I.B.08.2_21R0034 USDA-ARS Kerrville 4E - Commissioning Plan.pdf

Engineering | Architecture | Design-Build | Commissioning | Surveying | Geospatial Solutions

COMMISSIONING PLAN

COMPANY INFORMATION

KNIPLING-BUSHLAND U.S. LIVESTOCK

INSECTS RESEARCH LABORATORY

KERRVILLE, TX

Version: Ready to Advertise (100%)

12 February 2021

Prepared for:

Prepared by:

160 Clairemont Avenue, Suite 600

Decatur, Georgia 30030

Main: 404.789.2700

Fax: 404.378.7022 www.merrick.com

KNIPLING-BUSHLAND U.S. LIVESTOCK INSECTS

RESEARCH LABORATORY

COMMISSIONING PLAN BY:

MERRICK & COMPANY

February 12, 2021

About Merrick & Company

Merrick has continually built its expertise in biocontainment lab commissioning and is considered a specialist in this field for federal, university, institutional, and private sector clients. Merrick is a “Commissioning Provider Firm” registered with the Building Commissioning Association, signifying that Merrick is staffed with professionals who are dedicated to the growth and education of the commissioning industry and who regularly provide training at a variety of industry events. The firm provides commissioning services for:

Laboratories (research, diagnostics, containment)

Sensitive compartmented information facilities (SCIF)

Process/production facilities (bioprocessing plants, hazardous waste)

Renewable energy laboratories

Nuclear facilities

Environment controlled facilities

Central utility plants

61TGeorgia

Decatur

160 Clairemont Ave.

Suite 600

Decatur, GA 30030

TEL: +1 404-789-2700

FAX: +1 404-378-7022

Duluth

3575 Koger Blvd

Suite 2335

Duluth, GA 30096

TEL: +1 404-739-5100

FAX: +1 678-281-1142

61TCanada61T

Merrick Canada ULC

580 Prom. Terry Fox Drive

Suite 201

Kanata, Ontario Canada K2L-4B9

TEL: +1 613-592-5289

FAX: +1 613-592-2181

61TColorado61T

Greenwood Village, Colorado

Corporate Headquarters

5970 Greenwood Plaza Blvd.

Greenwood Village, CO 80111

TEL: +1 303-751-0741

FAX: +1 303-751-2581

OTHER MERRICK LIFE SCIENCES CONTACTS

Senior Vice President, Life Sciences Operations

Brad Andersen, RA, PMP

Vice President

TEL: +1 303-751-0741

Director of Commissioning Services

Gilles Tremblay, CET

Director of Life Sciences Engineering

Chris Kiley, PE

TEL: +1 678-281-0997

Director of Biosafety and Biosecurity Programs

Ryan N. Burnette, Ph.D.

TEL: +1 703-215-8365

Director of Laboratory Design

Paul Langevin, PEng

Director of Laboratory Planning & Programming

Sandy Ellis, RA

Director of Business Development

Jennifer Harms

TEL: +1 703-581-2142

TABLE OF CONTENTS

1. COMMISSIONING (Cx) PLAN DOCUMENT CONTROL

1.1 Cx PLAN ISSUE DATE

1.2 RELATED COMMISSIONING SPECIFICATIONS

2. COMMISSIONING (Cx) PLAN OVERVIEW

2.1 PURPOSE

2.2 APPLICABLE GUIDELINES AND STANDARDS

2.3 Cx PLAN OVERVIEW

3. PROJECT DESCRIPTION

3.1 GENERAL PROJECT INFO

3.2 OVERVIEW OF COMMISSIONING SCOPE

4. Cx TEAM

4.1 GENERAL

4.2 TEAM REPRESENTATIVES

4.3 TEAM MEMBER CONTACT INFORMATION

4.4 Cx TEAM MEMBER ROLES

4.5 Cx TEAM MEMBER RESPONSIBILITIES

4.6 COMMUNICATION AND INTERFACE

5. COMMISSIONING SCOPE, PROCESS, AND DELIVERABLES

5.1 Cx SCOPE OF WORK OVERVIEW

5.2 Cx PHASES / TASKS OVERVIEW

5.3 PRE-FUNCTIONAL AND FUNCTIONAL TESTING PROCESS

5.4 Cx WORK PROCESS

6. WEB-BASED Cx MANAGEMENT SYSTEM

6.1 QuiCx SYSTEM

6.2 ACCESS AND LOGIN

6.3 SUPPORT

6.4 EXECUTION

7. ABBREVIATIONS, ACRONYMS, AND DEFINITIONS

APPENDICES

APPENDIX A – PRE-FUNCTIONAL CHECKLIST FORMS (PFC)

APPENDIX B – SYSTEM TESTS (ST)

APPENDIX C – INTEGRATED SYSTEM TESTS (IST)

APPENDIX D – Cx SCHEDULE INTEGRATION

APPENDIX E – ISSUES LOG

RESEARCH LABORATORY - COMMISSIONING PLAN

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1. COMMISSIONING (Cx) PLAN DOCUMENT CONTROL

1.1 CX PLAN ISSUE DATE

The Cx Plan is intended to be a “living” document to be updated at various stages of the Cx Process with information available at that time. It is the intent that this Cx Plan will be updated and submitted for Cx Team review at the end of the following phases.

