Mechanical Commissioning Lead

LotusWorks is an Engineering Services provider specializing in managing Commissioning, Construction Services, Calibration, Operations & Maintenance scopes of work within global manufacturing facilities. LotusWorks operates globally across EMEA and North America partnering with the world's leading manufacturers across the Semiconductor, Pharmaceutical & Biologics, Medical Device and Data Center sectors. Our team of Engineering and Technical professionals is immersed in cutting-edge technologies and innovations. LotusWorks is committed to a diverse and inclusive workplace, integral to our people-first approach.

The Mechanical Commissioning Lead is responsible for the mechanical commissioning scope from design review through Integrated Systems Testing (IST) and final turnover. This role provides accountability to the Commissioning Authority and Commissioning Manager for mechanical system readiness, testing, documentation, and issue resolution across chilled water, condenser water, heat rejection, air handling, room cooling, ventilation, pressurization, BMS controls, fuel oil, and applicable plumbing and process water systems. The position directs mechanical commissioning engineers and technicians while coordinating mechanical contractors, controls integrators, TAB firms, and OEM representatives throughout the commissioning lifecycle.

Responsibilities:

Lead the mechanical commissioning process from design review and planning through startup, functional performance testing, Integrated Systems Testing, and final turnover.

Review mechanical drawings and specifications at the 30%, 60%, and 90% design stages, including flow diagrams, equipment schedules, sequences of operation, points lists, piping and duct layouts, and control diagrams.

Review mechanical design against the Owner's Project Requirements (OPR) and Basis of Design (BOD), including cooling redundancy, thermal ride-through, concurrent maintainability, design-day capacity, setpoints, and system failure behavior.

Review sequences of operation to identify gaps, conflicts, system integration concerns, and requirements that cannot be effectively tested during commissioning.

Identify commissionability gaps including missing test ports, inadequate system isolation, insufficient metering, and limitations affecting load simulation or redundancy testing.

Develop the mechanical sections of the Commissioning Plan and applicable Division 23 and Division 25 commissioning specifications.

Define commissioning levels, witness requirements, TAB scope, trend-log requirements, and mechanical documentation deliverables.

Establish clear responsibilities between TAB, commissioning, and controls integration activities.

Identify Factory Witness Testing (FWT) requirements for chillers, CRAH/CRAC units, AHUs, pumps, VFDs, cooling towers, dry coolers, and other applicable mechanical equipment.

Develop and maintain the mechanical commissioning schedule, including flushing, system fill, water treatment, TAB, load simulation, and seasonal testing milestones.

Attend or coordinate Factory Witness Testing for major mechanical equipment and verify testing against project design conditions and required part-load operating points.

Witness packaged equipment controls simulation including staging, failure response, alarm mapping, and BMS integration.

Document factory testing nonconformances and track identified issues through resolution or owner acceptance.

Review and witness mechanical completion activities including equipment installation, alignment, vibration isolation, piping supports, valve identification, insulation, labeling, and equipment access.

Verify piping and duct installation against approved drawings, including sizing, valve orientation, strainers, flow direction, expansion provisions, air vents, and drains.

Witness or review pressure testing, flushing, cleaning, system fill, and initial water treatment activities.

Verify BMS installation including sensor locations, calibration, actuator operation, valve and damper functionality, and point-to-point verification.

Confirm VFD parameters, motor rotation, and mechanical safety interlocks prior to startup.

Verify fuel oil system integrity testing and leak detection where included within the project scope.

Establish mechanical system readiness criteria and ensure critical pre-startup requirements are satisfied prior to equipment startup.

Review and approve startup Method of Procedures (MOPs) and coordinate power availability and startup sequencing with the electrical commissioning team.

Witness OEM startup of chillers, pumps, cooling towers, CRAHs, CRACs, AHUs, humidification systems, VFDs, and other mechanical equipment.

Witness and review Testing, Adjusting, and Balancing (TAB) activities for air and water systems and verify results against design requirements.

Verify BMS graphics, alarms, trends, historian functionality, and sequences of operation are operational prior to functional performance testing.

Confirm mechanical setpoints, reset schedules, and deadbands are configured in accordance with approved sequences of operation.

Execute Level 4 functional performance testing of mechanical components and subsystems using approved commissioning scripts.

Test chiller and chiller plant staging, load response, equipment failure scenarios, condenser water reset, and economizer or free-cooling sequences where applicable.

Test pumps for lead/lag operation, standby rotation, failure response, automatic changeover, differential pressure control, and minimum-flow requirements.

Test cooling towers and dry coolers for fan staging, basin controls, freeze protection, and equipment failure response.

Test CRAH, CRAC, and AHU systems for temperature and humidity control, fan operation, pressure control, redundancy response, and alarm functionality.

Test ventilation and pressurization systems including room pressure control, smoke control interfaces, and battery room exhaust where applicable.

Test fuel oil systems including transfer pumps, day tank controls, leak detection, and alarms where applicable.

Verify sequences of operation through documented functional testing and supporting trend data.

Execute failure-mode testing including loss of BMS communications, sensor failure, control power loss, and VFD faults to verify appropriate system response.

Own mechanical commissioning issues through classification, assignment, corrective action, retesting, and final closure.

Review and approve mechanical test records and perform quality reviews of commissioning documentation.

Coordinate with the electrical commissioning lead to develop and execute Integrated Systems Testing scenarios involving electrical and mechanical system interactions.

Execute full-load mechanical testing using appropriate heat-load simulation and verify environmental conditions remain within OPR requirements.

Test system-level mechanical failure scenarios under load, including loss of chillers, pumps, cooling equipment, BMS, and heat rejection equipment.

Verify concurrent maintainability by isolating mechanical maintenance paths under load and confirming continuity of cooling.

Verify mechanical thermal ride-through performance during electrical transfer and generator startup scenarios.

Confirm BMS alarm priorities, event capture, trending, and historian data support commissioning test requirements.

Document mechanical IST results, identified limitations, and system performance for inclusion in the Final Commissioning Report.

Verify O&M manuals, as-built documentation, final BMS programs and setpoints, TAB reports, water treatment records, and operator training are complete prior to turnover.

Deliver the mechanical portion of the Final Commissioning Report, including testing results, outstanding issue status, deferred testing, seasonal testing, and recommendations.

Track and coordinate deferred and seasonal mechanical commissioning activities.

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