Mechatronics and Instrument Servicing

Management level IV

• ‘

Commissioning
Mechatronics systems

Tuesday, May 12, 2020 BY ABEJE M 1

 LO1: Plan and prepare to undertake commissioning process

• OH & S policies and procedures

• Your Company Name is committed to the goal of
providing and maintaining a healthy and safe
working environment, with a view to continuous
improvement. This goal is only achievable by
adherence to established objectives striving to
exceed all obligations under applicable legislation,
and by fostering an enthusiastic commitment to
health, safety and the environment within Your
Company Name.
Tuesday, May 12, 2020 BY ABEJE M 2
 Cont…
• In particular:

• ƒ Management, working in cooperation with the Joint

Health and Safety Committee, will strive to take all
reasonable steps to reduce workplace hazards to as low as
reasonably achievable.
• Supervisors and managers are held accountable for the
health and safety of all employees under their supervision.
This includes responsibility for applicable training and
instruction, appropriate follow up on reported health and
safety concerns, and implementation of recommended
corrective action. This accountability is integrated into
the performance appraisal system.
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 Cont…
• Supervisors, workers and visitors are expected to
perform their duties and responsibilities in a safe and
healthful manner, and are accountable for the Health
and Safety of themselves and others.
• Your Company Name is committed to providing all
necessary training and instruction to ensure that
appropriate work practices are followed on the job, and
to promote their use off the job.
• if necessary, Your Company Name will take disciplinary
action where individuals fail to work in a healthy and safe
manner, or do not comply with applicable legislation or
corporate policies and procedures.
Tuesday, May 12, 2020 BY ABEJE M 4
 Occupational Health and Safety in
Workplaces
• Duties of Workers
One of your most important responsibilities is to
protect your Health and Safety as well as that
of your co-workers. This booklet will discuss
some of your duties under the occupational
Health and Safety legislation and help you to
make your workplace safer and healthier.

Tuesday, May 12, 2020 BY ABEJE M 5

 THE law requires
• Workplaces under the jurisdiction are
governed by your provincial legislation.
• The legislation places duties on owners,
employers, workers, suppliers, the self
employed and contractors, to establish and
maintain safe and healthy working Conditions.
The legislation is administered by your
provincial legislation. Your officials are
responsible for monitoring compliance.
Tuesday, May 12, 2020 BY ABEJE M 6
 Your Responsibilities

• You must also comply with the legislation. You

have responsibilities to:
• ƒ protect your own Health and Safety and that
of your co-workers;
• ƒ not initiate or participate in the harassment
of another worker; and
• ƒ co-operate with your supervisor and anyone
else with duties under the legislation.

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 Your Rights

The legislation gives your three rights:

• ƒ The right to know the hazards at work and how to
control them;
• ƒ The right to participate in Occupational Health and
Safety
• ƒ The right to refuse work which you believe to be
unusually dangerous.
You may not be punished for using these rights. An
employer can be required to legally justify any action
taken against a worker who is active in Health and Safety.

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 Your Right To Know

• The Act requires your employer to provide you

with all the information you need to control
the hazards you face at work. For example,
chemicals at the workplace must be listed. You
are entitled to review this list. Your employer
must train you to safely handle the chemicals
you will work with.

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 Cont…
If you are inexperienced, you must receive an
orientation which includes;
• What to do in a fire or other emergency;
• ƒ First aid facilities;
• ƒ Prohibited or restricted areas;
• ƒ Workplace hazards; and
• ƒ Any other information you should know.
You must also be supervised closely by a competent
supervisor.
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 Your Right To Participate

• You have the right to become involved in

occupational Health and Safety. The legislation
encourages employers and workers to work
together to maintain a healthy and safe
workplace. Employers at workplaces with (ten
or more – consult your provincial act) workers
must set up an occupational health committee
of employer and worker representatives.