ISSUE DATE

ISSUE ISSUE DATE DESCRIPTION

D-001 04-01-2020 95% Design Phase

1.2 RELATED COMMISSIONING SPECIFICATIONS

Section 01 91 00 - Commissioning Requirements

Section 01 91 13 – Commissioning Forms

Section 11 08 00 – Commissioning of Equipment

Section 22 08 00 – Commissioning of Plumbing Systems

Section 23 08 00 – Commissioning of HVAC Systems

Section 26 72 00 – Commissioning of Electrical Systems

Section 28 08 00 - Commissioning of Access Control

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2. COMMISSIONING (Cx) PLAN OVERVIEW

2.1 PURPOSE

The purpose of this commissioning plan is to provide a clear and consistent approach to verifying all critical building system components meet the design and owner requirements. This commissioning plan provides details for implementing the commissioning process as it relates to facility improvements at the Knipling-Bushland U.S. Livestock Insects Research Laboratory (KBUSLIRL) located in Kerrville, Texas.

2.2 APPLICABLE GUIDELINES AND STANDARDS

The publications listed below will be used to establish performance acceptance criteria to the extent referenced within this document and the Issued For Construction (IFC) Design Intent Document (DID) dated June 19, 2018.

• ARS-242.1 – ARS Facilities Design Standards (May 2012)

• Biosafety in Microbiological and Biomedical Laboratories (BMBL) – Fifth Edition (2007)

• ANSI/ASHRAE/IES Standard 202 - Commissioning Process for Buildings and Systems (2013)

• Guide for the Care and Use for Laboratory Animals (Eight Edition) as published by ILAR

• LEED v3.0 (2009)

2.3 CX PLAN OVERVIEW

This commissioning plan outlines and describes the commissioning process that will be used for this project. The plan identifies the specific members of the commissioning team, their roles and responsibilities, defines the scope of Cx activities, defines the Cx documentation required for final completion and includes specific details required to implement the various commissioning activities. At the completion of the commissioning process, all identified systems will have been started and tested in accordance with contract requirements and verified functionally against design intent and owners operational requirements.

This Cx Plan is meant to be dynamic in nature and will evolve and expand with more detail as the design and construction process evolves. Subsequent issues of this plan may be released with appropriate feedback from all parties and further detail as the project proceeds.

Commissioning is a systematic process of ensuring that building systems perform interactively according to the design intent and the owner’s operational needs. Commissioning for this project is achieved by reviewing the specifications, drawings, submittals, test and balance reports, equipment start-up reports, etc.

The Commissioning Agent (CxC) develops this Cx Plan using input from the project team. The Cx plan addresses the following:

• Commissioning Team – Defines the roles and responsibilities of the team members.

• Commissioning Scope of Work – This describes in detail the scope of work, the roles and responsibilities, and identifies the equipment and systems to be commissioned and defines the related commissioning specification requirements.

• Commissioning Forms – A description of the checklist and test forms to be completed.

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The Owner, Design Consultants, and Contractors shall review the Cx Plan with the CxC. The approved document will be distributed to Cx Team for information and action. As changes or modifications are needed to the Cx Plan, the CxC will incorporate them and redistribute the updated Cx Plan at the end of each Cx Phase.

It is important to note that Ucommissioning is not a replacement for good design and quality construction practicesU but is seen as a means to enhance the delivery process. The process consists of a series of checks and balances to ensure that the work is designed, installed and proven to operate as intended. Commissioning facilitates the transition from design through construction and into operations.

Commissioning for the KBUSLIRL is focused on testing, optimizing and documenting the systems and equipment; and to confirm the operational and functional aspects of the facility. The guiding principal is to achieve safe and reliable facilities and systems that would meet the expectations of the owner, users, and community. Knipling-Bushland U.S. Livestock Insects Research Laboratory (KBUSLIRL).

All commissioning documentation associated with the KBUSLIRL shall reside and be managed on a secure/password protected web based Cx management system.

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3. PROJECT DESCRIPTION

3.1 GENERAL PROJECT INFO

The Knipling-Bushland U.S. Livestock Insects Research Laboratory (KBUSLIRL) is located on a 32-acre campus in Kerrville, Texas, and is a vital national resource whose research is essential to the health of the U.S. livestock industry. Many of the KBUSLIRL’s existing campus was originally constructed in the 1960s and lacks adequate facilities for the KBUSLIRL’s growing workforce and expanding mission. Additionally, the USDA-ARS has committed to improving the efficiency of its overall livestock research program which entails transferring the current work being performed at the Avian Disease Oncology Laboratory (ADOL) in East Lansing, Michigan to the Kerrville campus of KBUSLIRL. The newly integrated KBUSLIRL and ADOL operations will create a National Livestock Health Laboratory will create programmatic and resource synergies with adjacent Russell Research Center Food Safety program. To support this a modernization effort is being employed that will demolish aging facilities, renovate some existing facilities, construct three new buildings and upgrade site utilities. Final design, construction, commissioning and occupancy is expected to be a phased approach with an estimated project completion by Spring of 2023.

The phased modernization of the KBUSLIRL campus will entail construction of the following new facilities:

• B994: Stanchion Barn

• B995: Maintenance Barn

• B996: Maintenance Barn

• B997: Fly & Tick Rearing Building

• B998: Admin & Lab Building

3.2 OVERVIEW OF COMMISSIONING SCOPE

Generally, all five buildings will be commissioned to confirm that operational, safety, sustainability and energy efficiency goals are met. Additionally, the Lab and Admin Building will be designed and constructed to achieve a Two Green Globes rating, including adhering to Criteria under 3.1.3.1 Pre-Commissioning, 3.1.3.2 Whole Building Commissioning, 3.1.3.3 Training, and

3.1.3.4 Operations and Maintenance Manual.

In accordance with 01 91 00 (Commissioning Requirements) and the referenced Cx spec sections, the following list identifies the equipment, components, and systems to be commissioned in each building as part of the pre-functional checks, system testing and integrated system testing approach of contract requirements. Refer to Appendix C – Pre-Functional Checklists (PFC);

Appendix D – System Tests (STs); and Appendix E – Integrated System Tests (ISTs) for a detailed list of Cx Forms to be developed and utilized as part of the Cx Process.

