No Interruptions: Commissioning Measures in Preventing ...

By Ryan S. Lean and Phil Karnicki

No Interruptions: Commissioning Measures in Preventing Unplanned Downtime

AIA Quality Assurance

The Building Commissioning Association is a Registered Provider with The American Institute of Architects Continuing Education Systems (AIA/CES). Credit(s) earned on completion of this program will be reported to AIA/CES for AIA members. Certificates of the Completion for both AIA members and non-AIA members are available upon request.

This program is registered with AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.

Questions related to specific materials, methods, and services will be addressed at the conclusion of this presentation.

BCxA Annual Conference – Chicagoland, IL – September 2019 2

Learning Objectives


1. Understand the importance of systematic planning at each stage to minimize unforeseen risks.

2. Identify and plan around risks associated with critical testing procedures.3. Understand the challenges associated with each trade and the impacts

they have on each other. 4. Leave with a greater appreciation of how difficult it is to bring new

systems online in a critical environment.


Chapter 1: OverviewWhy Does It Matter?

New Construction Commissioning Overview


STRManufacturer’s Start-Up

BMSBMS Programming

TABHVAC Testing, Adjusting and Balancing

FPTFunctional Performance Test

ISTIntegrated Systems Test

FATFactory Acceptance Testing

PFPCPre-Functional Performance Checklist

Cx Design ReviewCx Submittal Review

Systems Manual Training VerificationWarranty Review

• Typical apartment/hotel room units (PTAC, FCU, HP)

• Standard chiller plant or condenser water system

• Steam or hot water boiler plants• Standard fire alarm and fire pump

(wet sprinkler)• Service switchgear and distribution

panels• Life safety emergency generator

Residential/Hospitality Commissioning Projects


CR

ITIC

AL M

ETER

HIGH

LOW

• Typical terminal units for open office (VAV, FPB)

• Air handling system solution• Chiller plant or condenser water

system (if core and shell)• Packaged air conditioning units

(electric closets, etc.)• Steam or hot water boiler plants• Fire pump and fire tanks• Service switchgear and distribution

panels• Emergency generator serving LS and

emergency loads

Commercial Office Commissioning Projects


CR

ITIC

AL M

ETER

HIGH

LOW

Cultural Commissioning Projects


• Custom solution for open galleries (VAV, FPB)

• Air handling system solution with humidity control

• Chiller plant • Steam or hot water boiler plants• Fire pump and dry/gas fire

protection systems• Service switchgear and

distribution panels• Emergency generator serving

LS and emergency loads

CR

ITIC

AL M

ETER

HIGH

LOW

Critical Facility Commissioning Projects


• Redundancy across all systems• Air handling units for ventilation for trading• Packaged A/C units for data centers

(CRAC, CRAH)• Chiller plant (air and water cooled)• Electrical heating (for data centers with low

office reqs.)• Fire pump and dry/gas fire protection

systems• Service switchgear and distribution panels• Emergency generator serving LS and

emergency loads• UPS for data center

CR

ITIC

AL M

ETER

HIGH

LOW

Critical Facility Commissioning Overview



BMSBMS Programming











BMSBMS Programming








MOP’s:Call everyone!




BMSBMS Programming









PFPC, STR, BMS and FPT all

on same day




BMSBMS Programming








Night and

weekend testing



on same day




BMSBMS Programming








Night and

weekend testing


IST in phases as equipment comes online


on same day




BMSBMS Programming








Night and

weekend testing



Turnover immediate

(no deficiencies)


on same day




BMSBMS Programming








Night and

weekend testing



Turnover immediate

(no deficiencies)


on same dayTesting in isolation prior to swingover



• Commissioning is controlled chaos Critical nature of Data Center testing

requires attention Clear processes drive:

◦ Reduced stress ◦ Reduced confusion◦ Increased awareness

Practice, practice, practice (rehearsal)

Critical Facility Overview


• What is a data center?• Needs Power Cooling Security

• Requirements SLA’s (service level agreements) Contracts MOPs, SOPs, EOPs, etc.

Critical Facility Cx Flow Process


• Factory Acceptance Testing (FAT) Imperative to have both operating engineers and owner at FAT.

• Start-Up (STR) critically important.• Integrated Systems Test (IST) Scripts to be specific and updated (based on current technologies) Imperative for Client to review prior to testing



• Method of Procedure (MOP)



• Method of Procedure (MOP) Determine very early which entity owns MOP development.

Something to be determined in the Cx contract. Most existing data centers have developed their own MOPs for

existing equipment maintenance. CxP to provide and offer input on Cx process with a focus on that

specific facilities requirements. Help to manage RISK:

◦ Procedures change risk level (lose redundancy, add single points of failure).



• HVAC Equipment Air handling units for ventilation for trading Packaged A/C units for data centers (CRAC, CRAH) Chiller plant (air and water cooled) Hot water plants (only for office/trading component) Electrical heating (for data centers with low office reqs.)



• Electrical Equipment Service/distribution switchgear Emergency generators Uninterruptible power supply (UPS) Static transfer switches (STS) Power distribution units (PDU) Automatic transfer switches (ATS) Lighting and lighting controls



• Plumbing Equipment Hot water heaters

• Fire Protection Equipment Fire pump Preaction systems Dry pipe systems Nitrogen systems VESDA



• Low Voltage Systems Building management system (BMS) Security SCADA



• Simulate your IST conditions



• Integrated System Testing (IST) Must simulate the conditions (load test). Account for proper logistics (e.g.; where to put load banks). Test the electrical with the HVAC (i.e.; Room Verification Test). Use rack mounted load banks if available.


