“Addressing Challenges of International Operations During the … · 2014-07-09 · “Addressing...

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“Addressing Challenges of International Operations During the Design Phase”

WELCOME & INTRODUCTIONS


TERRY GILLICKPRESIDENT

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30 years experience in MEP-T design and commissioning Mission Critical, Pharmaceutical and Healthcare Member, Buildings Commissioning Association (BCA) Member, 7X24 Exchange Member, American Society for Industrial Security (ASIS) Member, Building Industry Consultative Services

International (BICSI) Member, US Army Chemical School, Counter Terrorism

Contingency Training

Commissioning Approach


SUCCESSFUL GLOBAL OPERATIONS PLANNING & DEPLOYMENT


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PLAN DOMESTICALLY – DEPLOY GLOBALLYDevelop a set of complimentary and homogenous guidelines for domestic and global deployments

• IBM: Global Technology Corporation• BOA: Global Financial Institution• Facebook: Global Social Networking • United States Government: Global Facilities -

Department of State, Department of Defense

Successful Global Operations Planning & Deployment

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PLAN DOMESTICALLY – DEPLOY GLOBALLYDevelop a set of complimentary and homogenous guidelines for:

• Planning & Design• Commissioning • Operations• Audits


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Develop mission critical project implementation guidelines Define global geographic regions Adapt the guidelines to each region Encourage collaboration of all stakeholders both

domestically, and in the project geography Incorporate operations elements into all project phases


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1. Design 2. Construct3. Commission4. Transition5. Operate

The Path to Global Operations Deployment



Planning & Design


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Planning – Statement of Requirements

• Project Intent • Project Location• Space Type and Size• Reliability Level Required (Tier 1,2,3,4)• Load Density• HVAC Requirements• Electrical Requirements

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Planning – Statement of Requirements

• Building Automation System (DDC, PLC, Hybrid) • Electrical Power Management System (EPMS)• Security Requirements• Tenant Considerations (Single or Multiple)• Seismic Requirements• Elevation/Altitude Adjustments• Facility Expansion• Equipment End of Life Planning

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Design – Statement of Work

• Project Description Narrative • Basis of Design• Data Center Efficiency• Environmental / LEED Considerations• Applicable Codes and Standards• Acceptance & Testing• Commissioning

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• Network Operations Center (NOC)• Building Automation System (DDC, PLC, Hybrid)• Electrical Power Management System (EPMS)• Tenant Considerations (Single or Multiple)• Seismic Requirements• Elevation/Altitude Adjustments

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• Short Circuit & Coordination Study• Arc Flash Study• Operations Safety• Operations Requirements• Maintenance Requirements• Nomenclature • Labeling, Valve Tags and Color Coding• Security Requirements



OU

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COMMISSIONING


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Commissioning - Definition

“The commissioning process is a quality-oriented process for achieving, verifying, and documenting that the performance of facilities, systems, and assemblies meets defined objectives and criteria. The process should also validate all operations and maintenance objectives.”



COMMISSIONING DRIVERS


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Commissioning Benefits

• Validation of facility operation at maximum design loads

• 100% complete and functioning facility upon turnover

• Increased reliability in operation of the data center

• Extended useful life of components

• Unparalleled training opportunity for operators

• Improved energy savings and optimization of O&M strategies and controls

• Reduced potential for outages due to incorrectly designed or installed components

• Validation of maintenance routines and configurations

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What Commissioning Is Not

• NOT manufacturer startup and checkout

• NOT testing of systems by the design engineer(s)

• NOT testing of systems by the installing contractor(s) or construction manager

• NOT testing of systems with no pre-defined and agreed-upon acceptance criteria

• NOT testing of systems without a reviewed and accepted detailed commissioning plan and procedures

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Commissioning Guidelines

• ASHRAE (American Society of Heating, Refrigeration, and Air-Conditioning Engineers)

• AABC Commissioning Group: ACG Commissioning Guide

• BCA (Building Commissioning Association)

• LEED: (U.S Green Building Council)

• NECA (National Electrical Contractors Association)

• NETA (National Electrical Testing Association)

• ASTM International – E2813



COMMISSIONING APPROACH


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Electrical Systems to be Commissioned

