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Laboratory HVAC Functional Performance Testing

Laboratory HVAC Functional Performance Testing. Elements of Commissioning. Design Intent Documentation (DID) Design review Site observations and site meetings Resolution Tracking Forms (RTFs) System Verification Checklists (SVCs) Organized systems start-ups

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Laboratory HVAC Functional Performance Testing

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  1. Laboratory HVAC Functional Performance Testing

  2. Elements of Commissioning • Design Intent Documentation (DID) • Design review • Site observations and site meetings • Resolution Tracking Forms (RTFs) • System Verification Checklists (SVCs) • Organized systems start-ups • Functional Performance Tests (FPTs) • Operation and Maintenance (O&M) training • O&M documentation • Commissioning report

  3. Pre-design Design Construction Acceptance Post-Acceptance Phases of theCommissioning Process

  4. Pre-Design Phase • Cx • Contract Cx services with owner • Determine Cx scope • Review Design Intent Document • Provide input on testing criteria • Identify the Cx team structure • Identify systems to be Cxed • Plan Cx time requirements • Calculate Cx cost estimates

  5. Design Phase Responsibilities Review bid documents for completeness and specificity prior to release Perform design reviews of 30%, 70%, and 95% DD’s Review 100% Design Documents Provide designer specification language for roles and responsibilities of the Cx process Prepare and submit a design phase Cx plan

  6. Cx TAB provisions: dampers, pressure ports, circuit setters, etc. Observation provisions for viewing operations Access devices for O&M activities Barrier & interconnection issues of building spaces Equipment selection and location vs. occupancy considerations Design Intent compliance BAS and DDC layout and availability O&M training plans Design Reviews

  7. Cx Construction team support services, facilitation, and coordination Coordinate planning Review TAB procedures Review HVAC submittals Update Cx Plan Site observations Update project schedule Construction Phase

  8. Cx Resolution Tracking Forms Conduct Cx meetings Monitor installation Evaluate controls progress Validate controls point-to-point checks Manage HVAC start-ups Verify corrective actions Re-test Facilitate TAB readiness Assist with O&M documents Coordinate training events Conduct trial tests to prepare for functional performance tests Communicate with owner personnel Construction Phase (continued)

  9. Acceptance Phase Final O&M reviews Final O&M training Clarify acceptance and warranty initiation conditions Document HVAC controls installation Participate in TAB report review & verification Direct functional performance tests Direct FPT re-testing Coordinate O&M training

  10. Post-Acceptance Phase Cx activities continue beyond substantial completion Off-season modes testing Final Cx Report Assist owner with warranty enforcement

  11. Codes and Standards Codes and Standards NFPA 45: Fire Protection for Labs Using Chemicals ANSI/AIHA Z-9.5: Lab Ventilation ASHRAE 110: Fume Hood Testing ASHRAE 90.1: Energy Standard for Buildings ASHRAE 62: Ventilation for IAQ ASHRAE 52: Thermal Comfort

  12. The Code Footprint * Small-scale snapshot * Fire protection/occupant safety * Schematic/textual form * 11”x17” sheet * Sheet for each floor * Basic building, code and site information * Field use tool • .

  13. Laws OSHA, federal OSHA, state EPA, federal EPA, state Codes NFP (fire) – NFPA 45 (ed. 2000) ANSI/AIHA Z9.5 (ed. 2000, ed.2001 not yet released) ASHRAE-62, 90A, 110 (Ventilation for comfort, energy efficiency, fume hood testing) Building (BOCA, UBC, etc.) Technical (ASME, JIC, NEC, etc.) Design Authorities

  14. National Conformance Standards ANSI/ASHRAE Fume Hood Performance 110-1995 ANSI/AIHA Z9.5-1992 ANSI/ASHRAE III 1988 Testing & Balancing ANSI/ASHRAE 62 – Supply Air Quality Standards ,Guidelines and Recommended Practices SEFA Prudent practices in the laboratory Industrial ventilation guide Typical Capture Velocities American National Standards for Laboratory Ventilation National Research Council, Prudent Practices in the Laboratory American Conference of Governmental Industrial Hygienists Minimum Design Duct Velocities American National Standard for Laboratory Ventilation National Research Council, Prudent Practices in the Laboratory American Conference of Governmental Industrial Hygienists Design Authorities