• Architectural & Equipment (Specification sections 08 08 00 and 11 08 00) o Autoclave o Class II Biological Safety Cabinets (BSCs) o Laboratory Washers

• Plumbing (Spec section 22 08 00) o Gas-fired Semi-instantaneous Water Heaters o Electric instantaneous Water Heaters o CO2 Manifold

Page | 5 o Gas Meter o Incinerator o Sump Pumps o Plumbing Fans o Sanitary Vent HEPA Filters

• HVAC (Spec section 23 08 00) o Chillers o Boilers (heating water) o Chilled Water Pumps o Heating Water Pumps o Energy Recover (Run-around Coil) Pumps o Air Handling Units o Energy Recovery Units o Fan Coil Units o Unit Heaters o Misc Fans (including toilet exhaust and incinerator combustion air intake fans) o Air Valves o Reheat Coils o Chemical Treatment System o BAS Hardware o Exhaust Fans o Steam Generators o Directional Airflow Testing

• Electrical (Spec section 26 72 00) o Generators o Switchgear o Pad-mounted Service Transformers o Distribution Panelboards o Branch Circuit Panelboards o Variable Frequency Drives o Branch Feeders / Circuits o Lighting Control System o Dual Power Feed (Redundant Power) Testing o Emergency Power Feed Testing

• Access Control / Security (Spec section 28 08 00) o Video Surveillance System (including CCTV Fixed & PTZ Cameras) o Access Control System (including card readers, keypads and door contacts)

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4. Cx TEAM

4.1 GENERAL

Commissioning is a team effort among all parties involved in the project and requires clear communications and cooperation by all parties in various phases of a project. Successful delivery of a project will be achieved by having a balanced and well-informed project team. The commissioning team comprises of members from Uall groupsU who have either a responsibility to deliver or participate in the commissioning process or have a role in the outcome of the commissioning process that confirms project acceptance, building performance or contract documentation as it relates to operational readiness.

Each Cx team member has specific responsibilities to ensure that the commissioning process is completed in accordance with the commissioning plan, design specifications and operational requirements. The commissioning agent (CxC) provides leadership by communicating goals for the commissioning process, defining systems to be commissioned and managing/executing the commissioning activities. Each commissioning team member shares responsibility to support the commissioning process in order to achieve a fully functional facility.

4.2 TEAM REPRESENTATIVES

The KBUSLIRL Cx Team shall consist of the following main representatives who will be responsible in participation of all associated Pre-Functional Checklists (PFC), System Tests (ST) and Integrated System Tests (IST) specified in the contract documents. The designated representatives shall be the primary point of contact for their designated company or role and responsible for coordinating their involvement and timely responses to Cx activities.

COMMISSIONING TEAM: CONTRACTORS, OWNERS, DESIGNERS, AND COMMISSIONING GROUP

GROUP DESIGNATION REPRESENTATIVES

Commissioning Group CxC Commissioning Agent

Owners Group CO Contracting Officer EPM Engineering Project Manager RPR Research Program Representative BSO BioSafety Officer FE Facilities Engineer

Design Group A Design Architect

E Design Engineer Construction Group GC Contractor’s Project Manager

QC Contractor’s Quality Control Manager MC Contractor’s Mechanical Representative EC Contractor’s Electrical Representative

TAB Contractor’s Testing, Adjusting and Balancing Representative CC Contractor’s (BAS) Controls Representative SC Contractor’s Security Representative

FAC Contractor’s Fire Alarm Representative

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4.3 TEAM MEMBER CONTACT INFORMATION

4.4 CX TEAM MEMBER ROLES

There are three primary groups making up the KBUSLIRL Cx Team:

Commissioning Group (CxC) - The role of the Commissioning group in the commissioning process is to oversee the process and to assist all other parties in achieving the goals of the project.

Owners Group (CO, EPM, RPR, BSO, FE) – The Owner’s group is critical in providing feedback and final direction on processes, documentation and issues brought up during the Cx process. The owner’s group is also responsible for reviewing and commenting on documents related to the execution of the commissioning process as well as witnessing Cx activities.

Design-Build Group (GC, QC) – The D-B Contractors’ Group is responsible for executing the Cx activities, coordinating schedules, verifying sub-contractor’s installation, completing all pre-functional checklists and supporting all functional system testing.

• D-B Architect / Engineers (DB-A, DB-E) - The D-B Contractor’s Architect and Engineers retains all responsibility for designs. Any CxC feedback during the design review process is to assist the DB-A / DB-E and is intended to be

DESIGNATION NAME COMPANY TELEPHONE EMAIL

CxC

CO

EPM

COTR

RPR

BSO

FE

GC

QC

A/E

A/E

A/E

MC

EC

TAB

CC

SC

FAC

Page | 8 constructive. Comments are generally suggestions. It shall be the DB-A / DB-E's sole responsibility to incorporate or disregard CxC comments. The DB-A / DB-E shall respond to the comments, noting inclusions/exclusion.

• D-B Subcontractors (MC, EC, TAB, CC, SC) - Installing sub-contractors retain all responsibility for the field installations, pre-functional checklists and supporting operational and functional testing. CxC installation verifications and testing requirements will determine the adequacy and completeness of the installations in order to continue with operational and functional testing. CxC participation does not alleviate contractor's responsibility for ensuring the systems are complete, tested and functional in accordance with user requirements.