Chapter 2: Specific Challenges

Working with Existing Systems

29

Critical Facility Commissioning in Existing BuildingsHVAC



CRACs/CRAHs and chiller plants to be tied into existing systems.

Data center clients must be protected from any type of outage (e.g.; CHW plant goes

down due to inadvertent alarm).

Challenges






Have MovinCool ready in case remaining CRACs/CRAHs go down.

Challenges Potential Solutions






Have MovinCool ready in case remaining CRACs/CRAHs go down.

If redundant CHW plant, prepare valve arrangement for quick changeover. If no

redundant CHW plant, potential arrangement for roll-up ACC.




SLAs will have temperature requirements for server racks and notices to clients if the

temperatures are out of range.

Testing including ISTs and Room Verification Testing, needs to be done within specific time

frames and windows.

Challenges






frames and windows.

Establish baseline trends prior to swing over. Confirm all sensor calibration prior to

swing over.







frames and windows.

Establish baseline trends prior to swing over. Confirm all sensor calibration prior to

swing over.

Coordinate load bank requirements and logistics of placement, including all cabling

and time for setup and breakdown.




Control points to be integrated into existing BMS software.

• DP, OA, flow sensors.• Programming that selects lowest value or

an average.• Chiller plant line-ups, pump rotation, etc.

Challenges



Control points to be integrated into existing BMS software.

• DP, OA, flow sensors.• Programming that selects lowest value or

an average.• Chiller plant line-ups, pump rotation, etc.

Functionally test each unique piece of equipment prior to integration.

Confirm building standard prior to matching approved BMS submittal.




“False” alarms during swing over (cause shutdowns, maybe cascading).

Migration to corporate system (before you get locked out).

Challenges






Confirm no existing alarms on network.







Confirm no existing alarms on network.

Coordinate with corporate for date (moving target) for migration.

Finish commissioning prior to migration.



Critical Facility Commissioning in Existing BuildingsElectrical



Generators, UPS, STS, PDU, switchgear and controls tied into existing systems.

Single-ended vs. double-ended power. Power cannot be interrupted to the clients.

Challenges





Must engage client on potential testing pathways. Develop a mock control system.






Must engage client on potential testing pathways. Develop a mock control system.

Dry run testing procedures. Utilize existing transfer systems to protect downstream loads

(with client permission).




Cascading issues that could cause an upstream circuit breaker to trip open.

Upstream breakers may be supporting client loads.

Lighting controls for office spaces.

Challenges






Mitigate risk by performing dry runs and developing concrete back-out plans.







Mitigate risk by performing dry runs and developing concrete back-out plans.

Coordination to access client spaces.


Critical Facility Commissioning in Existing BuildingsPlumbing & Fire Protection


Tying into existing piping.

Challenges



Tying into existing piping.Drain down lines in order to perform work if available. Confirm flushing procedures

followed prior to tie-in.




Pre-action and dry pipe sprinkler systems over operating equipment.

Accidental discharge of gaseous systems.

False alarms during testing (evacuate an operating building).

Challenges






Provide protection under piping near operating equipment.

Take equipment offline if allowed.









Have safety provisions including egress paths open and masks ready.









Have safety provisions including egress paths open and masks ready.

Take the building offline prior to testing.


Critical Facility Commissioning in Existing BuildingsSecurity


New spaces need security to be coordinated with existing spaces.

Access to these spaces may be difficult with Client requirements.

Challenges





Engage security vendor/designer for existing spaces. Submittal coordination is critical

(existing vs. new install).




Challenges



Potential Solutions

Engage security vendor/designer for existing spaces. Submittal coordination is critical

(existing vs. new install).

Always inform clients of ongoing work and utilize processes in place in order to gain

access to spaces.

Critical Facility Commissioning in Existing BuildingsInfrastructure


Required partial or localized PTP on the newly installed equipment.

Separate systems fed by the entire infrastructure.

Challenges: Pull-The-Plug (Blackout) Testing





Confirm which transfer switches feed new systems and lock out others.

Challenges: Pull-The-Plug (Blackout) Testing Potential Solutions



Challenges: Pull-The-Plug (Blackout) Testing



Potential Solutions




Chapter 3: FinSummary and Takeaways


• Lessons Learned:

Summary


• Key take-aways: Labeling

◦ UPS Boards◦ Breaker Panels◦ EPO◦ Pull Stations◦ Etc.

Summary


• Lessons Learned:

Summary


• Key take-aways: It takes a village.

◦ Don’t go at this yourself◦ Lots of overnight testing◦ Lots of writing and rewriting the test procedures◦ Avoid fatigue – leads to errors

Summary


• Key take-aways: Owner required challenges. Service level agreement challenges. Existing building data centers more challenging than new data centers

due to potential for outage (power or cooling).

Summary


• Key take-aways: As data center launch nears, pressure increases. Coordination and communication among all parties involved in the

commissioning process is crucial. Existing building processes/standards must be followed at all points of

commissioning.

Summary

Ryan S. LeanAssociate PartnerJaros, Baum & Bolles212.530.9447 | [email protected]

67

Phil KarnickiFacilities ManagerCBRE DCS732.740.6661 | [email protected]

No Interruptions: Commissioning Measures in Preventing ...

Documents

Transcript of No Interruptions: Commissioning Measures in Preventing ...