a look inside the commissioning process · a look inside the commissioning process ... final...

Garry Caldbeck, Principal

Randy Teed, PE, CEM

A Look Inside the Commissioning Process

Commissioning

Commissioning is a quality assurance process that provides documented confirmation that building systems are planned, designed, installed, tested, operated and maintained in compliance with the owner’s project requirements.

Commissioning is highly successful when collaboration exists between the design professionals and the construction team.

Who are the Shareholders?

Owner

Architect

Engineers / Design Team

Commissioning Firm

Building Automation System (BAS)

Building Trades Personnel

Commissioning is an investment in a successful project.

Who are the Cx Team Members?

Engineer

Professional Engineer, Energy Engineer

Control Engineer and Control Technician

HVAC, Plumbing, Hydronic, Refrigeration Technicians

Testing, Adjusting and Balancing (TAB) Technician

Building Envelope Specialist

Infrared Level 1 Thermographer Specialist

Indoor Air Quality (IAQ) Specialist

A Look Inside the Commissioning Process

Shareholder presence and involvement

How does Commissioning (Cx) affect construction?

Does it slow it down?

Does it improve the process?

Why Commission: Cost Vs. Investment

Overview of the Process

Today we will discuss:

Why Commission?

International Energy Conservation Code (IECC)

C402.4 Includes requirements for Air Barrier/Building Envelope

C403 Raises the bar for equipment minimum efficiency requirements

- Utility rebate programs align to these standards as well

C403.2.8 Minimum pipe insulation thickness based on fluid operating temperature, insulation conductivity, and pipe size

C403.2.4 Requires Automatic Start controls for each HVAC system

- Must be capable of adjusting start time to condition space prior to occupancy

C403.3.1 Requires air or water economizer on all cooling systems with fans

- Must be capable of integrating with BAS to modulate OA

International Energy Conservation Code, IECC -2012 (Commercial)

Commissioning as a Code Requirement (IECC - 2012)

CDs clearly indicating provisions for commissioning

Commissioning Plan

- Narrative of commissioning activities at each phase

- List of systems and equipment to be commissioned

- Functions (calibrations and controls) to be tested

- Testing conditions and measurable critera for performance

Air and Hydronic Systems Testing and Balancing

Functional Performance Testing

Preliminary Report listing all deficiencies at that point

Final Commissioning Report

IECC – 2012, Section C408 Requires:

Regional Adoption of IECC

State-wide adoption of IECC - 2012

State-wide adoption of IECC - 2009

Limited Statewide Adoption or Local Government Adoption

No adoption of IECC

IECC - 2012 pending adoption

Benefits of the Energy Codes

Command higher rents & higher sale prices

Hold value longer

Produce better results for building owners/tenants

- Marketing

- Image

- Reduced Operating Costs

National Association of Realtors confirms, energy efficient buildings:

Benefits of Commissioning

In a study of 60 commercial buildings

- Over half suffered from control problems

- 40% had problems with HVAC equipment

- 15% were missing specified equipment

$0.02-$0.19/ft2 in annual energy cost savings

$0.23-$6.96/ft2 in annual non-energy cost savings

- Reduced maintenance, extended equipment life

Intangible benefits

- Proper ventilation, light levels, temperature control

Pacific Northwest National Labs found:

Systems to be Commissioned

MEP Systems

- Mechanical, Electrical, Plumbing

BAS (Building Automation System)

Building Envelope – All 6 Sides

Domestic Hot Water

The building systems to be commissioned may include:

Systems to be Commissioned

Fire and Life Safety- Fire/Smoke Damper Testing

- Smoke Evac System Testing

- System Interlocks for Shutdown and Equipment Restarts

Renewable Energy Systems- Solar Hot Water

- Photovoltaics

Security/Access/IT Data

The building systems to be commissioned may also include:

Types of Commissioning

Mission Critical Cx

- Data Centers

- Hospitals

- Central Plants

LEED (Leadership in Energy and Environmental Design)

- Fundamental Cx

- Enhanced Cx

- Existing Building Cx

Sustainable Cx

- Green – Sustainability

- Often High Performance

Multiple paths to obtain an efficient and functional building:

More Types of Commissioning

Building Envelope Cx (BECx)

Continuous or “On-Going” Cx

- Measurement and Verification

Retro-Commissioning (RCx)

The amount of time required for Cx depends on:

- Project Size

- Complexity

- Number of Systems to Commission

- When Commissioning Begins (the earlier it starts, the better!)

Nine steps to a successful commissioning project

Early involvement at design stage

Cx Plan and Cx Kick-Off meeting

Building Automation System Controls Meeting

Site visits during construction

Functional performance testing

1

2

3

4

5

Issue log and corrective action reports

Owner training

Lessons learned - Building turn over

6

7

8

10 month review during warranty period9


Early involvement at design stage1

Allows the commissioning provider to work with the design team

Assists with articulating the Owner’s Project Requirements (OPR)

Reviews the engineer’s Basis of Design (BOD)

Reviews 50% and 95% Construction Documents, with Back-Checks

The BOD and OPR are LEED requirements, but they are valuable on any project

The goal is to discover problems early,

allowing changes to be made while still a pencil stroke.