4.5 CX TEAM MEMBER RESPONSIBILITIES

The responsibilities of the primary Cx team groups are further described below:

RESPONSIBILITY MATRIX

Cx TEAM MEMBER RESPONSIBILITY Commissioning Agent

(CxC) General

• Coordinates and directs the commissioning activities in a logical, se-quential and efficient manner using consistent protocols and forms, centralized documentation, clear and regular communications and consultations with all necessary parties, frequently updated timelines and schedules and technical expertise.

• Develops and maintains/updates the Cx Plan throughout the design and construction process.

• Provides and maintains the Web-enabled Cx database.

Design Phase

• Review and comment on design documents to ensure commissioning activities are accommodated.

• Review and comment on Basis of Design (BoD) Project Requirements documents (PRD) to ensure that the design is meeting the intent of the PRD.

• Develops Commissioning Specifications for bid and provide to A-E for inclusion in the total design package.

• Update Cx plan with design specific information and submit to EPM and A-E for review.

Construction Phase

• Conducts initial Cx kick-off meeting and coordinates commissioning status meetings, which shall occur monthly or as needed up until the time on-site functional testing begins (at which time meetings may occur more often, as necessary.

• Shall make recommendations to CC for modification of the Construction Schedule to incorporate Cx activities.

• Obtains and reviews all applicable submittals for systems to be commissioned in order to develop PFCs, STs and ISTs.

• Develops and submits PFC, ST and IST test forms for review by CC, A-E and EPM.

• Review and comment on Final Startup Reports.

• Verifies completion of PFCs by CC (or SUB).

• Reviews specific equipment tests, start up procedures, and systems submittals / shop drawings and provides feedback to A-E for coordinating responses to CC.

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• Reviews the CC integrated construction schedule to ensure commissioning tests periods and dates are accurate.

• Perform site visits, as necessary, to observe component and system installations. Report any discrepancies with the BoD and contract documents to CC, EPM, and A-E. Attend selected planning and job-site meetings to obtain information on construction progress.

Review construction meeting minutes for revisions / substitutions relating to the commissioning process. Assist in resolving any discrepancies.

• Review TAB plan and provide input in execution.

• Recommend approval of air and water systems balancing by reviewing completed reports and by selected site observation.

• Maintains Issues Log based on field and testing observations.

• Coordinates testing observation by client and submits suggestions to Owner for resolution of conflicts relating to Cx activities.

• Reviews O&M manual for completeness and ensures changes made during the course of the project, as a result of the Cx process, are incorporated.

• Reviews CC provided training plan and verifies training is scheduled and completed by CC

(or SUB) prior to facility turnover.

• Reviews results of third party testing agencies.

• Directs and executes ST's and IST's with the support of CC (or SUB)

Occupancy & Operations Phase

• Provides final commissioning report

• Carry out and document any required "off season" or deferred ST and ISTs

• Revise commissioning report after "off season" ST and ISTs as needed

Cx TEAM MEMBER RESPONSIBILITY Contractor’s Representatives

(GC, QC)

General

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

• Ensure that all subcontractors and vendors execute their commissioning responsibilities according to the contract documents.

• Update/maintain project schedule to accommodate commissioning activities.

• Provide access means (lifts, ladders, etc.) to support commissioning activities.

• Coordinates with LEED® Consultant and subcontractors to accommodate project LEED® certification process.

Construction Phase

• Attend the commissioning kickoff meeting and all commissioning team meetings.

Coordinate attendance of SUBs.

• Integrates Cx activities into construction schedule.

• Provides CxC with submittals pertinent to the development and execution of PFCs, STs and ISTs.

• Develops start-up plans and incorporates into construction schedule, keeping CxC informed of any changes.

• Performs and documents equipment start-ups. Rectifies any system or equipment deficiencies found during system start-up.

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• Submits completed, signed, and dated start-up reports to CxC.

• Review and sign-off on Final Start-up Reports.

• Reviews the final PFCs, STs, and ISTs for safety concerns, equipment and warranty protection, and general comments prior to their execution. Submits review comments to CxC.

• Responsible for all subcontractors completing PFCs prior to the execution of ST and ISTs.

• Coordinates TAB agency in completion and documentation of test and balance work.

Submits TAB report to CxC for review.

• Clearly identifies any outstanding issues with associated piece of equipment or system prior to scheduling ST's or IST's.

• Support the CxC in resolution of issues recorded in the Issues Log.

• Submit training plan and coordinate the SUBs to provide the training of owner personnel as required by the contract documents.

• Coordinate the submission of the Operation and Maintenance Manuals, according to the contract documents, including clarifying and updating the original sequences of operation to as-built/as-tested conditions.

• Produce final as-built drawings and specifications.

• Coordinates SUBs in execution of and witnesses ST and ISTs.

• Provide utilities and testing equipment necessary to complete associated STs and ISTs.

Occupancy & Operations Phase

• Carry out / coordinate O&M staff training for effective, on-going operations and maintenance of all systems.

Cx TEAM MEMBER RESPONSIBILITY

Sub-Contractor’s Representatives

(MC, EC, TAB, CC, SC)

General

• Sub-Contractors representatives shall be designated for all critical Sub- Contractors associated with the commissioning process. This will include but not be limited to;

representatives from Mechanical, Electrical, TAB, Controls/BMS, and any manufacturer/vendor subcontractors. These team members shall be identified in the Cx Plan.

• Attend the commissioning kick-off meeting and selected commissioning team meetings as required.