Building Service Entrance Generator Switchgear and Controls (GPS) Generators UPS Modules UPS Systems UPS Batteries Stationary Battery Systems Automatic Transfer Switches Distribution Switchgear, Switchboards & Panels Power Distribution Units Remote Power Panels Emergency Power Off Systems

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Mechanical Systems to be Commissioned

Fuel Oil Storage and Delivery Systems Fuel Oil Polishing Systems Chillers (air/water cooled) Condenser Water Systems (Towers, Dry Coolers, etc.) Pumps and Pumping Systems Computer Room Air Conditioning Systems (CRACs) Computer Room Air Handler Systems (CRAHs) Make-Up Air Systems Leak Detection Systems Variable Frequency Drives (VFDs) Unitary Products (VAVs, FCUs, Unit Heaters, Exhaust) Plumbing Systems

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Automation Systems to be Commissioned

Building Management Systems (DDC, PLC, Hybrids) SCADA Systems Electrical Power Monitoring Systems (EPMS) Fire Detection / Suppression Systems DCIM Systems CMMS Systems

Commissioning vs. Testing – Project Structure

StructuralSubcontractor

Owner

A/EDesign Team

General Contractor

ConstructionManager

Cx Authority

SustainableCoordinator

MechanicalSubcontractor

Other (many)Subcontractor

ElectricalSubcontractor

Fire ProtectionSubcontractor

Elec Testing(NETA specs)

EquipmentVendors

• Trusted Adviser• Consultant role• O&M Validation

Full Life Cycle Commissioning

• Owners Project Requirements• Basis of Design (BOD)• Rigor of Cx

• Schematic Design Review, Phase DD Review

• Cx Kickoff Meeting• Cx Specification• Cx Plan (CxP) • 100% Construction

Document (CD) Review

• Cx Plan Updated• Role and

Responsibilities• Bidding Phase &

Evaluation Support

• Construction Phase Cx Kickoff Meeting

• Cx Schedule Coordination• Submittal Review • Factory Witness Testing• Site Acceptance Inspection -

Installation QA/QC • O& M Review and Coordination• Preliminary Training Plan

Review and Coordination• Final Cx Procedure

Development to include MOP/SOP

• Pre-Functional Testing & Startup

• Discrepancy Log/Corrections

• Functional Performance Testing

• Standard Operating Procedure

• Integrated Systems Testing

• Training Coordination• Close-out

Documentation• Cx Report

• Methods of procedures• Seasonal testing• 10-month warranty review• Reliability Assurance Testing• Maintenance Planning• Systems Manual

Post Occupancy Phase

Acceptance/ Occupancy

Phase

ConstructionPhase

DesignPhase

Pre-Design / Programming

Phase

Construction Phase

Integrated Systems Testing

Functional Performance Testing

Start Up Acceptance Testing

Site Arrival Inspection

Factory Acceptance Testing

COMMISSIONING LEVELS

A/E and MEP infrastructure from design through its entire operating life-cycle.

Transition To Operations



OPERATIONS & MAINTENANCE


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• Include O&M considerations in the programming phase• Organization: reporting structure & budget• O&M Staffing: in-house, outsourced, SLA, or a combination• Training Program: Day-1, new hire & recurring• O&M Programs & Processes• Facilities Management Spaces:

• Offices• Command Center• Shops• Storage

Designing for Operations & Maintainability

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Systems Operations & Maintenance Manuals should be organized by MEP system & sub-system. Include for each system:

• Descriptive Narrative• Single-Line Diagrams • Sequences-of-Operations, Set Points, Alarm

Thresholds and Safeties• BMS Points Lists • Operating Procedures (normal, maintenance &

emergency)• Approved Submittals• Spare Part Lists (including on-site inventory)• Warranties• Service Level Agreements


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Specifications should define operator training:• Instructor qualifications• Duration and times and shift coverage• Testing and/or certifications• Safety considerations (OSHA, Arc Flash, PPE)• Operating procedures (normal, maintenance,

emergency)• Equipment-Level, Systems-Level, and Integrated

Systems-Level scenarios• Maintenance procedures (inspections, preventive,

predictive, corrective, replacement, etc.)


