HVAC Systems Commissioning Manual

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SMACNA T I T L E * H V A C C M

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HVAC SYSTEMS COMMISSIONING MANUAL

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SHEET METAL AND AIR CONDITIONING CONTRACTORS NATIONAL ASSOCIATION, INC.

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HVAC SYSTEMS COMMISSIONING MANUAL

FIRST EDITION - OCTOBER 1994

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SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION, INC. 4201 Lafayette Center Drive Chantilly, VA 22021

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HVAC SYSTEMS COMMISSIONING MANUAL %MACNA 1994 All Rights Reserved by

SHEET METAL AND AIR CONDITIONING CONTRACTORS' NATIONAL ASSOCIATION, INC. 4201 Lafayette Center Drive Chantilly, VA 22021 Printed in the U.S.A.

FIRST EDITION - OCTOBER 1994

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Except as allowed in the Notices to Users, no pari of this book may be reproduced, stored in a retrievable system, or transmitted, in any form or by any means, electronic, mechanical photocopying, recording, or otherwise, without the prior written permission of the publisher.

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FOREWORD With the introduction of the total quality management (TQM) concept and the extension of that process into the construction industry, the term commissioning has evolved to represent the TQM process in the construction trades. Commissioning includes the final act of verifying compliance with project specifications. It also includes demonstrating and verifying system and subsystem operational performance and is a detailed documentation of building systems and components to be used by building management throughout the life of the building. While the concept of commissioning applies to all components of a structure, this manual focuses on the HVAC systems and the parties responsible for the proper design and installation of these systems. --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

In terms of operating costs, HVAC systems-in virtually any building-are one of the most energy intensive. Additionally, HVAC systems can be the source of indoor air quality (IAQ) problems but can also be the vehicle to the solution of those problems. Poorly designed, improperly installed, or inadequately maintained systems can cause high operating costs and occupant discomfort, affecting the long term fiinancial viability of a building. The purpose of this manual is to introduce the contractor to the commissioningprocess and to give the contractor an understanding of the skills and expertise required to apply the concepts to the construction process. Contractors who understand the process will be in position to offer this service to building owners and designers.

The SMACNA Building Services Committee has decided to introduce the commissioning process as a multi-level concept applicable to projects large and small, simple and complex. The manual treats the subject in sufficient detail to provide a professionally run organization, with a commitment to the TQM process, with the expertise to direct the activities of a commissioning team. We have also introduced the concept of re-commissioning to emphasize that the commissioning process applies to both the new construction and the renovation and retrofit markets. The manual includes a sample specification and a sample commissioning report. Also included are samples of commissioning Checklists for a wide variety of HVAC systems and components. Although these checklists are comprehensive, they are intended as guidelines. Forms actually used in the commissioning process are generally customized for the equipment and systems involved and usually reflect the requirements of the commissioning authority. SMACNA recognizes that this manual might be expanded and updated in the future. Continuing effort will be made to provide the industry with the latest methods and engineering data from recognized sources, supplemented by SMACNA research and the services of local SMACNA chapters and contractors.

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BUILDING SERVICES COMMITTEE John Desmond, Chairman Cox Engineering Company Brighton, MA

George O. Kukia Air Systems Balancing & Testing Services Rochester, NY

Richard Cramer, II Dee Cramer, Inc. Flint, MI

G.A. Navas SMACNA, Inc. Chantilly, VA

Mitch J. Fritch Fritch Heating & Cooling, Inc. Peoria, IL

Bob Wasilewski SMACNA, Inc. Chantilly, VA

Kevin Gill McCusker-Gill, Inc. Weymouth, MA 02 188

OTHER CONTRIBUTORS Cedric Trueman, P. Eng. Victoria, B.C.

iv

Robert G. Hetherington, P. Eng. Rymar Services, Ltd. Victoria, B.C.

HVAC Systems Commissioning Manual

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NOTICE TO USERS OF THIS PUBLICATION 1.

ACCEPTANCE

This document or publication is prepared for voluntary acceptance and use within the limitations of application defined herein, and otherwise as those adopting it or applying it deem appropriate. It is not a safety standard. Its application for a specific project is contingent on a designer or other authority defining a specific use. SMACNA has no power or authority to police or enforce compliance with the contents of this document or publication and it has no role in any representations by other parties

that specific components are, in fact, in compliance with it.