• Provide utilities and testing equipment necessary to complete associated PFC’s, ST’s and IST’s.

• Provide access means (lifts, ladders, etc.) to support commissioning activities.

• Develops start-up plans and incorporates into Contractors construction schedule, keeping

CxC informed of any changes.

• The Sub-Contractor verifies that all associated installation and pre-functional checks as well as start-up have been completed by qualified factory trained representatives.

• Submits completed, signed, and dated start-up reports to Contractor and CxC.

• Clearly identifies any outstanding issues with associated piece of equipment or system prior to scheduling PFC’s, ST’s and IST’s.

• Reviews the final PFC’s, ST’s and IST’s for safety concerns, equipment and warranty protection, and general comments prior to their execution. Submits review comments.

• Supports, witnesses and signs off on respective PFC’s, ST’s and IST’s.

• Rectifies any system or equipment deficiencies found during system start-up or other commissioning testing.

• Support the CxC in resolution of issues recorded in the Issues Log

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• Provides training for Principals personnel as required per contract documents.

• The EDS Sub-Contractor shall provide BI Factory Acceptance Testing to validate performance Cx TEAM MEMBER RESPONSIBILITY

Design Representatives (A, E)

General

• Coordinates with LEED® Consultant to accommodate project LEED® certification process.

Design Phase

• Incorporate Cx specification sections prepared by the CxC in the total construction document package.

• Review Cx Plan.

Construction Phase

• Attend the commissioning kickoff meeting and selected commissioning team meetings as needed.

• Review contractor submittals for compliance with contract documents.

• Support CC submittal review for commissioning issues.

• Review, and approve the O&M manuals.

• Attend commissioning specific pre-construction, planning, and coordination meetings as necessary.

• Provide construction punch-lists.

• Review and comment on test and balance documentation.

• Review contractor's as-built documents for completeness and accuracy.

• Provide clarifications on any design narrative and sequences documentation requested by the CxC. The designers shall assist (along with the contractors) in clarifying the operation and control of commissioned equipment in areas where the specifications, control drawings or equipment documentation is not sufficient for writing detailed testing procedures.

• Resolve Issue Log deficiencies associated with design items.

• Provide feedback and review of PFCs, ST's and IST documentation.

• Witness testing of selected pieces of equipment and systems.

Cx TEAM MEMBER RESPONSIBILITY Owner’s Representatives

(CO, EPM, RPR, BSO, FE)

General

• Facilitate the coordination of the commissioning work by the CxC, and, with the CC and

CxC, ensure that commissioning activities are being incorporated into the master schedule.

• Develop and maintain the Project Requirements document (PRD) throughout the design and construction process.

• Assign operation and maintenance personnel and schedule them to participate in commissioning team activities.

• Review and approve the final Cx Plan.

Design Phase

• Provide the PRD documentation to the CxC and Contractor for information and use.

• Provide the BoD document, prepared by the A-E and approved by owner, to the CxC for use in developing the commissioning plan, PFCs, STs, and ISTs.

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• Coordinate the resolution of non-compliance and design deficiencies identified in all phases of commissioning.

Construction Phase

• Attend Cx meetings and approve/reject results of Cx efforts as required to ensure optimal performance of systems as per Owner's requirements and contract documents.

• Perform the normal review of contractor submittals.

• Reviews initial and final PFCs, STs and ISTs. Provides approval and direction to move forward with Cx activities.

• Support the CxC in resolution of issues recorded in the Issues Log

• Engage owner's personnel in witnessing of installation verification, system and integrated system testing. The owner's personnel shall be designated by the EPM for the specific Cx activities as deemed necessary. They shall include but not be limited to representatives from Facilities Maintenance Staff, Environmental Health and Safety Staff, BioSafety Staff, etc.

Occupancy & Operations Phase

• Assist the CC in coordinating the training of owner personnel.

• Provide final acceptance of PFCs, STs and ISTs.

• Provide final acceptance of equipment, systems and ultimately the project.

• Assist the CxC as necessary in the seasonal or deferred testing and deficiency corrections required by the specifications..

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4.6 COMMUNICATION AND INTERFACE

The lines of communication are critical to the effectiveness of the Cx process. The roles of each Cx team member and the lines of communication between the Cx groups are illustrated below.

COMMISSIONING LINES OF COMMUNICATION

DIRECT

• Direct Cx communication of reports, schedules, checklists, test forms, issues log, action items, etc.

INDIRECT

• Indirect Cx communication of reports, schedules, checklists, test forms, issues log, action items, etc.

• CxC shall copy all involved parties on activities impacting their involvement on any issues arising during the Cx process.

Note: all formal direction to proceed with work or repairs must come from the Owner Group.

GC and QC

A and E

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5. COMMISSIONING SCOPE, PROCESS, AND DELIVERABLES

5.1 CX SCOPE OF WORK OVERVIEW

The commissioning scope of the KBUSLIRL is detailed in the following specification sections:

• 01 91 00 – Commissioning Requirements.

• 11 08 00 - Commissioning of Equipment

• 22 08 00 - Commissioning of Plumbing Systems

• 23 08 00 - Commissioning of HVAC Systems

• 26 72 00 - Commissioning of Electrical Systems

• 28 08 00 - Commissioning of Access Control Systems

Additional details of the Cx scope and activities are broken out by Cx Phase in the sections below.

5.1.1 CxC Deliverables

All CxC deliverables will be submitted via electronic format only and uploaded to the web-based Cx Management System.

