Terminal Commissioning Case Study- Terminal A Logan International Airport ACI-NA Environmental and Operations & Technical Conference May 4, 2008 Brad Jones, PE, AP Sebesta Blomberg Sam Sleiman, PE, CCM Massport
AGENDA Commissioning What is Commissioning? Who Performs Commissioning? How to Internalize Commissioning? What are the Costs of Commissioning? Keys to Success Case Study: Terminal A Logan International Airport
Commissioning On your projects, have you ever experienced: When the project is over, have you ever felt that you did not get the building you wanted and paid for? Incomplete training of your O&M staff? Lack of quality as-built drawings and/or systems manuals? Inheriting incomplete work from your contractor, that now has to be completed by your O&M staff?
Commissioning On your projects, would you prefer: the Terminal A project has been by far the best project that was turned over to Massport to have our personnel available to visit the site, comment and to be a part in the Commissioning process was invaluable. Manager, CHP/HVAC
Boston Logan Terminal A 500,000 sf 22 Gates $500M Three Contract Packages Terminal, Tunnel, Satellite First Certified Airport Terminal
Project Highlights Developed by Delta Air Lines, turned over to Massport for operations Multiple engineers mechanical & electrical by different firms Proprietary systems fire alarm and building controls established airport systems Delta utilized third party commissioning for and to demonstrate to Massport that systems were properly functioning (Note: Massport requires meeting requirements for any development on land it owns)
Definition of Commissioning Systematic process of assuring by verification and documentation, from the design phase to a minimum of one year after construction, that all project systems function and perform interactively in accordance with the design documentation and intent, and in accordance with the owner s operational needs, including training preparation of O&M personnel.
What Is Commissioning? Deliver a Building that Works Develop an Operations Team that can keep it working Documentation Testing Training
What Is Commissioning? How does Commissioning differ from Inspections? Building Inspections Required by law and are minimum standards Construction Inspections Review of static installation Building Commissioning Proactive process that builds from installation inspections through performance checks of dynamic operation of systems
Question: Aren t I already paying for this?
Answer: 1995 Study of New Buildings 50% suffered from controls problems 40% had HVAC equipment problems 25% had malfunctioning: Energy management systems Economizers Variable speed drives 15% had missing equipment
Cx Review Question: How will large equipment be moved into and out of the penthouse mechanical room in the future there doesn t appear to be any roof access? Answer: That s a Day 2 project. Architect
Design Review Comment: The sequence of operations is general and will not provide enough information to the controls contractor. Answer: That s how we always do it. Engineer
Scheduling Question: So now that the fire alarm vendor has finished his check out, are we ready to schedule the system tests? Answer: I can get a good look at a T-bone by sticking my head up a bull s ass, but I d rather take the butcher s word for it. Electrical Contractor
The presence of an independent third party commissioning agent helped to keep design and construction teams focused on developing resolutions to construction issues that would not impact long term building operations. The easy resolution was often not the best for the long term building operation.
Commissioning Process Pre-Design Phase Design Phase Construction Phase Acceptance Phase Warranty Phase
Commissioning Process FUND. FUND.
Design Phase Cx Activities FUND. FUND. Design Intent Document ENHANCED ENHANCED FUND. FUND.
Early Construction Phase Cx milestones into the master construction schedule Keeps Cx off Critical Path Activities Review Commissionability Accessibility & maintainability Design Intent Document ENHANCED ENHANCED ENHANCED ENHANCED ENHANCED ENHANCED
Testing and Training Phase ENHANCED ENHANCED FUND. FUND. All Cx Activities Blank Test Procedures FUND. FUND.
Warranty Phase ENHANCED ENHANCED FUND. FUND. O&M Staff meeting ENHANCED Areas of concern ENHANCED wish list for system optimization Update with warranty phase activities
Who Provides Commissioning? Designers Contractors Third Party Professional Owner Design/Construction Team Operators Someone leads effort as Cx Authority, but it s a TEAM EFFORT!
What Systems are Commissioned? Factors influencing decision: Past problems? Risks of malfunction? Political implications of poor system operation? How easily will issues be identified with out Cx? How many parties involved with design & construction of the system? resolution of issues Program requirements, utility
What Systems Are Commissioned? HVAC Building Controls System Electrical Life Safety Lighting Plumbing Building Envelope Specialty Systems Selected to meet project needs,
Systems Commissioning
Streamlining the Cx Process Integration w/ Authorities Having Jurisdiction Massport Fire & Rescue Simulated Power Outage Test Smoke Evacuation Tests Fire Alarm - Check of AHU s start/stop, but not damper operation
Importance of Systems Testing Example: Tunnel Fire Alarm Testing
Importance of Systems Testing Example: Tunnel Fire Alarm Testing
Importance of Systems Testing Architect Mechanical Engineer Electrical Engineer Code Consultant Delta Owner s Rep Massport Owner s Rep Massport Facilities Massport Fire & Rescue Massport Code Consultant Construction Manager Mechanical Contractors (3) Electrical Contractors (3) Sheet Metal Subs (3) Air Balancing (3) Controls Contractor Fire Alarm Contractor
Overview of Results Short Circuit & Coordination Study Caught Incorrect Breaker Settings Minimum speed settings on VFD s and damper operation in smoke evacuation mode safety issues Conflicts between designed and installed operating sequences identified and clarified (e.g. preheat coil valves) Impact of programmed sequences at central plant Control point alarm labels clarified at central facilities identified and resolved AHU piping and clearances for coil pulls Duct work access panels Timers for sump trap primers
Owner Commissioning? How to Internalize Commissioning Needs Support at All Levels Identify Champion Build Proper Procedures Know Resources/Limitations Funding Sources Capital Planning? Operations? Ask for Help
Cost of Commissioning 0.5-1% of Total Construction Cost 2-5% of the Construction Cost of the Systems Being Commissioned Recommended not Using $/S.F. Unit Costs (too many variables in scope)
Benefits of Commissioning for Terminal A Supports Effective QC Eases Building Turn-Over Reduces Warranty Callbacks Energy Savings Persistence of Savings Occupant Acceptance Certification/Accreditation
Keys to Success Develop effective relationships with all team members Mutual respect for each team member s contribution Involve Operations Staff wherever practical Early & Diligent Scheduling Manage Expectations Facilitate a Win-Win Conclusion for All
Summary What is Commissioning? Systems-based Documentation, Testing, Training; 0.5-1% of project cost Why Commission your building? Independent party keeps focus on owner s needs When does Commissioning start? Ideally early design phase; project dependent based on needs Who Commissions the building? Whole project team; Commissioning Agent leads & facilitates What to Commission? Project dependent based on needs
QUESTIONS? Brad Jones, PE, AP bjones@sebesta.com 781-721-8319 Sam Sleiman, PE, CCM hsleiman@massport.com 617-561-1873