2. AMENDMENTS The Association may, from time to time, issue formal interpretations or interim amendments, which can be of significance between successive editions. 3. PROPRIETARY PRODUCTS SMACNA encourages technological development in the interest of improving the industry for the public benefit. SMACNA, does not, however, endorse individual manufacturers or products.

4. FORMAL INTERPRETATION A formal interpretation of the literal text herein or the intent of the technical committee associated with the document or publication is obtainable only on the basis of written petition, addressed to the committee and sent to the Association's national office in Chantilly, Virginia and subsequent receipt of a written response signifying the approval of the chairman of the committee. In the event that the tition r has a substantive disagreement with the interpretation, an appeal may be. filed with the Technical Resources Committee which has technical oversight responsibility. The request must pertain to a specifically identified portion of the document that does not involve published text which provides the requested information. In considering such requests, the Association will not review or judge products or components as being in cornpliance with the document or publication. Oral and written interpretations otherwise obtained from anyone affiliated with the Association are unofficial. This procedure does not prevent any committee chairman, member of the committee, or staff liaison from expressing an opinion on a provision within the document, provided that such person clearly states that the opinion is personal and does not represent an official act of the association in any way, and it should not be relied on as such. The Board of Directors of SMACNA shall have final authority for interpretation of this standard with such rules of procedures as they may adopt for processing same. APPLICATION Any Standards contained in this publication were developed using reliable engineering principles and research plus consultation with, and information obtained from, manufacturers, users, testhg laboratories, and other having specialized experience. They are subject to revision as further experience and investigation may show is necessary or desirable. Construction and products that comply with these Standards will not necessarily be acceptable if, when examined and tested, they are found to have other features which impair the result contemplated by these requirements. The Sheet Metal and Air Conditioning Contractors' National Association and other contributors assume no responsibility and accept no liability for the application of the principles or techniques contained in this publication. Authorities considering adoption of any standards contained herein should review all federal, state, local, and contract regulations to specific installations. 5.

6. REPRINT PERMISSION Nonexclusive, royalty-free permission is granted to government and private sector specifying authorities to reproduce only any construction details found herein in their specifications and contract drawings prepared for receipt of bids on new construction and renovation work within the United States and its territories, provided that the matenal copied is unaltered in substance and that the reproducer assumes all liability for the specific application, including errors in reproduction.

7. THE SMACNA LOGO The SMACNA logo is registered as a membership identification mark. The Association prescribes acceptable use of the logo and expressly forbids the use of it to represent anything other than possession of membership. Possession of membership and use of the logo in no way constitutes or reflects SMACNA approval of any product, method, or component. Furthermore, compliance of any such item with standards published or recognized by SMACNA is not indicated by presence of the logo.

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TABLE OF CONTENTS

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SMACNA T I T L E * H V A C C M

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TABLE OF CONTENTS Foreword Building Services Committee Notice to Users of This Publication

iii iv V

CHAPTER1 PURPOSEANDSCOPE

1.1 1.2 1.3

Definition Purpose Scope

1.1 1.1 1.1

Historical Background Why Commissioning? SMACNAs Response Quality Management

2.1 2.1 2.1 2.2

3.1 3.3

Benefits Benefits of Recommissioning costs

Overview Program, or Pre-design, Phase Design Phase Construction Phase Acceptance Phase

8.1 8.2 8.3 8.4

General Critical Applications Commissioning Organization Level 3 Procedures

3.1 3.3 3.3

9.1 9.2 9.3 9.4 9.5

4.4

General The Commissioning Agent Skills and QualificationsCommissioning Agent The Commissioning Authority

4.1 4.1 4.1 4.2

9.6 9.7 9.8 9.9

CHAPTER 5 OVERVIEW OF THE PROCESS

APPENDICES

5.1 5.2

A

5.3

General Organizational Options for Commissioning Levels of Commissioning

5.1

Commissioning Schedule Level 1 Pre-Start and Start-up Checklists Level 2 Pre-Start and Start-up Check1ists Functional Performance Test Checklists Sample Specification: Commissioning of HVAC Systems Sample Report

6

5.1 5.2

C D

CHAPTER 6 LEVEL 1, BASIC COMMISSIONING

E 6.1 6.2 6.3 6.4 6.5 6.6 6.7

Overview Preparations Commissioning Plan Pre-Start Checks Functional Performance Tests Operations Instruction and Demonstration Summary

