description Discipline Mechanical Master Checklist Develop Date 14-Dec-15

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 20

Equipment Data Location Data

Equipment Type Building Name

Manufacturer Floor #

Model # Room #

Serial # Area Served

Vendor Parent Equipment

Nameplate Data Specified Submitted Installed Ctr CQC Cx Comment #

Fan Powered Induction Unit Data

Inlet Diameter (in)

Total Air Volume (cfm)

Primary/Outside Air Volume (cfm)

Induced Air Volume (cfm)

Fan Data, Supply

Volume (cfm)

ESP (in WG)

V/Hz/Ph

HP

FLA

Coil Data, Cooling-Blended Chilled Water

Airflow (cfm)

Capacity (MBH)

Entering Air Temp (°F DB/°F WB)

Leaving Air Temp (°F DB/°F WB)

Rows

Fins Per Inch

Entering Water Temp (°F)

Leaving Water Temp (°F)

Water Flow Rate (GPM)

Filter Data

Filter Size / Type

Ctr CQC Cx Comment #

Installation & Cleanliness Inspections

Clean and free of debris

Coil fins undamaged

No obvious defects or damage

Tag # FPIU-M-010 Section # Description Discipline Mechanical Master Checklist Develop Date 14-Dec-15

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 21

Inspection Items Ctr CQC Cx Comment #

Permanent equipment ID tags installed and correct

Accessibility & Mounting Inspections

Installed in proper location per contract documents

Unit securely mounted per manufacturer's recommendations

Proper clearance and service access

Vibration isolation equipment installed per contract documents

Unit level

Shipping lockdowns, packing, etc. removed

All covers and guards in place

Fan Powered Induction Unit Inspections

Access doors close tightly and gaskets not damaged

Unit to duct flexible connectors installed and undamaged

Correct filters in place and fit tight in filter rack

Condensate drain pan installed/included

Moisture sensor provided and installed that closes blended chilled water valve upon water detection in drain pan

Coil Inspections, Cooling-Blended Chilled Water

Piping installation complete and properly supported

Piping connected to correct inlet and outlet of coil

Flexible connectors installed in both supply and return piping at coil

Unions installed in both supply and return piping at coil

Isolation valves installed in both supply and return piping

Strainer installed in correct direction in supply piping

Thermometers installed in both supply and return piping

2-way automatic control valve installed in return piping

Combination balancing/isolation valve installed and in correct direction in return piping

Piping insulated per contract documents

Piping labeled with correct ID and flow arrows

Fan Inspections, Supply

Fan rotates freely

Wheel is properly aligned

Bearings lubricated per manufacturer recommendations

Fan balanced per manufacturer's recommendations

Tag # FPIU-M-010 Section # Description Discipline Mechanical Master Checklist Develop Date 14-Dec-15

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 22

Electrical Connection and Wiring Inspections

Safety disconnect switch installed and labeled

Incoming electrical connections match unit nameplate data

Proper grounding installed for each component

Electrical connections tight and enclosed

Electrical wiring labeled per contract documents

Controls Inspections

All control devices have been installed per drawings and per specifications

Local thermostat/control unit mounted in specified location

Control wiring is completed

Control equipment labeling is complete per the specifications

Communications to all control equipment has been established

Metasys Verification: ZN-T field point is mapped and reliable

Metasys Verification: Moisture Sensor field point is mapped and reliable

Metasys Verification: Current Sensor field point is mapped and matches BAS Command

Metasys Verification: Damper field point is mapped and reliable

Point to point checkout is completed and paperwork is available

Documentation Ctr CQC Cx Comment #

Startup

Verify and record proper line voltage to unit:

Verify and record proper unit amperage:

Isolation valves open

Strainers are installed and clean

Ductwork, dampers and any other equipment that could obstruct airflow complete

Clean filters installed and secured in place

Fan rotates freely in correct direction

No unusual vibration or noise at any normal operating frequency

No obvious or audible air leaks

No water leaks at operating pressure

Tag # FPIU-M-010 Section # Description Discipline Mechanical Master Checklist Develop Date 14-Dec-15

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 23

Documentation Ctr CQC Cx Comment #

Reporting & Certification

Piping pressure tested and flushed, report submitted

Manufacturer start-up complete, report submitted

TAB complete, report submitted

O&M data provided

Type

Contractor

Name Company Sign Off Date

Cx Rep

Mechanical Contractor

Electrical Contractor

CM/COR

CxS

CxA

Prepared By

Final Completion Date

Functional Performance Test – WHS Cx Projects Contract HQ0034-16-R-00XX Name W2 FPIU Control Type 10 Status For Review Draft Develop Date 14-Dec-15 Number FPIU-M-010 Final Develop Date Discipline Mechanical Estimated Test Duration (hr) 1

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 24

Test Summary

Validation of Type 10 FPIU operation – Drawing H-FPIU10-01, Current Revision 12/5/06

Test Procedures

I. FPIU Type 10 - Pre-Test Checkout

Expected Result Actual Result Status Checked By

A. Verify that associated AHU and blended chilled water system has been started-up and programmed to meet contract documents.