5.1.2 Cx Issues Log

The CxC shall maintain an Issues Log that tracks all Cx related issues, responsible parties, action dates and the issue’s final resolutions. The issues log is meant to track Cx issues and not be a punch list for installation deficiencies. Contractor, Design Group and Owners group punch lists will be maintained separately from the Cx Issues Log. When an issue it assigned to a member of the Cx Team, that individual shall be responsible for providing an appropriate response (e.g. indicating resolution, clarification, or disagreement) within the web-based Cx Management System. The CxC will review responses and close out or reassign issues as appropriate.

5.1.3 Deficiencies & Non-Conformance

The Contractor (or assigned subcontractor / vendor) shall address all deficiencies noted in the Cx Issues Log and provided an appropriate response to each issue in a timely manner (typically within one week). Corrections of minor issues identified may be made during functional testing at the discretion of the CxC with the issue and resolution documented in the ST/IST forms or Cx Issues Log as appropriate.

Every effort will be made to expedite the testing process and minimize unnecessary delays, while not compromising the integrity of the procedures; however, the CxC will not be pressured into overlooking deficient work or loosening acceptance criteria to satisfy scheduling or cost issues without a written directive from the CO. Retests or aborted tests that result from a lack of due diligence by the Contractor (or associated subcontractor / vendor) prior to testing may result in back charges to the Contractor and delays in the Cx Process.

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5.2 CX PHASES / TASKS OVERVIEW

Commissioning is conducted in concert with activities performed during the stages of project delivery. Cx starts in Planning and Design stages to minimize issues during Construction in order ensure the built facility is constructed and proven to operate optimally under weather, environmental and occupancy conditions to meet functional and operational requirements. Cx activities includes transfer of critical knowledge to facility operational personnel.

Based on ASHRAE Guideline 0 “The Commissioning Process” (2005), the commission process can be divided into four distinct phases:

• Pre-Design Phase

• Design Phase

• Construction Phase

• Occupancy & Operations Phase

The USDA-ARS plans to employ a design-build (D-B) project execution mechanism to complete the KBUSLIRL campus modernization project. While Cx activities are typically divided into these four phases, the nature of the D-B project execution will require that many of the activities, especially during the Design and Construction phases, will need to be completed concurrently. For the purpose of this Cx Plan, Cx activities will still be associated with the specific phases as established below.

The following lists the typical tasks completed during each phase of the commissioning process; the general order in which they occur; and expected Cx deliverables for each phase:

5.2.1 Pre-Design Phase

The Pre-Design phase is a preparatory phase in which information about the project is gathered by the CxC to start the Cx process. During this phase the Owner’s requirements for the project are developed and defined. Activities associated with this phase are as follows:

• Establish the Cx Team: Representatives of the commissioning and owner’s group have been documented in Section 4 of this Cx Plan. Representatives for the contractor group (including designers and subcontractors) will be identified once the D-B team is selected.

• Document Owner’s Project Requirements: Owner requirements have been documented in the Program of Requirements (POR) document last updated in October 2015. The CxC will review this document to identify any information that is missing and confirm with the Owner that these requirements are still applicable.

• Define Cx Scope and Budget: Based on the Owner’s project requirements as defined in the POR document, the CxC will propose a scope and associated budget for Owner review and approval.

• Develop Initial Cx Plan: This initial version of the Cx Plan has been developed by the CxC with information known at the time. The Cx Plan is meant to be dynamic and will be updated with information as it becomes available. Updates to the Cx Plan will be submitted at the end of each Cx phase.

Commissioning deliverables to be submitted under the Pre-Design Phase are listed in the table below.

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PRE-DESIGN PHASE DELIVERABLES

DELIVERABLE SUBMITTAL DATE

Initial Cx Plan 04/01/2020

5.2.2 Design Phase

During the Design Phase of the project delivery process, the owner’s project requirements are translated into construction documents. Cx activities associated with this phase are as follows:

• Design Document Reviews: The CxC will review and provide written comments on design documents as provided by the design build team. The CxC review of the design documents will focus on compliance with the owner goals and requirements detailed in the POR document; on the adequacy of O&M personnel training; documentation and for issues that could negatively impact the Cx process. CxC comments, responses and final disposition will be maintained on a web-based Cx management software for access by members of the Cx team, including the owner, and design build team. These comments will be submitted to the Owner Group in an agreed upon format. Merrick will participate in an onsite design review meeting after each round of review to discuss the comments with the design team.

• Review Design Intent Document (DID): The CxC will review the design team’s submitted DID for compliance with the intent of the Bridging Documents

Commissioning deliverables to be submitted under the Design Phase are listed in the table below.

DESIGN PHASE DELIVERABLES

DELIVERABLE SUBMITTAL DATE

5.2.3 Construction Phase

During the Construction phase of the project delivery process, systems and assemblies are installed, inspected, tested and placed into service in accordance with the contract construction documents. Cx activities associated with this phase are as follows:

• Cx Kick-off Meeting: The CxC will lead a Cx kick-off meeting at the project site for the Cx Team. The intent of the meeting will be to provide an overview of the Cx process (including testing procedures for containment labs, “lessons learned”, schedules, sequences of testing events, quality control, constructability, and acceptance requirements). At this meeting, the CxC will provide the Cx Team with instructions for accessing/utilizing the web-based Cx management

Page | 17 software and discuss Cx team roles and responsibilities in executing the Cx process. The CxC will provide a written agenda, presentation slides, and meeting minutes prior to the meeting.