6.1 6.1 6.2 6.2 6.3

F INDEX

6.3 6.4

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8.1 8.1 8.1 8.1

Overview 9.1 Preliminary Investigation 9.2 Survey and Documentation Phase 9.2 Surveys to Confirm Existing Documentation 9.3 Surveys to Produce New or Revised Documentation 9.4 Analysis 9.5 Modifications 9.5 Recommissioning Tests 9.6 Documentation and Training 9.6

CHAPTER 4 AGENT AND AUTHORITY

4.1 4.2 4.3

7.1 7.1 7.2 7.3 7.5

CHAPTER 9 RECOMMISSIONING

CHAPTER 3 BENEFIT AND COSTS

3.2

7.1 7.2 7.3 7.4 7.5

CHAPTER 8 LEVEL 3, CRITICAL SYSTEMS COMMISSIONING

CHAPTER 2 INTRODUCTION

2.1 2.2 2.3 2.4

CHAPTER 7 LEVEL 2, COMPREHENSIVE COMMISSIONING

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CHAPTER 1

PURPOSEANDSCOPE

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CHAPTER 1 1.1

PURPOSEANDSCOPE

DEFINITION

Commissioning may be defied as: "the process of advancing systems from a state of static physical completion to a state of full, demonstrated, and documented working order, according to design requirements, during which time the owner's operating staff are instructed in correct systems operation and maintenance." In order to carry out the full commissioning process, it is necessary to plan and document it. Otherwise, for example, confirmation that a state of fully demonstrated and documented completion may not occur. 1.2

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PURPOSE

Over the past several years, there has been increasing recognition in the building construction industry of the need for effective building systems commissioning. For a number of reasons, industry commissioning efforts have focussed on heating, ventilating and air-conditioning (HVAC) systems. First, HVAC systems are among the most complex and interconnected of building service systems. Second, considerable energy is consumed in HVAC systems. Inefficient operation increases operating cost. Third, occupant comfort demands and concerns about substandard indoor air quality are both increasing. HVAC systems must be designed properly, then installed, operated, maintained, and serviced correctly, if both comfort and indoor air quality are to be attained.

This manual covers commissioning during the construction phase of a project in considerable detail. It puts particular emphasis on the commissioning agent, the commissioning authority, the commissioning plan, communication and coordination during construction, and commissioning documentation. This is to give the clearest possible guidance to contractors and others whose involvement is primarily during the construction phase of a project. This manual does not provide material specific to any particular building. The material within is intended to cover the entire commissioning process, providing not only organizational and procedural steps, but also the rationale behind them. This assists users of the manual to adapt the information to the successful commissioning of building projects. 1.3

The HVAC Systems Commissioning Manual is intended to cover the full range of HVAC equipment and systems typically found in commercial and institutional buildings. The level of commissioning varies to suit the specific requirements of each project as determined by the owner. The manual describes in detail the commissioning process for three different levels of commissioning. In addition, as an aid to users, it provides examples of pre-start checklists and functional performance test checklists for many types of equipment and systems. These include:

The primary purpose of this manual is to provide guidance to contractors on how an effective HVAC systems Commissioning process should be planned and carried out. A second purpose is to provide a clear explanation of the reasons for commissioning to make it understandable for a broad cross section of the industry. Contractors who understand commissioning are in a position to sell its use to owners, designers, and others.

Hot water and steam boilers; with atmospheric or power burners; gas, oil, or combination gasfoil fired. Chillers; with reciprocating, scroll, screw, or centrifugal compressors; air-cooled or watercooled; with or without condensers; and including heat recovery models.

Another purpose of the manual is to provide guidance on recommissioning HVAC systems in existing buildings. Any existing building with poor temperature control, dissatisfied occupants, excessive energy or maintenance costs, or other evidence of improper design or operation is a candidate for recommissioning. Because there are many existing buildings with these characteristics, and owners often contact contractors directly for remedial work on them, provision of recommissioning services is a potentially important field for knowledgeable contractors.

Cooling towers, closed-circuit heat rejectors, and both air-cooled and evaporative condensers. Hot water, chilled water, and condensing water pumps associated with the preceding. Constant volume, single zone air systems (including all components such as fans, coils, furnaces, condensing units, dampers, and controls, as applicable).