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 Committees Have Duties To:

 ƒ Regularly inspect the workplace;

 ƒ Conduct accident investigations;
 ƒ Deal with the Health and Safety concerns of
employees;
 ƒ Investigate refusals to work;
ƒ Meet at least (four times a year – consult your
provincial act); and return minutes of each
meeting to the Division
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 Commissioning procedures
• Commissioning is a “quality-oriented process for
achieving, verifying and documenting whether the
performance of a building’s systems and assemblies
meet defined
objectives and criteria.” This internationally established
definition is quite close to the definition used by ASHRAE
(the American Society of Heating, Refrigerating, and Air
Conditioning Engineers), that stipulates that
Commissioning is “ the process of ensuring that systems
are designed, installed, functionally tested and capable
of being operated and maintained to perform in
conformity with the design intent.
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 Cont…
In practice one can differentiate 4 types of commissioning
which are describe
• Initial commissioning begins during design and continues
through construction and
occupancy. It helps ensure that the performance of the
new building or major retrofit meets owner’s
expectations.
• Retro commissioning is the first time commissioning is
implemented in an existing building in which a
documented commissioning process was not previously
implemented.
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 Cont…
• Re commissioning is another type of commissioning
that occurs when a building that has already been
commissioned undergoes another commissioning
process. Most buildings experience degradation in
performance that, if left untreated, will reduce
occupant productivity and energy efficiency, often
well before comfort complaints trigger a response.
Lifetime commissioning or ongoing commissioning
is a commissioning process conducted continually for
the purposes of maintaining, improving and
optimizing the performance of building systems
initial or re/retro commissioning.
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 Cont…
• Through this process, a necessary improved coordination
between design, construction and occupancy will occur and
permit to reach financial, comfort and performance benefits,
as described here:
 Reduced life-cycle costs
in the long term, the projected life-cycle costs of buildings
and facilities will be reduced as a result of the integrated
efforts of the designer and the building operators to meet
commissioning requirements. It will contribute to reduce
construction costs while ensuring a more efficient use of
energy over the years.

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  Cost effective maintenance
• Involvement of O&M staff in commissioning, plus the
training and documentation
provided, is the basis for more effective operation,
maintenance and management throughout the life of
the facility.
 Occupant satisfaction
The primary and immediate beneficiaries of a properly
designed, constructed and commissioned facility are the
occupants. They will enjoy the advantages of living or
working in an improved indoor environmental quality
that’s comfortable and safe and in
surroundings that meet their everyday needs.
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  Quality assurance

• The Owner/Investor is assured that a quality facility

and a "surprise-free" product/environment have been
provided. There will be fewer system deficiencies at
building turnover. This will be achieved by ensuring
that:
 the Contract Documents include all commissioning
specifications,
 the requirements of these specifications will be met
 fully documented tests and inspections will prevent
minor errors from developing
into serious operational flaws. these are
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 Sequence of testing
• Static tests
• Component installation verification
• System Balancing
• System functional performance tests
• 5. Intersystem functional performance tests

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 Retesting
• Contractor shall repeat, at no additional cost to the
Owner, the complete functional test procedure for each
test in which acceptable results are not achieved and the
failed test is due to the Contractor’s action or
nonconformance to contract requirements. Repeat tests
until acceptable results are achieved. Compensate the
Owner for direct costs incurred as the result of tests
repeated to achieve acceptable results, if the
requirement for retesting is a direct result of the
Contractor’s action or non-conformance to contract
requirements.
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 COORDINATION