Why Commission Early?

Example – Design Review

Review By: SystemWorks

Project Architect: . Architect Associates

Project M/E Engineers: Engineering Group Back Check Review

Date of Review: July 30, 2012 Date of Review: 10-26-12

Date of Response: October 25, 2012 Review By: SystemWorks

Date of Back Check : October 26, 2012 Document Status: 95% CD

The following are comments based on review of the 95% CD plans & specifications dated October 25, 2012.

Item System Document Review Comment Response / Action Back Check Review

1Air Cooled

ChillerM2

Review the refrigerant proposed for the air

cooled chiller. R-22 freon is being

discontinued. Consider using one of the

newer refrigerants.

R-22 freon is deleted. It was an oversight.

New chiller will be selected with the proper

refrigerant.

SW back checked 10/26/12. OK

2 Controls 230993

Recommend including BAS graphics

requirements in specification, (ex. link to

sequence of operations, floor plans, flashing

alarms, etc.)

Updated SW back checked 10/26/12. OK

3 Controls

Current drawings need additional information

shown i.e... thermostat type (adjustable, flat

plate, caged, insulated) placement, height,

mounting location (wall, ceiling, column)

override button, display.

Included SW back checked 10/26/12. OK

4

PipingAdd pipe flushing requirements. Updated SW back checked 10/26/12. OK

Example – Design Review

Heating Water Steam Valves

Pump


Cx Plan and Cx Kick-Off Meeting2

Commissioning Plan

Project Milestones

Roles and Responsibilities of the design team and contractors

Commissioning Kick-Off Meeting

Explains Cx to the design team and contractors

Opportunity to explain Construction Checklists (specific to each trade)

Opportunity to explain the Commissioning Authority’s (CxA) role

Open door for Communication and Collaboration

Accountability and Deliverables


Building Automation System (BAS) Controls Meeting3

Reviews the controls sequences for functionality and comformance with the engineer’s Basis of Design

Meeting is held with Owner, Design Team, BAS field programmer and commissioning provider to discuss and clarify the engineer’s design intent.

The Owner’s input is essential in order to have a fully functional final product.

Equipment operation scheduling

Daily hours of operation

Hard-wired Safeties – Critical Alarms

Then functional performance test (FPTs) are prepared based on the engineer’s Basis of Design and control sequences.


“Site Visits” during construction4

“A picture is worth a thousand words.” During Site Visits, the commissioning provider notes details that may affect equipment performance and serviceability.

Site Visits during construction identify problems and allows resolution to be done before concealment.

Site Visit pictures also document activites being performed correctly per the contract specification.

During Site Visits the commissioning provider interfaces with the design team and building trades to fill in the GAPS.

What’s wrong with just commissioning at the end of the project, during the post-construction phase?

Example – Site Visit Pictures

Improper storage – Drywall is sitting directly on wet floor

Proper Storage – Drywall is covered and off the floor


Improper Storage – Ductwork open and sitting on floor in standing water

Proper Storage – Ductwork covered and on pallets off the floor


Installation/Serviceability – Strainer installed too close to floor; cannot be removed for service

Installation – Sleeves installed at hanger joints to protect insulation


Contract Specification – Geothermal differential pressure sensors are installed per specification

Contract Specification – Pump is correctly piped and installed per specification


Serviceability – Cable tray in front of service door for fan powered box

Serviceability – Proper installation of equipment for serviceability


Safety – Fire-rated wall integrity compromised by conduit

Safety – One hour fire-rated wall with fire caulk at decking


Circuit setter and two isolation valves are not installed where they should be, per the drawings

Safety – Manual ball valve vents and drains are not capped


The outside air exhaust louver to AHU-1 and ERV-1, located in tunnel, is not flashed or sealed

This wrench was preventing the dampers from closing 100%


The air filters are 100% plugged and collapsed inward

Hydronic fittings are not insulated


Pipe labeling does not indicate correct flow Per manufacturer’s recommendations, the suction diffusers should be supported.


Boiler is positioned very tight in the corner, the side panel and front panel are not accessible

Wiring for flow meter in boiler room is not in conduit


Dielectric fittings between chiller and heat exchanger piping may not be appropriate

Flex fitting should not be tightly stretched, to allow for movement


Penetrations to the outdoors are not properly sealed

Supply fan’s canvas connections need to be repaired in order to achieve design flow


Chilled water supply and return lines are properly capped

Supply grilles are being kept covered to keep ductwork clean


Functional performance testing5

Writes a functional performance test for each system and piece of equipment involved in the commissioning process.