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SCOPE

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Constant volume, reheat air systems (including all central equipment, zone reheat components, and controls). Variable air volume (VAV) systems (including all central equipment, VAV terminals, and controls).

8

Outside air makeup and exhaust systems.

8

Pressurization systems, for fire emergency use.

8

Smoke control systems.

8

Controls integral with any of the preceding equipment and systems.

8

Valves, sensors, actuators, and controls external to the equipment, but required for control of fluid flow, temperature, or other parameters.

VAV reheat systems (including all central equipment, VAV reheat terminals, and controls). VAV systems with fan-powered terminals (including all central equipment, fan-powered VAV terminals, and controls). Water loop heat pump systems (individual heat pumps and loop pumping, heat rejection, and supplementary heating). Fan-coil units (including their controls and the systems used to provide them with outside air, heating, and cooling, as applicable).

In addition to the preceding specific equipment and systems, the manual also covers the commissioning of automatic actuation interfaces between HVAC systems and other building systems. The most common of these are f i e alarm systems and sprinkler systems.

HVAC Systems Commissioning Manual

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CHAPTER 2

INTRODUCTION

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INTRODUCTION

CHAPTER 2 2.1

HISTORICAL BACKGROUND

Over the years, buildings and their services have gradually become more complex and varied. At one time, systems were simple, with few controls (mostly manual), and similar from building to building. After installation, a simple equipment start-up by the contractor was often all that was needed. The equipment, and thus the system, either worked or not. If not, diagnosis and correction was usually obvious and quick. Building operators understood such simple systems and, thus, usually were able to keep them operating correctly. When energy consumption was not a concern, equipment oversizing could often compensate for incorrect operation and comfort conditions would not be affected. Today, there is a wide range of equipment and systems used for building HVAC. These systems are often complex, particularly in their controls. They have come about in order to meet a whole series of conflicting pressures: capital cost constraints; more stringent building codes, particularly with respect to smoke control; higher energy costs; energy conservation standards and codes; and occupant demands for better comfort and good indoor air quality. 2.2

WHY COMMISSIONING?

The primary purpose of commissioning is to obtain a building whose service systems function in all respects according to design intent and to meet the needs of the occupants. To achieve this, it is essential to implement a commissioning process in which functional and environmental performance is tested, verified, and documented prior to occupancy-and is maintained during occupancy. The simple start-up of old is no longer adequate. If modem building systems are going to function properly, they must be designed competently and then installed correctly. On the installation side, this means checking that all aspects of the installation are complete before start-up. Once started, system operation must be checked and verified in detail. Once that is done, operators must be familiarized with all aspects of the operation of the systems. This is critical, because correct systems operation often requires a basic understanding of their capabilities, limitations, and intended control sequences. Without instruction, operators often do not have this knowl-

edge. in addition, due to smaller safety factors and more demanding occupants in today's buildings, there is less margin for error. Finally, building owners and operators must be provided with usable documentation on inspection, service and maintenance requirements and be instructed on the importance of carrying them out. An effective, ongoing service and maintenance program is essential for achieving efficient system performance, providing occupant comfort, and extending equipment life. Unfortunately, in many cases, the construction industry has not updated its practices to meet the demands of today's systems, owners, and building occupants. In addition, many owners think they are getting, and paying for, a fully commissioned building when, in fact, they are not. Application of information in this manual will enable contractors to upgrade their skills and update their commissioning practices to meet today's needs.

2.3

SMACNA exists to encourage and enable sheet metal and air conditioning contractors, and others in the industry, to improve their capabilities and the quality of the installations they produce. The development and distribution of standards and manuals and participation in training programs are a central part of this effort. The contractor has traditionally had the responsibility of providing a complete and fully functioning installation. In essence, "fully functioning" also means "fully commissioned." Thus, the traditional responsibility includes all the activities involved in planning the commissioning process and implementing it on site. Refer to Chapter 5, Overview of the Process. For this reason, this commissioning manual advocates that commissioning be aggressively adopted by the construction industry and retained as part of the contractor's responsibilities. Section 5.2 provides more detail in this regard. A total quality management philosophy, as described in Section 2.4, is also an integral part of this approach. The commissioning agent is an integral part of implementing the commissioning process. Chapter 4 provides some information on commissioning agents, and Section 4.3 details the skills and qualifications