• Commissioning Team
A. Members of the Commissioning Team (CT) shall consist of:
a. Commissioning Agent (CA)
b. Owner’s Representative(s) (OR)
c. Design Professional (A/E)
d. Prime General Contractor (GC)
e. Prime HVAC Contractor (MC)
f. Prime Plumbing Contractor (PC)
g. Prime Electrical Contractor (EC)
h. Test and Balance Sub-Contractor (TAB)
i. Controls Sub-Contractor (CC)
j. Prime Contractor Installation Sub-Contractors
k. Equipment Suppliers and Vendors
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 B. Installation verification and start-up
documentation.
C. Functional Performance Testing.
Once the installation verification and start-up checks
have been completed and all deficiencies identified
have been corrected, a functional operational
demonstration of the equipment shall be
performed. The CA shall develop a functional
performance testing protocol and then witness
the operational testing activities as the Contractor
demonstrates the operation. The OR may elect to
also witness activities on a case-by-case basis.
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 D. Training.
• As specified the technical sections of this specification,
Prime Contractors are responsible for coordinating and
providing training to the building operators. The CA shall
work with the Owner’s Facility Management Department
to define the areas of focus for the training and develop
the training plan. It shall be the Prime Contractors’
responsibility to prepare the training sessions in
accordance with the training plan and execute the
training sessions utilizing qualified and experienced
instructors and in accordance with the training plan.

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 E. Meetings.
• Participate in regularly scheduled
commissioning meetings. In order to
coordinate the commissioning activities, the
CA shall conduct regular commissioning
meetings. These would typically follow a
project progress meeting.

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 F. Management:
• The Owner shall provide the services of the
CA. The CA directs and coordinates
commissioning activities and reports to OR. All
members of the Commissioning Team work
together to fulfill contracted responsibilities
and objectives of the Contract Documents.

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 G. Scheduling:
• 1. In cooperation with the CA, the Prime Contractors
shall integrate commissioning activities into the master
construction schedule. This integration of commissioning
activities, in general terms, shall be developed early in
the project and then refined as the project progresses.
2. Scheduling issues shall be resolved at monthly
commissioning meetings. The CA shall provide an initial
schedule of primary commissioning events at the
commissioning kick-off meeting. As construction
progresses, more specific activities and milestones shall
be incorporated into the master construction schedule.

Tuesday, May 12, 2020 BY ABEJE M 26

 Cont…
• 3. There shall be at least one commissioning
scheduling meeting for all commissioning team
members to integrate key commissioning activities
(i.e. equipment start-ups and functional testing) with
critical construction milestones. Participants shall
include both the Contractor Project Managers and the
key on-site representatives. This meeting typically
occurs about two months prior to equipment start-
ups and can take up to a day.

Tuesday, May 12, 2020 BY ABEJE M 27

 Cont…
• 4. Prime Contractors shall provide written timely notice
to OR of any changes in date, time, location or
anticipated duration of start-up and test activities. For
the purpose of this paragraph written notice shall be
received by OR a minimum of 72 hours in advance to be
considered timely. Prime Contractor shall reimburse
Owner for actual costs incurred
by the Owner as the result of failure to provide timely
notice, per preceding paragraph, of changes in date,
time, location, or anticipated duration of start-up and
test activities.
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 FUNCTIONAL PERFORMANCE TESTING
• the objective of Functional Performance Testing is to
demonstrate each system is operating according to
the A/E Basis of Design as defined in the Contract
Documents. Functional Performance Testing
facilitates bringing systems from a state of
substantial completion to full dynamic operation.
Additionally, during Functional Performance Testing,
areas of deficient
performance are identified and corrected the
improving operation and functionality of systems
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 Selection & use of proper tools & equipment

• Proper tools and equipment are essential for the effective

operation of any civil Works site. Equipping the electrical
construction site with the correct tools and equipment
plays an essential role in achieving timely and good quality
results. For every electrical construction activity there is an
optimal combination of tools, equipment and labour.
Depending on the nature and content of the works, the
technical staff needs to know which tools to use and how
to effectively combine them with manual labour. Once on
site, equipment requires trained operators and supervisory
staff who are proficient in its operation and maintenance.

Tuesday, May 12, 2020 BY ABEJE M 30

 Cont….
• Faulty equipment is a common reason for
delays on construction sites. A major
responsibility of the project management is to
ensure that tools and equipment are
maintained in a good condition and are readily
available when required for the various work
activities.