NOTE: Commissioning affords excellent training opportunities

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Staff the facility O&M department to meet site-specific needs:1. Compile list of tasks required to O&M the site

infrastructure2. Differentiate between operations and maintenance tasks3. Develop “job descriptions” that group tasks and assess

what requisite skills and knowledge are required4. Consider what qualifications, certifications, or other

credentials are required5. Determine how critical vs. non-critical work will be

structured

O&M Staffing & Organization

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Develop position descriptions• Position descriptions describe the jobs and associated

tasks, duties and responsibilities expected for a specific staff position

• Assemble with the following considerations:• Combined O&M or separate operations from

maintenance• “Jack-of-all-trades” or trade-specific mechanical,

electrician, controls • 24x7 Coverage or Business Day + On-Call for off

hours• Decide how to staff each position - direct

employees, in-house contractors or a combination


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Develop an organization and reporting structure• Enterprise-Level Oversight• Facilities-Level organization• Critical Facilities vs. Non-Critical Facilities • Operations with Shift Coverage• Maintenance Broken Down by Trades:

• Electrical• Mechanical• Monitoring & Controls• Vendor and Contractors Support

• Administration: Procurement, Work Authorizations and Staffing


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Establish Operations Program and Processes• Work Authorization Process (routine, PM, emergency)• Event Notification & Escalation Protocols• Define Operations Key Performance Indicators • Critical vs. Non-Critical Operating Protocols

o Practice (perform dry-runs)o Double Verificationo “Mimic” boards or other real-time configuration statuso Valve and switch position status tagso Lock-Out/Tag-Out and other Safety Programs

Operations & Maintenance Processes

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• Specific to each system• Normal, maintenance configurations and emergency• Include pre-requisites

o Work authorization requirementso Safety considerations – Lock-Out /Tag-Out, PPE, o BMS and alarm lock-outso Verification of status of redundant or backup systems


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• Provide step-by-step procedure including action to be taken, expected result and means to collect resulting datao Embed digital photos of equipment, components, and

display and control panelso Annotate with “arrows” and relate to specific steps,

actions, readingso Consider using a flowchart format

• Include contingency and response if actual result does not match predicted result

• Include completion/closeout checklist to ensure all aspects of system are restored to normal operating status


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Establish Maintenance ProcessesComputerized Maintenance Management System (CMMS)

• Implementation tool for the maintenance program• Include install date, warranty duration,

lifespan/replacement date• Provides input to develop 5-year & 10-year capital

plans• Stagger work dates, include seasonal considerations

& freeze periods• Tie to maintenance procedures (daily, weekly,

monthly, quarterly)• Develop logical ID convention that facilitates

filtering, searching, and reporting


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Establish Maintenance Processes & Types of Maintenance Program

• Corrective (run to failure)• Preventive (routine based on frequency or run-hours)• Predictive (on-line condition monitoring with

thresholds; extrapolate trends to predict failures)• Vibration Analysis• Thermography and Temperature Sensors• Tribology - Lubricant Analysis• Laser Alignment• Computerized Balancing

• Create equipment histories and review routinely


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Establish Maintenance Procedures• Specific to each system and piece of equipment• Develop separate procedure for daily, weekly, monthly

and quarterly• Include pre-requisites and similar to operations

procedures• Provide step-by-step processes similar to operations

procedures• Include acceptance criteria, tolerances and settings• Include access considerations, ladder, confined space,

PPE• Include completion checklist to ensure all aspects of

system are restored to normal operating status


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Implement BIMS (Building Information Modeling System)• BIMS products are still relatively new to the industry• BIMS software uses databases to link electronic data,

records, and documents including AutoCAD drawings• BIMS can link AutoCAD “objects” to associated specs,

quantities, suppliers/vendors, submittals, warranties, inventory, ordering info, maintenance history, and almost any other electronic record

• BIMS implementation, use, and upkeep requires significant pre-planning and resource allocation


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Key Take-Aways

Begin planning of operations and maintenance during the project design

Specify operations and maintenance elements in the project bid documents

Validate the specified operations and maintenance elements during construction and commissioning

Conduct operations and maintenance training during 3rd

party commissioning

Incorporate transitional services into the project bid documents

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Key Take-Aways

Implement a rigorous operations program with measurable performance metrics

Implement a rigorous maintenance program with measurable performance metrics

Implement a continuous training program

Implement a rigorous operations audit program

Implement a rigorous MEP audit program

Questions?

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QUESTIONS?


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