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SMACNA'S RESPONSE

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needed by them. Contractors have to be prepareà to retain external commissioning agencies, or to develop the required expertise internally, in order to undertake HVAC systems commissioning as described in this manual. The owner, and his designers, determine the terms of reference, the scope of work, and the detailed specification requirements, all as contained in the contract documents. If specific commissioning requirements are contained therein, it is the contractots responsibility to meet them. The owner should have some means of ensuring the contractor carries out those responsibilities. This corresponds with Level 2 commissioning, as described in Chapter 7. However, even when the contract documents do not contain any explicit commissioning requirements, commissioning can still be planned and carried out by the contractor. This is what is referred to as Level 1 commissioning and is described in Chapter 6. In essence, Level 1 commissioning is the minimum that should be carried out by any responsible and knowledgeable contractor committed to quality work. This manual outlines how, if commissioning is done properly and expertly, a better product can be produced at no additional cost.

2.4

QUALITY MANAGEMENT

Commissioning is essentially a quality process. Quality is built into a product-not achieved by trying to fix problems after they have occurred. A quality product does not need to cost more to produce, but many changes to both processes and attitudes may be necessary to achieve the goal of quality products. SMACNA is convinced that commissioning, as an integral part of the design and construction process, is one of the means of raising the quality of the HVAC systems that contractors turn over to owners. Helping the industry to improve its quality management performance is one of the goals of this manual. It

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focusses on a commissioning process, which is truly integrated into the overall construction process, as a means of moving toward that end. If commissioning is planned and carried out properly, this increase in quality can be achieved with a reduction in construction cost. In other words, the cost of undertaking the commissioning process is more than offset by efficiency in other areas. Nevertheless, when a comprehensive commissioning process is required of the contractor, the specifications must clearly define the work required. The specifications must d e f ï e the commissioning procedures to be followed and all related contractor responsibilities, including those of the commissioning agent. They must also define the scope of equipment, subsystems and systems to be commissioned. Only when process and scope are both defined, can contractors bid the work fairly. And finally, only when the specification is enforced objectively by the owner's designer or commissioning authority, is this fairness carried through to the end of the project, to the benefit of both owner and competent contractors. Unfortunately, a building is not a product for which prototypes can be built, tested, revised, and fine tuned before full production begins. Every building is a prototype. Furthermore, the construction industry is fragmented, involving a vast array of contractors, subcontractors, suppliers, tradesmen, test and balance specialists, controls technicians, equipment startup specialists, designers, inspectors, and owner's staff. With competitive bidding on every element, a lowest immediate cost mentality prevails for every item, at every level of bidding. In such an environment, it is very difficult for the contractor to consider an overall quality management approach, let alone achieve it. However, a quality management approach, incorporating a commissioning process as outlined in this manual, has the potential to produce a better product for the customer at a reduced overall cost. It is a goal worth achieving.

HVAC Systems Commissioning Manual

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CHAPTER 3

BENEFITS AND COSTS

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CHAPTER 3

BENEFITS AND COSTS

3.1

BENEFITS

3.1.1

Overview of Benefits

The benefits of commissioning accrue to owners, designers, contractors, and occupants or tenants. Ultimately, however, the majority of benefits, in the form of a building that functions properly, accrue to the owner. To request commissioning beyond the basic Level 1, the owner must be convinced of these benefits. Many, perhaps most, owners think they are already getting, and paying for, a completely functional building, when in fact they are not. Such owners are not be aware of the benefits available to them from commissioning. They need to be informed of these benefits by designers and contractors who understand both the practice of, and the rationale for, the commissioning process. 3.1.2

and accurate diagnosis is likely, leading to quicker and possibly less expensive corrective action. In dealing with occupants, trained operators can provide more accurate information on the nature of the problem and do so in a way which instills confidence in the owner's staff. Of course, the problems must be resolved. But when they are, the resulting happy occupant or tenant is a valuable asset to a building owner. 3.1.3

Benefits to Designers

There are more demands on designers today than ever before. The changes in systems, energy concerns, indoor air quality (IAQ) issues, increasingly stringent codes, and the revolutionary changes in controls technology are all responsible. Designers are asked to design systems which not only meet design conditions, but operate well at part loads, are accessible for service and maintenance, and are within the owner's budget.