• Cx Schedule Integration: The CxC will work with the Contractor during the early development of the construction schedule to properly integrate Cx tasks (such as PFC completion, ST & IST execution) and pre-requisite contractor responsibilities (such as start-up / performance testing, BMS controls I/O verification, TAB) into the overall project schedule. In general, system/equipment start-ups shall not be scheduled prior to Pre-Functional Checklist /Installation Verifications (PFC’s) being complete. System Tests (STs), and Integrated System Tests (ISTs) shall not be scheduled until PFCs are fully complete and equipment is fully started, tested, and checked out by the associated sub- contractor.

Refer to Appendix F – Cx Schedule Integration for more details.

The CxC will then review and comment (if necessary) on regular construction schedule updates submitted by the contract as it relates to the progress of the Cx process.

• Review Construction Submittals: The CxC will review and provide comment on contractor submittals that are pertinent to the systems being commissioned. Once the contractor submittal register is available, the CxC will identify the applicable submittals. The CxC will return submittals with comments within 7 days of receipt.

• Conduct regular Cx Status meetings: Additional meetings will be required throughout construction, facilitated by the CxC with the Contractor, Owner and with all necessary parties attending, to coordinate, schedule future activities and resolve issues. Meeting minutes, including the latest Cx Issues Log will be maintained and updated at the commissioning meetings. Cx meetings will be held on an as needed basis – initially every other month, then monthly, and weekly frequency as required.

• Witness Sample Contractor Start-ups & Testing: Forms for start-up and field testing of commissioned systems will be developed by the contractor (or a designated sub-contractor) and reviewed / approved by the CxC. Once approved, the contractor/sub-contractor shall execute the start-up / field testing in accordance with the approved forms and document the results. Any deficiencies or issues of non-compliance with the contract documents shall be resolved and retested by the contractor prior to Cx functional testing.

The CxC will be on site to witness the startup / performance testing of major equipment to determine system readiness for Cx functional testing. The contractor shall provide at least 2 weeks notification to the Cx Team prior to starting up major equipment or systems. The CxC will follow-up the witnessed contractor start-up / testing with a field observation report.

• Develop PFC/ST/IST Form Templates: The CxC will develop PFC, ST & IST template forms for each type of component, equipment and system associated with the systems to be commissioned on this project. These forms will be submitted for review / comment by all relevant stakeholders of the Cx Team (contractor, owner and design groups). Comments shall be compiled for each group and returned to the CxC within 30 days of submittal. The CxC will respond to comments received; integrate agreed changes and resubmit the template forms for final approval / record. Once approved by the owner group, these templates will be associated with specific equipment, component or systems to generate the actual forms that will be used in the field.

• Check contractor completion of PFC prior to ST/IST: Once the approved PFC forms have been associated with specific components and equipment, the Contractor (or designated sub-contractor) shall complete the forms using Cx Alloy, the web-based Cx management system. Prior to beginning Cx functional testing (ST or IST) the CxC will check the PFCs for completeness and spot check for accuracy. Any deficiencies or issues of non-compliance with the contract documents will be documented by the CxC in the Cx Issues log, assigned to the responsible Cx Team member and tracked to resolution.

• Direct and document the results of ST/IST execution: Upon completion the associated equipment PFC forms by the contractor and successful start-up / field testing, the Contractor shall schedule a System Readiness Check meeting with the CxC to discuss the status of pre-requisite activities prior to Cx functional testing. Once system readiness is

Page | 18 confirmed, the contractor shall provide at least 2 weeks notification to the Cx Team of the upcoming functional testing

(ST/IST).

The CxC will direct the Contractor (or designated subcontractor) in the execution of Cx functional testing in accordance with the approved ST/IST forms and document the results. Any deficiencies or issues of non-compliance with the contract documents will be documented by the CxC in the Cx Issues log, assigned to the responsible Cx Team member and tracked to resolution.

• Review Training Plan, Outline and Content: The CxC will review and provide written comments on the Contractor-submitted training plan, outline and content prior to scheduled training for commissioned systems. CxC comments will be maintain on the web-based Cx software for contractor response and tracked to resolution.

• Review O&M Data: The CxC will review and provide written comments on the Contractor-submitted O&M Data for commissioned systems. The CxC will review the O&M data packages for completeness and applicability. CxC comments will be documented in the web-based Cx software and communicated to the Contracting Officer.

• Update Cx Plan: The Cx Plan will be updated by the CxC based on information available at the end of this phase and submit to the Cx Team for review.

Commissioning deliverables to be submitted under the Construction Phase are listed in the table below.

CONSTRUCTION PHASE DELIVERABLES

DELIVERABLE SUBMITTAL DATE

Kick-off Meeting Agenda and Minutes Construction schedule comments (if necessary) Monthly during construction Submittal Review Comments for commissioned systems On-going Field Observation Reports On-going PFC / ST / IST form templates “Ready for Execution” PFC / ST / IST forms (after Owner approval) Final PFC / ST / IST forms (after testing is complete) Training Plan, Outline, & Content Review Comments (for commissioned systems) O&M Data Review Comments (for commissioned systems) Cx Issues Log Updated Cx Plan

5.2.4 Occupancy & Operations Phase

The Occupancy & Operations phase of the Cx process begins at substantial completion and continues through the end of the warranty period (1 year). Cx activities associated with this phase are as follows:

• Final Cx Report / Documentation: The CxC will compile a Final Cx Report that encompasses all data and results collected during the Cx process. This Cx report will include an executive summary of testing results, field observation reports, meeting minutes, completed PFC forms, completed ST & IST forms, trend data, and a complete Cx Issues Log (including resolutions made). A draft Cx Report will be submitted for one round of review/comment by the Cx Team

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(owner, design build team). Merrick will provide written responses to comments while integrating them into the Final Cx Report which will be provided to the owner electronically.