Performs hands-on testing to verify installation and performance

Hands-on performance testing occurs after Testing, Adjusting and Balancing (TAB) work is completed. Random sample of TAB work will be verified.

Requires assistance of design team and control technicians to resolve minor concerns as they arise.

Makes sure all concerns are addressed by the appropriate individual.

Backchecks are used to validate completion of these items.

An issue log is used to track each of the items through to completion.

Functional Performance Testing

Trend Data Analysis

Trending System Using the Building Automation System

Quantify Savings

Identify any ‘Off-season’ issues

Tuning the PID loops

Before Cx After Cx

Daily Energy Usage Over Similar Weeks

Functional Performance Testing Equipment

NIST Traceable Equipment

HOBO Onset Data Loggers

TeleAire CO2 Sensor with Data Logger

Vaisala HM34 Humidity and Temperature

Gray Wolf Multi Mode Monitor IAQ, Direct Sense Environmental Tester

Shortridge HydroData and AirData Mulit-meters

Bacharach Test Monitor Analyzer

Fluke Remote Read Electrical Multi-meter, Electrical Clamp Meter

Simpson Sound Measuring System


Issue logs and corrective action reports6

An issue log is created to track concerns or deficiencies found during functional performance testing.

Minor deficiencies corrected during testing are noted on the issue log and simply documented to show its final resolution.

A corrective action report may be utilized to track concerns or deficiencies that were not resolved during functional performance testing.

Retesting will be scheduled, as required, to ensure that the corrected issues meets the design documents … trust but verify.

Example – Issue Log

ITEM #

Complete Y/N DATE DATE REVIEWED

System SystemWorks Reviews / Observations LISTED CO MPLETE WITH Resolution / Status

1 Y OAHUWhen a low limit trips a "Fire/Smoke" alarm is generated along with

the low limit alarm. Fire/Smoke shutdown is not tripped.06/12/12 09/05/12 GC

7/12/12- Re-Tested - No Change. 8/2/12 - Re-Tested, No Change,

8/10/12 - Re-Tested, No Change. 9/5/12 - SW Re-Tested

Complete.

2 R OAHU

Upon tripping a saftey device (low limit, static) the AHU (supply

fan + exhaust fan) will not restart after resetting the saftey device.

The fault on each VFD must manually be reset in addition to the

saftey device. All other Conditioning Unit VFD's have been

programmed to automatically restart after a fault.

06/12/12 GC 7/12/12- Re-Tested - No Change.

3 N Hangers

Some piping hangers have isolators and some do not. Specification

15245-8 (3.2, A) states that all piping within 15m (50') of vibrating

equipment in mech rms need isolation hangers. (3.2, B ) Outside

mech rms isolation hangers shall be used on piping greater than

100mm (4")

01/15/12 GC

2/20/12 - SW verified isolators are now installed in AHU-2B

mechanical room. 3/8/12 - Isolators are still missing in the following

mechanical rooms

4 Y CHW

Large amount of air in the chilled water system. Need to review

the methods used to purge as a group. Should automatic air vents

be installed temporarily or permanently?

01/15/12 3/19/12 GC

2/20/12 - Contractor has installed temporary air vents, has 12 more

on order to install at each AHU coil. GC plans to write an RFI to

identify and ask if the air vents should be removed or left after the air is

out of the system. 3/19/12 - Air vents will remain in system and be

piped to floor drain.

Green items are for SystemWorks backcheck when ready

Red items were noted complete but found incomplete

Yellow items for BG response or not complete yet


Owner training7

Verifies facility personnel have been trained by the installation contractors, designers and manufacturers’ representatives in the operation and maintenance of the building.

Examples: Control contractor demonstrates how the critical alarms will report to facility personnel. Vendors demonstrate proper operation of the equipment and recommended maintenance schedule.

Videotaping the training sessions provides a permanent record of operation and maintenance of the equipment and can also be used to train new staff when hired.

The Scope of Owner Training


Lessons learned - Building turn over8

A lessons learned narrative is a summary of the knowledge and experience gained during the functional testing of the building systems.

This knowledge is unique to that building.

The benefits of building commissioning results in a smooth building turn over. Owners have confirmation that building systems are installed and operating per the OPR, BOD, control sequences, and contract specifications.


10 month review during warranty period9

Return visit to review current operation and identify any potential warranty related problems before the typical 12 month warranty expiration

Talk with building operating staff to identify their concerns

Final opportunity to fine tune the control loops and to look at building pressure changes during opposite season conditions.

Many times these conditions are simulated, but best practice is to return in the opposite season for actual testing.

Trend Data Analysis

Energy Consumption Trends

Summary

Changes made during the design phase are the most cost-effective

Owner input is essential

Commissioning touches all trades

To deliver a fully-functional building, all trades must be successful

Commissioning is an investment; invest early and reap the rewards throughout the life of the building.

Do You Have Any Questions?