Benefits to Owners

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Commissioning benefits owners by adding value to a project. It can result in the owner's needs for the building being thought through and documented carefully at the program phase. Design intent and the designer's bask sf design can thus be more responsive to the owner's needs. When commissioned, the facility operates in accordance with design intent, maintains thermal comfort, and produces a high level of occupant satisfaction. Another benefit to owners is fewer unidentified deficiencies at takeover, particularly hidden ones resulting from incorrect functioning of controls. Thus, owners will not have to either pay for later correction or live with the problems. Well commissioned systems are set up to function at maximum efficiency, minimizing energy and operating costs. In order to achieve this third benefit, knowledgeable building operators are essential. Owners must put sufficient priority on this aspect of their building operations and maintenance management. Operator involvement in the commissioning process itself can be an important familiarization and educational experience. But it must be followed up, particularly as staff changes take place over time.

In addition to the operational benefits already mentioned, knowledgeable operators bring other benefits to the owner. When there are problems, fast

Designers can benefit from commissioning through involvement with the functional performance verification and acceptance tests, especially in instances when properly installed and operating systems do not meet design criteria. These tests measure how the design performs dynamically in the field and can provide valuable feedback to help guide future designs. 3.1.4

Commissioning benefits are maximized when contractors are an integral part of the commissioning process and, thus, are in a position to make it work for them. Contractors who merely tolerate the process-or worse, try to avoid it entirely or work against it-will not see these benefits. The benefits of commissioning to contractors can include the following: Improved construction planning and coordination, 0

Fewer outstanding deficiencies at substantial completion,

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Quicker project completion,

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Better documentation of equipment start-up, which aids warranty administration,

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Benefits to Contractors

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More satisfied clients and owners after completion,

process, have seen correct system operation and understand it, will not complain unjustifiably. On both counts, customer satisfaction is increased

Reduced callbacks, and 0

Another benefit to the contractor is reduced callbacks. These can result from deficiencies discovered after substantial completion. As noted, commissioning provides a practical means to minimize these. Callbacks can also result, when there is no real problem, because operators do not understand the-operation or lim&ions of the design. When the commissioning process is carried out properly, more knowledgeable operators result, reducing this cause of callbacks.

0

Finally, commissioning can reduce overall contractor costs. Planning and carrying out commissioning definitely has a cost (Section 3.3), but these costs can be more than offset by the savings made possible by the process. Improved site labor utilization can result from better site coordination. Tradesmen can be assigned to tasks truly critical to timely completion with some confidence that the necessary prerequisite work has actually been completed. Reduction in unproductive time results. Fewer deficiencies reduce the time and effort (and thus the cost) of getting trades back to site to correct them. Fewer callbacks reduce another source of cost.

Each of these benefits is expanded upon in the followine: The first benefit, an overriding one, is that commissioning can produce better planning and coordination. Having a commissioning plan and dedicated commissioning personnel committed to following through on it is important in this regard. Priority items, and responsibilities for them, can be identified and followed up. Improved on-site communications are critical but are facilitated by the commissioning personnel.

A second benefit to contractors is fewer deficiencies at substantial completion. The various pre-start checks and functional performance tests result in early identification of deficiencies from faulty equipment or incomplete or incorrect physical installation work (including controls problems not detectable by physical inspection, but requiring dynamic testing). When deficiencies are identified, the step-by-step logic of the commissioning checks and tests often isolates their causes and, therefore, who should be responsible for correction. If it is an installation problem, correction by the responsible trades while they are still on site is commonly possible. If it is a design problem, it can be referred with documented evidence to the designer. All these factors are money and time savers for the contractor. Potential for more timely payment and project closeout. Commissioning results in improved documentation. It is easier to identify specific equipment and system start dates for warranty and payment purposes. In addition, documentation will usually c o n f i that correct equipment start-up procedures were followed.