  15. Design Authorities Hood Class Velocity Values ANS, NSC, ACGIH Hood Class Velocity Range (fpm) Class A 125 – 150 Class B 100 Class C 80

  16. Users of Codes Architects Engineers Plan Reviewers Authority Having Jurisdiction(AHJ) Facility Owners Facility Operators Maintenance Personal First Responders Building Officials Inspection Personnel Researchers Commissioning Authorities

  17. System Description The air handling (AHU) unit is a variable air volume (VAV) unit with hot water preheat, chilled water cooling with outside air economizing, variable frequency (VFD) drives on both the supply and return fans, and a supply air humidifier.

  18. System Components The system consists of: • Air Handling Units No. 1, 2, and 3 • Supply Air Fans No. 1, 2, and 3 • Return Air Fans No. 1, 2, and 3 • Circulating Pumps – P-1, 1A, 2, 2A, 3, 4, 5 • Exhaust Fans No. 1, 2, 3, 4, and 5 • Chilled Water System • Hot Water System

  19. Modes of Operation • Occupied • Economizer • Unoccupied • Warm-up • Alarms and Safeties

  20. Purpose: Demonstrate Air handling Unit and associated components function as an integrated system, to produce the design intent of the system’s and equipments as installed.

  21. Points to consider during planning Estimated Duration: Acceptable Results: Affect on Building Systems: Test Conditions: Staffing: Test Instruments Required:

  22. Staffing • Owner’s Representative • Mechanical Engineer • Construction Manager/General Contractor • Commissioning Agent • Mechanical Contractor • TAB Agency • BAS Contractor

  23. Special Test Equipment Required

  24. Initial Requirements Verify affected systems are in full operation, with SVC complete and equipment interface checked. • Air Handling Unit No. 1, 2, and 3 • Return Air Fan No. 1, 2, and 3 • Exhaust Air Fan No. 1, 3, 4, and 5 • Chilled Water System • Heating Water System

  25. Verify System Verification / Start-up Checklist are complete • Air Handling Unit No. 1, 2, and 3 • Return Air Fan No. 1, 2, and 3 • Exhaust Air Fan No. 1, 3, 4, and 5 • Chilled Water System • Heating Water System

  26. Verify BAS point interface check is complete • Air Handling Unit No. 1, 2, and 3 • Return Air Fan No. 1, 2, and 3 • Exhaust Air Fan No. 1, 3, 4, and 5 • Chilled Water System • Heating Water System

  27. Verify testing and balancing is complete. • Air Handling Unit No. 1, 2, and 3 • Return Air Fan No. 1, 2, and 3 • Exhaust Air Fan No. 1, 3, 4, and 5 • Chilled Water System • Heating Water System • Pencil copy of the TAB Report

  28. Verify Fire Alarm System interface is checked • Obtain a copy of the fire alarm testing for record purposes only.

  29. AHU-1 Sequence of Operation Occupied Mode The air handling (AHU) unit is a variable air volume (VAV) unit with hot water preheat, chilled water cooling with outside air economizing, variable frequency (VFD) drives on both the supply and return fans, and a supply air humidifier. When indexed to the occupied mode, the return air smoke damper and the supply air smoke isolation damper will open and when it is proven by their end switch, the return fan (RF-1) shall start and the VAV terminal units shall be put into the occupied mode. The supply air smoke damper will open 15 seconds (adj.) after the return air fan is on. When proven open by its end switch, the supply air fan shall be energized and operate under its control sequence.