• Deferred Seasonal Testing: The CxC will direct the Contractor (or designated subcontractor) in the execution of any ST / IST functional testing that was deferred in order to achieve adequate weather conditions for demonstration. Any deficiencies or issues of non-compliance with the contract documents will be documented by the CxC in the Cx Issues log, assigned to the responsible Cx Team member and tracked to resolution. At the time of deferred seasonal testing, the CxC will also confirm resolution of and close-out any outstanding issues remaining.

• Warranty Review: Approximately 10 months after substantial completion of each facility, the CxC will perform a warranty review of the commissioned systems. This will entail meeting with the facility O&M and user staff to document their feedback on the performance of the systems over the first 10 months of occupancy. Occupant surveys will be gathered at this time. Information gathered along with any issues noted and recommendations will be compiled in a field observation report and provided for inclusion in the Final Cx Report.

Commissioning deliverables to be submitted under the Occupancy & Operations Phase are listed in the table below.

OCCUPANCY & OPERATIONS PHASE DELIVERABLES

DELIVERABLE SUBMITTAL DATE

Final Cx Report Field Observation Reports Updated ST / IST forms after completion of deferred / seasonal testing Warranty review report

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5.3 PRE-FUNCTIONAL AND FUNCTIONAL TESTING PROCESS

The pre-functional and functional testing process is designed specifically for this project to confirm and document that the installation and performance of commissioned systems is in accordance with the contract documentation. For an efficient execution, this process is performed in conjunction with the contractor’s startup, testing and quality control processes.

5.3.1 Cx Form Development, Review and Approval

Pre-functional Checklist (PFC), System Test (ST) and Integrated System Test (IST) forms are developed by the CxC for use during the pre-functional and functional testing process. Through a series of checklists and test procedures, it is intended to confirm complete installation, functionality and performance of the individual components as well as the integrated systems are in accordance with the contract documents, approved submittals and the owner’s requirements. Forms developed will be specific to the systems commissioned for this project.

The PFC, ST & IST form development process will incorporate one round of review and comment by the Cx team, including the owner, general contractor, subcontractors, and vendors (where applicable). This review period will last approximately 2 weeks. It is recommended that the Cx team use this review period to provide input and comment on any concerns with the proposed test methods. During their review, the contractors and vendors should indicate whether any of the proposed test methods cause concern for damage to equipment; may cause an unsafe environment or whether the indicated acceptance criteria meets their understanding of system performance.

For the Draft PFC, ST and IST submittal, template forms will be developed and submitted by the CxC. These templates will be representative forms for each type of equipment. For instance, one PFC form will be developed for a base-mounted, end-suction pump that will be used for all chilled water and heating hot water pumps. Once the template PFC form is finalized and accepted, each pump will have its own PFC form based on the approved template.

Comments received from the Draft form submittal will be collected by the CxC and responses issued. Where necessary, the CxC may initiate additional discussions to get clarification on comments made. Changes made as a result of the Draft review will be incorporated into the PFC, ST & ST forms accordingly, and the Final (ready for testing) forms will be issued by the CxC. Final PFC, ST & IST forms will be uploaded to QuiCx (the web-based Cx management tool) for reference by the Cx Team.

5.3.2 Completion of PFC Forms

PFC forms that are ready for completion will be maintained in QuiCx for access by the Cx Team. Each PFC is divided into three main sections: Nameplate Data, Inspection Items and Sign-off.

The Nameplate Data section typically captures key identifying features (such as Manufacturer, Model, Size, HP, Volts/Phase/Hz, etc) and is intended to confirm consistency (or note any discrepancies) between what was specified, what was submitted and what was installed.

The Inspection Items section is intended to confirm that final installation is complete; complies with the contract documents and approved submittals; and is ready for functional testing. Checklist items in this section typically fall into the following categories (where applicable). Each of these categories will be assigned to the Responsible Contractor for completion:

• General Installation and Cleanliness

• Equipment Mounting and Supports

• Equipment-specific Inspections (e.g. fans, coils, filters, etc.)

• Piping & Valve Inspections

• Ductwork Inspections

• Electrical Inspections

• Controls Inspections

PFCs will be completed using the QuiCx web-based Cx management tool (Refer to Section 6 of this plan for more information).

All sections are to be completed first by the installing contractor, then by the QC manager and then back-checked for completion

Page | 21 by the CxC – each has a column of checkboxes. Any discrepancies and clarifications shall be noted appropriately in the PFC. Any items deemed as not applicable shall be noted with an “N/A”, a note indicating the reason shall be entered and the check box checked. At completion of the PFC, all checkboxes shall be checked.

Once they have completed all sections, the installing contractor and the QC manager shall complete the Sign-off section of the PFC indicating that the PFC form has been completed in its entirety. At this time, the CxC will backcheck the PFC form to confirm completion by the installing contractor and the QC manager. In the field and just prior to beginning functional testing of a system, the CxC will spot check the installation and sign off on PFCs for equipment installations deemed acceptable and ready for functional testing. Any items in the PFC found by the CxC to be incomplete in the field and checked off by the installing contractor and/or the QC manager will be documented and tracked in the Cx Issues Log and functional testing will be postponed.

PFC form completion (as a percentage of total checkboxes / PFC) and sign-off will be tracked in QuiCx and reported regularly to the Cx Team by the CxC. All applicable PFCs must be complete and signed off by the installing contractor, QC manager and CxC prior to beginning functional testing (ST & IST) of any system.

5.3.2 Contractor Pre-requisite Startup & Testing

Prior to functional testing of any system (ST & IST), the contractor must complete all prerequisite verification (including PFCs) startup and…