Tuesday, May 12, 2020 BY ABEJE M 31

 Quality of Tools
• Hand tools are the main instruments used by the workers to
carry out the activities involved in constructing a machine
using labour-based work methods.
• It is therefore important that project staff know how to
select and maintain the tools since they have a significant
influence on the work outputs. Hand tools are used much
more intensively on labour-based construction work than in
electrical machine. Many tools commonly used for electrical
work are not strong enough for use on construction sites
and will quickly break if used intensively. It is therefore
essential that the tools used on a electric works project are
properly designed to stand the quality wear and tear of a
construction site.
•   May 12, 2020
Tuesday, BY ABEJE M 32
 LO2: Commission Mechatronics systems

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 Check Mechatronics systems
.

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 Cont…
• Mechanical systems are increasingly integrated with
actuators, sensors and digital Electronics. For designing
Mechatronics systems the interplay for the realization
of functions in the mechanical and electronic part is
crucial. Compared to pure mechanical realizations, the
use of amplifiers and actuators with electrical auxiliary
energy has already led to considerable simplifications,
as can be seen from watches, electrical typewriters and
cameras. A further considerable simplification in the
mechanics resulted from introducing microcomputers
in connection with decentralized electrical drives, e.g.,
for electronic typewriters, sewing machines, multi-axis
handling
Tuesday, May 12, 2020 systems and automatic
BY ABEJE M gears. 35
 Cont…
The mechanical–electronic system can be
considered as consisting of a feed forward
energy flow and a feedback information flow.
Presently a development is taking place to
integrate the mechanical systems, the
actuators, sensors and microelectronics,
forming an inseparable overall system

Tuesday, May 12, 2020 BY ABEJE M 36

 Cont…

Tuesday, May 12, 2020 BY ABEJE M 37

 Perform Commissioning procedures

RELATED DOCUMENTS
SUMMARY
ABBREVIATIONS
COORDINATION
COMMISSIONING GENERAL PROCESS
RESPONSIBILITIES

Tuesday, May 12, 2020 BY ABEJE M 38

 LO3: Test commissioned Mechatronics systems

• Test the commissioned Mechatronics systems according

to procedures
The purpose of these tests is to ensure that all
components and systems are in a satisfactory and safe
condition before start up. Preliminary adjustment and
setting of equipment at this stage shall also be carried
out at the same time to pave way for the coming
functional performance tests.
Before carrying out any test, the Contractor shall ensure
that the installation complies with all relevant statutory
requirements and regulations. The T & C works shall
also comply with all site safety regulatory requirements.
Tuesday, May 12, 2020 BY ABEJE M 39
 Report on the commissioning process

• This brochure is intended especially for persons who play

a part in their organization in setting up and
implementing a reporting procedure and integrity policy.
This applies to public and private organizations. Integrity
professionals are involved, such as compliance and ethics
officers and integrity coordinators. But this brochure is
also useful for HRM and Legal Affairs employees,
managers and board members and members of the
works council. Employer organizations, sector
associations, umbrella and professional organizations will
also find it useful.
Tuesday, May 12, 2020 BY ABEJE M 40
 Cont…
• They are an obvious point of contact for their members
and can ‘translate’ new legislation and general
frameworks, such as this brochure, into the specific
frameworks in which their members operate.
• Employees can only claim legal protection for
disadvantage if they report an abuse in the correct
manner. Therefore, in your procedure indicate:
• where employees can report suspicions of abuses
internally;
• when they can or even should make a report
externally. If a person makes a false or deceitful report,
he or she cannot claim protection against disadvantage.
Tuesday, May 12, 2020 BY ABEJE M 41
 E
.

SAV
N D
E A
.

O M I F E
H
T U R OUL
Y A O Y
STA Y NK
A
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.

Tuesday, May 12, 2020 BY ABEJE M 42