  30. Supply Fan Control When the AHU is indexed to start, the minimum outside air, relief air and return air dampers shall be controlled as indicated in the contract documents. When the supply fan is de-energized, the outside air and relief air dampers shall close and the return air damper shall open, and the chilled water coil control valve shall be closed. A supply duct static pressure censor and control shall modulate the supply fan variable speed drive (VFD) to maintain the supply duct static pressure set point (1.0 IWC, adj.) A potentiometer in the unit control panel will allow adjustment of the supply-return fan motor speed tracking control loop offset. The panel-mounted controller digital output will allow the control loop offset to equal the potentiometer set point (RAF 10% slower the SAF, adj.) when fans are operating in normal occupancy modes. The offset will be removed during morning warm-up and night setback modes.

  31. Minimum Outside Air Damper Control A minimum position potentiometer in the unit control panel will allow adjustment of the outside air damper position. The CCMS will control a panel mounted digital output that will allow the outside air damper to open to the potentiometer minimum set point. The field controller will energize the air damper minimum position output when the supply fan motor is energized during the time clock occupied period and the return temperature is above the warm-up mode set point (67° F, adj.), or the supply air fan has been operating in the occupied mode for the warm-up period set point duration (600 seconds, adj.). The field controller will de-energize the air damper minimum position output when the supply fan motor is de-energized, or the unit is not operating in the time clock occupied period, or the return air temperature is below the warm-up set point and the supply fan has not been operating in the occupied mode for the warm-up period set point duration.

  32. Return Air Damper Control A mixed air static pressure control loop will modulate the return air damper position to maintain the outside air volume at set point when the unit is operating. The CCMS field controller will control a panel-mounted controller digital output that will allow the return air damper to modulate in response to the mixed air static pressure control loop. The CCMS field controller will energize the digital output and enable the return air damper control when the supply fan motor is energized. The field controller will de-energize the output and fully open the return air damper when the supply fan motor is de-energized. A hardwire interlock will override the field controller and disable the return air damper close enable when the unit supply fan motor is de-energized.

  33. Return Air Damper Close A static differential pressure sensor will be installed between the outside air reference and the mixed air stream and connected to an analog input of a panel-mounted digital controller. The high side of the sensor will terminate at the outside air pressure reference. The low side of the sensor will terminate at the mixed air pressure probe. When the outside air damper minimum position control is enabled, a controller analog output will modulate the return air damper closed as required to maintain the mixed air static pressure at set point (determined by air balancing contractor, - .2IWC, adj.). On a fall in static pressure below set point, the dampers will further close to increase the outside air volume. On a rise in static pressure above the set point, the damper will further open to decrease the outside air volume.

  34. Discharge Air Temperature Control Control of the hot water and chilled water coil valves will be enabled when the supply fan motor is energized. A supply air temperature sensor controller input shall modulate the hot water and chilled water coil valves as required to maintain the supply air temperature set point (55 F, adj.). A hot water coil leaving air temperature sensor controller input shall override the supply air temperature sensor and modulate the hot water coil valve as required to maintain the coil leaving air temperature above the low-limit set point (50 F, adj.).

  35. Humidity Control A supply air humidifier shall be controlled by the manufacturer’s controls to maintain return air humidity set point. ATC has no work associated with this. The ATC shall supply a redundant return air relative humidity sensor to be used for monitoring only. The return air humidity value will be displayed on the ATC graphics screen.

  36. Economizes Damper Enable The CCMS shall monitor the (Sequence indicated economizer to be based on outside air temperature verse return air temperature, coordinate with university to see if control by enthalpy is acceptable.) return air and outside enthalpies, and enables the OA/REL dampers for economizer operation when the outside enthalpy is less than the return air enthalpy.

  37. Morning Warm-up Control Within an hour after system initial startup, the unit shall be indexed into the warm-up mode or cool down mode whenever the return air temperature falls below the warm-up set point, 67° F (adj.), or rises above the cool down set point (76°, adj.). When operating in the warm-up or cool down, the supply and return fans shall be started and the outside air damper and relief damper shall be held closed. During warm-up mode, the outside air and relief dampers shall be held closed, the return air damper shall be help open, the DAT set point shall be raised to (70° F, adj.), and the VAV terminal dampers shall modulate in a hot primary air state to maintain their individual set points. When the return air temperature rises above the warm-up off set point (2° F above cool down set point, adj.), the unit shall be indexed to the occupied mode and the VAV terminal units shall be indexed to normal operation with local zone sensors regaining control of associated VAV terminal units in the cooling state.

