Mechanical Commissioning Lead at LotusWorks, Grafton, WI

Mechanical Commissioning Lead at LotusWorks in Grafton, WI. Contract. Est. up to $100k. Apply with swipeandhired.

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.

LotusWorks is seeking an experienced Mechanical Commissioning professional to support the commissioning of critical mechanical systems within a large-scale data center environment. This role will lead mechanical commissioning activities from design review and startup through functional testing, Integrated Systems Testing (IST), and final turnover. The position will focus on chilled water, condenser water, heat rejection, air handling, room cooling, ventilation, pressurization, BMS controls, fuel oil, and plumbing/process water systems. The successful candidate will coordinate with contractors, controls integrators, TAB firms, OEM representatives, and commissioning teams to ensure systems are tested, issues are resolved, and the facility is ready for operations.

Responsibilities:

Level 0 — Design review & planning

• Review 30/60/90% mechanical drawings and specs: flow diagrams, equipment schedules, sequences of operation (SOO), points lists, piping/duct layouts, control diagrams

• Check the design against the OPR/BOD: cooling redundancy (N+1, 2N), thermal ride-through, concurrent maintainability, design-day capacity, setpoints, and failure behavior

• Review the SOO line by line for gaps, conflicts with the electrical topology, and untestable statements — the SOO is the mechanical equivalent of the coordination study and it's the most common source of L4 failures

• Flag commission ability gaps: missing test ports, no isolation to test redundancy, insufficient metering (flow, BTU, kW) to verify capacity, no provision for load simulation

• Write the mechanical Cx Plan section and Division 23/25 Cx spec language: levels, witness requirements, TAB scope, trend-log requirements, documentation deliverables

• Define the TAB/Cx boundary and the controls integrator's point-to-point responsibilities in writing

• Identify FWT candidates (chillers, CRAHs/CRACs, AHUs, pumps/VFDs, cooling towers/dry coolers) and write FWT requirements

• Build the mechanical Cx schedule: flushing and fill milestones, water treatment, TAB, load simulation method (electric heaters, load banks, or server simulators), seasonal constraints

Level 1 — Factory witness testing

• Attend or delegate FWT for chillers (performance test per AHRI 550/590 at project conditions), CRAH/CRAC units, AHUs, cooling towers, pumps and VFD packages

• Verify the factory test runs at the project's design conditions and part-load points, not just the OEM rating point

• Witness controls simulation on packaged units: staging, failure response, alarm mapping, BMS protocol integration

• Document nonconformances and hold ship release until resolved or owner-accepted

• Collect FWT reports, performance curves, and controller firmware/settings as the site baseline

Level 2 — Installation verification (pre-start-up)

• Review or witness MC checklists: equipment set, aligned, vibration isolation, piping supports, valve tags, insulation, labels, access clearances

• Verify piping and duct installation match the drawings: pipe sizing, valve orientation, strainers, flow direction, expansion, air vents and drains

• Witness or review pressure testing, flushing, cleaning, fill, and initial water treatment — confirm water chemistry meets spec before any pump runs on the permanent system

• Verify BMS installation: sensor locations and calibration, actuator stroke, valve/damper end-to-end, point-to-point against the points list

• Confirm VFD parameters, motor rotation, and safety interlocks (low-temp, high-static, freeze stats) before power

• Verify fuel oil system integrity testing and leak detection where in scope

• Gate: no start-up until piping is clean, controls are point-to-point verified, and safety-related L2 items are closed

Level 3 — Start-up

• Review and approve start-up MOPs; coordinate with the electrical lead on power availability and sequencing

• Witness OEM start-up: chillers (refrigerant charge, oil, safeties, controller), pumps (rotation, seal, NPSH), cooling towers, CRAHs/AHUs, humidification, VFDs

• Witness TAB: air and water balance, verify readings against design, review the TAB report critically — this is where undersized or mis-set systems show up

• Verify BMS graphics, alarms, trends, and historian are live and the SOO is loaded before L4

• Confirm setpoints, reset schedules, and deadbands match the SOO, not the integrator's defaults

• Collect start-up reports, TAB report, controller settings, and log deviations

Level 4 — Functional performance testing

• Execute component- and subsystem-level tests against approved scripts:

• Chillers and chiller plant: staging up/down, load steps, failure of a chiller, condenser water reset, free cooling/economizer changeover

• Pumps: lead/lag/standby rotation, failure and auto-swap, differential pressure control, minimum flow

• Cooling towers/dry coolers: fan staging, basin controls, freeze protection, failure of a cell

• CRAH/CRAC/AHU: temperature and humidity control, fan speed and pressure control, unit failure and redundancy pickup, filter alarms

• Ventilation and pressurization: room pressure control, smoke control interfaces, battery room exhaust

• Fuel oil: transfer pumps, day tank controls, leak detection, alarms

• Verify every SOO statement is tested and the result documented — trend logs are the evidence, not a checkmark

• Run failure-mode tests: loss of BMS comms, sensor failure, control power loss, VFD fault, and verify safe default behavior

• Issues log ownership: classify, assign, track retests; no L4 sign-off with open critical items

• Review and sign test records; QC Cx engineers' documentation daily

Level 5 — Integrated systems testing

• Coordinate with the electrical lead to design IST scenarios where electrical events drive mechanical response: utility loss → gen start → chiller restart and thermal ride-through against room temperature limits

• Execute full-load tests with heat load simulated at the IT space, at design load and at the redundancy margin; verify room and supply conditions hold within the OPR envelope

• Run system-level failure scenarios: loss of a chiller plant, loss of a pump header, CRAH/fan wall failure under load, loss of BMS server, cooling tower cell loss on a design-day equivalent

• Verify concurrent maintainability by isolating each maintenance path under load and confirming no loss of cooling

• Verify thermal ride-through: chilled water storage or UPS-backed pumps/fans carry the load through the gen start window

• Confirm BMS captures every event with correct alarm priorities and the historian data is usable for the report

• Document results and operational limitations for the Final Cx Report

Turnover & post-occupancy

• Verify O&M manuals, as-builts, final BMS programs and setpoints, TAB report, water treatment logs, and training completion

• Deliver the mechanical section of the Final Cx Report: test results, issues log status, deferred/seasonal tests, recommendations

• Track deferred tests — opposite-season testing is nearly always required for mechanical

• Support lessons-learned review with the owner and Cx team

Skills Required:

8–10+ years of experience in mechanical construction, TAB, controls, or commissioning, with mission-critical experience.

Strong knowledge of mechanical commissioning processes from design review through testing and turnover.

Working knowledge of ASHRAE Guideline 0/1.1, ASHRAE TC 9.9, AHRI performance standards, and NEBB/AABC TAB standards.

Strong BMS/controls literacy, including reading SOOs, points lists, and controller logic.

Ability to build and interpret trend logs and evaluate system performance during commissioning.

ACG CxA, BCxA CCP, or AEE CxP certification preferred.

Education / Licenses / Certifications:

Equivalent combination of relevant mechanical commissioning, TAB, controls, or mission-critical experience will be considered.

Industry certifications such as ACG CxA, BCxA CCP, or AEE CxP are preferred.

Benefits:

• Medical, Dental and Vision Insurance

• Life, Short-Term, Long-Term Disability Insurance

• Training and Education Assistance

• 401k Retirement Plan

• Extra Annual Leave with Years of Service

• Maternity/Paternity Leave

• Recognition Rewards

LotusWorks is an equal opportunity employer and prohibits discrimination and harassment of any kind. We are committed to creating a diverse and inclusive workplace where all employees feel valued, respected, and empowered.