Professional Documents
Culture Documents
July 1, 2008 Presented by Abbe Bjorklund, PE, LEED AP Sebesta Blomberg & Associates and Bruce Nicholson Cooperative Consulting Services, Inc.
Topics Covered
Beneficial commissioning processes Roles and responsibilities Benefits, costs and challenges of a formal startup/commissioning process Coordination and conflict between construction startup/commissioning OEM coordination issues and how to address
Beneficial Commissioning Processes from Construction through Systems Testing, Performance Testing, Environmental Testing, and Reliability Testing
Beneficial Commissioning Processes Design Purchase Install Construct Turnover to startup/commissioning Equipment checkout System testing/initial operation and system functional testing Integrated system/plant functional testing Performance testing Environmental/compliance testing Reliability/acceptance testing Turnover to the Owners/plant final acceptance
Design Phase Construction Phase Design Engineering Commissioning Agent Construction Manager GTG Vendor HRSG Vendor General Contractor Inst & Controls Electrical Contractor Mechanical Contractor Piping Contractor Construction Management Procure Install Construction Completion Construction Testing
Startup & Commissioning Support Startup & Commissioning Support Startup & Commissioning Support
Construction Construction
Construction
Construction
SU&C
CXing Agent
CONSTRUCTION ORGANIZATION
CM Mech Piping Elec I&C HRSG GTG
OWNER
Representative
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Construction Completion
Typically 20 to 30 items such as: Complete Required Data Sheets and Test Records Prepare System Completion punchlists Perform System As-Built
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Construction Testing
Typically 25 to 50 items such as: Perform Nondestructive Testing Perform Pressure Testing Verify Installation of Instruments and Controls Schedule Vendors Required for Construction Testing Alignment of Rotating Equipment Megger Cables and Equipment Verify Installation is in accordance with Design Required Equipment Maintenance Interface with Startup on Systems Ready for Turnover Assemble Initial Turnover Packages and records Perform Turnover Walkdown and Exception Lists Initial System Turnover (to SU&C)
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System Testing
Typically 10 to 20 items such as: Interface with local Utilities Lineup System for Operation Initial Energization of Power Supply Systems, Rotating Equipment Initial Run In Functional checks of Controls, Equipment & Systems
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Plant Testing
Typically 40 to 50 items such as: Perform Final HVAC Balancing Fine Tune Combustion Controls Final Tuning of Instruments, Controls, and Valves Finalize controls & tuning settings, software Execute System Functional Test Procedures Performance, Emissions, Reliability Testing
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Project Completion
Typically 20 to 40 items such as: Finalize System Turnover Packages Finalize Project Punchlist Perform Turnover Walkdowns with Owners
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Benefits
A formal program ensures that an organization with commissioning experience is put in place Formal program includes
Formal turnover process Well-documented functional performance criteria O&M documentation Operator training program
Benefits
Track deliverables
Identified early in the project Are a part of the Contract Specifications Are formally tracked
Benefits Track progress of construction and commissioning with tools developed and implemented which allow for easily tracking the overall process
Master Tracking Matrix Notification schedule Deliverables list Integrated Construction and Startup/Commissioning schedule Project punchlist System turnover exceptions lists
Costs
Turnover process may require an additional person to manage Formal documentation of testing activities
Time to develop formal test procedures, checklists and datasheets Staff hours for testing are relatively the same Additional time to formally document test data and results
Costs Any cost increase should be offset at the end of the project
System turnover packages and documentation streamlines the review and acceptance Documentation can be reviewed on a system by system basis
System boundaries are defined Each organization has same understanding of the scope of each system. Owner's representatives spot checks the progress and results
Warranty claims can be handled smoothly both during the startup/commissioning phase and after acceptance by the owners
Typically vendors will ask for test data such as:
vibration analysis, meggar records, system cleaning records, lubrication records
Challenges Proper planning early in the project with the right people
Cxing plan that clearly defines roles and responsibilities Detailed commissioning specifications which are included in the RFP All parties embrace a formal startup and commissioning program and fulfill specified roles and responsibilities
Need an Owner that fully supports a formal startup and commissioning program General Contractor develops purchase orders and equipment specifications that include requirements for startup & commissioning
Challenges Involvement of Owners operators in the startup/cxing process Initial operation of equipment and testing on a campus
Some activities are loud, some are sudden and may appear unusual. Campus events can impact the activities of the project Communicate a well thought out startup/commissioning plan and schedule to the general campus population
Detailed specifications issued with the RFP help minimize conflicts later
Detailed lists of deliverables and tracking mechanisms
Beneficial Commissioning Processes Design Purchase Install Construct Turnover to startup/commissioning Equipment checkout System testing/initial operation and system functional testing Integrated system/plant functional testing Performance testing Environmental/compliance testing Reliability/acceptance testing Turnover to the Owners/plant final acceptance
Thank you!
Questions???