  38. Unoccupied Control When the AHU system is indexed to the unoccupied mode, the supply fan shall be de-energized. Upon a fall in any zone air temperature below the unoccupied set point (55 F, adj.), the supply and return fans shall start, the outside air and relief dampers shall remain closed, the return air damper shall remain open, and the unit and associated VAV’s shall operate in the occupied mode. When the space temperature rises to the unoccupied off set point (58 F, adj.), the supply fan shall be de-energized.

  39. Static Pressure High Limit Interlock A manual reset high static pressure switch mounted in the supply duct shall stop the supply fan, return fan, close the outside air and relief dampers and open the return air damper when the supply duct static pressure rises above the high limit set point (7.0 IWC, adj.). The CCMS shall monitor the SA static pressure high limit switch and initiate a CCMS alarm if a high static condition exists.

  40. Freeze Protection When the outside air temperature falls below the low limit set point (35 F, adj.), then the heating coil circulating pump shall be energized and run continuously. When the outside air temperature rises above the low limit off set point (41 F, adj.), the heating coil circulating pump shall be de-energized. On a fall in the mixed air temperature through the control loop proportional band (47 F to 43 F, adj.), the mixed air low limit selector will override the economizer signal by taking the lower of the DAT economizer damper signal and the mixed air lower limit signal to modulate the economizer damper to the minimum outside air set point position. When the mixed air temperature falls below mixed air hot water valve set point (38 F, adj.), an alarm will be indicated on the CCMS. On a fall in mixed air temperature through the control loop proportional band (40 F to 37 F, adj.), the field controller will start the hot water (HW) circulating pump.

  41. Freezestat Interlock A freezestat shall be mounted on the entering air side of the chilled water coil and shall be connected through hardwired interlocks to de-energize and disable the supply and return fans, close the outside air and relief dampers, open the return air damper, drive the chilled water (CHW) and hot water (HW) valves open, start the hot water (HW) circulating pump, and initiate a CCMS critical alarm, if the chilled water coil entering air temperature fall below the low limit set point (37 F, adj.).

  42. Smoke Detector Interlock Smoke detectors located in the supply and return ducts shall de-energize and disable the supply and return fans, close the supply and return air smoke dampers, close the outside and relief air damper and open the return air damper, and initiate a CCMS alarm if product of combustion is senses.

  43. Filter Status The CCMS shall monitor filter status via a pressure differential switch connected to a local controller and initiate a CCMS alarm when dirty filter condition exists.

  44. Functional Performance TestAir Handling Unit 1 • Test Mode: Occupied • Start Date: • End Date: • Agent: • Contractor: • Owner:

  45. Record the initial temperatures and humidity

  46. Test Mode:Normal - On

  47. Command the system through the BAS system Verify the follow occurs. (All operation are to be automatic, no intervention from the operator.) The return air smoke damper and supply smoke isolation dampers open (the supply damper is delayed for 15 seconds before it will open), when proven open, the return air fan will start and then the supply air fans start, the return air fan is set to operate at 10% slower then the supply air fan. VAV terminal will be indexed to occupied mode.  Pass  Fail  Retest

  48. The outside, relief and return air dampers will move to their correct position, the outside to its minimum position, the relief air to its minimum position and the return air damper will open. • Pass  Fail  Retest • The supply air static pressure sensor will modulate the VFD to maintain its set point of (___). (This value will be determined by the TAB technician.) •  Pass  Fail  Retest

  49. The discharge air temperature will be maintained at ____ by modulating either the chilled water or hot water valve to maintain set point. • Pass  Fail  Retest • Once system is in the normal operating state, the minimum outside air CFM will be maintained by the pressure differential across the outside air and mixed air plenum, the set point will be determined by the TAB contractor. (___) •  Pass  Fail  Retest

  50. Record the temperature and humidity after systems have been in operation for a period no shorter than 30 minutes

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