1. Associated AHU system start-up and programming complete.

2. Blended chilled water system operational and providing building the specified temperature blended chilled water.

B. Verify FPIU PFC has been completed and accepted by the Commissioning Agent.

1. Outstanding or deficient items do not impede testing or cause unsafe conditions.

C. Verify that all FPIU components are in AUTO and are not in ALARM.

1. ALL components are in AUTO.

2. No components are in ALARM.

D. Set or verify associated AHU and FPIU are energized in OCCUPIED mode.

1. Associated AHU is energized in OCCUPIED mode.

2. FPIU is energized in OCCUPIED mode.

II. FPIU Type 10 – Readings

Expected Result Actual Result Status Checked By

A. Verify proper sensor installation, accuracy and calibration. Record the current reading of each sensor as noted at the BAS.

1. Supply fan status (ON / OFF)

2. Fan speed (Hz or %)

3. Make-up air airflow (cfm)

4. Supply air temperature (°F)

5. Zone air temperature (°F)

6. Zone humidity (% RH)

7. Calculated zone dew point temperature (°F)

8. Blended chilled water temperature (°F)

9. Warm / cool adjust temperature (°F)

B. Record the current command of each piece of equipment as noted at the BAS.

1. Make-up air damper command (% OPEN)

2. Blended chilled water control valve command (% OPEN)

C. Record the current command of each piece of equipment as noted at the BAS.

1. Temporary OCCUPIED mode (ON / OFF)

2. Manual purge mode (ON / OFF)

Number FPIU-M-010 Final Develop Date Discipline Mechanical Estimated Test Duration (hr) 1

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 25

III. FPIU Type 10 - Setpoints – Airflow

Expected Result Actual Result Status Checked By

A. Note all sensor programmed setpoints

1. Make-up airflow (cfm) TAB Value

2. 150% make-up airflow (cfm)

3. 100% fan speed - TAB set value (%)

4. 65% fan speed - TAB set value x 0.65 (%)

IV. FPIU Type 10 - Setpoints – Temperature

Expected Result Actual Result Status Checked By

A. Note all sensor programmed setpoints.

1. Occupied cooling zone temperature (74°F)

2. Occupied heating zone temperature (72°F)

3. Occupied offset temperature (+/- 1°F from setpoint)

4. Unoccupied night set-up Temperature (80°F)

5. Unoccupied night set-up dead band (2°F)

6. Warm / Cool Adjust Limit (-/+ 1.5°F)

V. FPIU Type 10 - Setpoints – Alarms

Expected Result Actual Result Status Checked By

A. Note all sensor programmed setpoints.

1. Zone temperature alarm (+/- 5°F from active setpoint)

2. Dew point > blended chilled water temperature alarm (30 min)

3. Damper open > normal setpoint alarm (30 min)

4. Blended chilled water control valve = 100% Open Alarm (30 min)

VI. FPIU Type 10 - Setpoints - Time Limits

Expected Result Actual Result Status Checked By

1. Temporary occupied mode (120 min)

2. Manual purge mode (60 min)

3. Unoccupied step-up not meeting setpoint (30 min)

4. Unoccupied step-up achieved (30 min)

5. Unoccupied dew point temperature remains above blended chilled water temperature (20 min)

VII. FPIU Type 10 - Setpoints – Schedule

Expected Result Actual Result Status Checked By

A. Note occupancy schedule at BAS. Verify BAS is controlling all units on the floor to this schedule.

1. Monday

2. Tuesday

3. Wednesday

4. Thursday

Number FPIU-M-010 Final Develop Date Discipline Mechanical Estimated Test Duration (hr) 1

Department of Defense Date Printed: 14 December 2015 Washington Headquarters Services Page 26

5. Friday

6. Saturday

7. Sunday

VIII. FPIU Type 10 - Alarm Overrides for Testing

Expected Result Actual Result Status Checked By

A. Override system alarm time limits to 2 min.

1. Max blended chilled water valve alarm time limit set to 2 min.

2. Make-up air damper open greater than normal alarm time limit set to 2 min.

3. Zone dew point reading greater than blended chilled water temperature alarm time limit set to 2 min.

IX. FPIU Type 10 - Timer Overrides for Testing

Expected Result Actual Result Status Checked By

A. Override system time limits to 2 min.

1. Temporary occupied time limit set to 2 min.

2. Purge mode time limit set to 2 min.

3. UNOCCUPIED step-up achieved setpoint time limit set to 2 min.

4. Occupancy Sensor time limit set to 2 min.

B. Override system time limits to 5 min.

1. UNOCCUPIED step-up not meeting setpoint time limit set to 5 min.

2. UNOCCUPIED dew point temperature remains above blended chilled water temperature time limit set to 5 min.

X. FPIU Type 10 - Manual Control

Expected Result Actual Result Status Checked By

A. Modulate the FPIU make-up air damper from the BAS. Standard positions are: 0% Open, 100% Open and Design Airflow.

1. FPIU make-up air damper modulates to 0% OPEN, 0 CFM make-up airflow and damper position noted at BAS.

2. FPIU make-up air damper modulates to 100% OPEN, MAX make-up airflow and damper position noted at BAS.

3. FPIU make-up air damper modulates to design airflow, design CFM and damper position noted at BAS.

B. Return the FPIU make-up air damper to AUTO from the BAS.

1. FPIU make-up air damper controls per normal operation.

C. Modulate the FPIU blended chilled water control valve from the BAS. Standard positions are: 0%, 50%, and 100%.

1. Blended chilled…