A most important benefit is a satisfied client or owner after completion. This results from systems that function as intended; in other words, the quality promised is delivered. Operators who, through their exposure to the commissioning

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3.1.5

Benefits to Occupants and Tenants

The dominant benefit in this category is increased employee productivity brought about by occupant satisfaction with the building and minimum time lost to complaints or absenteeism caused by what is termed ”sick building syndrome.’’ When commissioning has been carried out competently and thoroughly, the building systems function as designed and, with good operation, will continue to do so. Environmental conditions and IAQ will be in accordance with design intent, so a high level of occupant satisfaction with respect to these factors is to be expected. While definitive comparisons are extremely rare, it is recognized that improved employee satisfaction results in improved productivity, with benefits vastly greater than any costs from commissioning or other means of achieving the improved building conditions.

In owner-occupiedbuildings, benefits in this category could be considered among those received by owners. In tenant-occupied buildings, these benefits flow directly to the occupants, but, in a very real sense,

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they also go to the owners because, if the tenants are satisfied, retaining existing tenants and obtaining new ones will be much easier.

3.2

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O

HVAC systems not functioning correctly,

0

HVAC systems operating inefficiently, thus wasting energy and increasing cost,

o HVAC systems zoning and layout do not match

current occupancy or usage, O

Comfort needs of occupants not being met,

0

IAQ problems,

O

Occupant complaints, or

O

Reduced occupant productivity.

Many of the noted conditions or problems can be interrelated. The following discussion provides additional information. HVAC systems that are not functioning correctly often contribute to occupant discomfort. Sometimes such situations are of such long standing, they have become accepted as normal and are difficult to diagnose. Nevertheless, they are real.

e Often, tenant alterations occur without correspond-

ing adjustments to the HVAC. As a result, the HVAC layout and zoning no longer match the current occupancy. This contributes to ventilation, temperature control, and other problems. e

Systems not operating properly are often less efficient. There is an energy savings opportunity in proper operation..

O

When comfort needs are not being met, for whatever reason, there are almost always increased costs of some sort.

m

O

Poor IAQ can be one of a building owner's most severe problems. In extreme cases, buildings have been evacuated while corrective measures are identified and carried out. Clearly, the direct cost of such an event is extremely high, and there is huge potential for indirect costs related to litigation and bad building "reputation." It is important to owners to avoid problems of this magnitude.

0

Occupant complaints and reduced productivity are often related. Both, however, result in additional costs, one from investigations of causes of complaints, the other from reduced work output.

BENEFITS OF RECOMMISSIONING

Recommissioning is the practice of applying the commissioning process to an existing building or systems. Recommissioning can bring enormous benefits to owners, mostly by eliminating sources of avoidable cost or overcoming problems, such as occupant complaint or excessive vacancy. Some reasons for recommissioning are:

0

m

Unfortunately, most owners do not recognize they have problems or avoidable costs that would justify recommissioning until they are so severe as to be overwhelming. Often, the best way to identify whether or not a building is a candidate for recommissioning is to carry out a preliminary survey to evaluate the factors noted above. Knowledgeable contractors, particularly those with design expertise, are often in a good position to carry out such surveys and advise owners concerning the costs and benefits of recommissioning. Where recommissioning is justified, the emphasis should be on the savings opportunities available. Contractors can benefit from recommissioning in three ways. First, it is a potential source of new business, but only for thosewith staff having the necessary knowledge and skills (Section 4.3). Second, because of the extreme importance of capable operations and maintenance in keeping buildings functional, it is an opportunity to sell owners on improved maintenance programs and more capable operators. Third, to the extent owners of existing buildings recognize the benefits of commissioning, there will be an increase in the demand for improved commissioning in any new construction they undertake. 3.3

COSTS

3.3.1

Overview of Costs

Commissioning requires time and, therefore, has a cost. All commissioning costs are eventually borne by the owner, either directly or indirectly. It is important to remember, however, these costs are more than offset by benefits to the owner. Total costs for Level 1 or Level 2 commissioning typically range between 2 and 5 percent of the HVAC

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construction cost. In general, these percentages tend to: o Drop as the project size rises, 0

0

Rise for projects located further away from major urban centers, and Rise as controls and interfaces between systems become more complex.

Each of the major parties to the commissioning process incur some of the total cost: Costs to Owners. In Level 2 commissioning, the owner incurs costs for making staff (or service contractors) available for familiarization, instruction, and demonstration. Typically, for H V A C commissioning, such costs do not exceed 0.5 percent of the mechanical cost. In Level 1 commissioning, the owner imposes no specific commissioning requirements and, therefore, may not participate in the commissioning process; however, a wise owner will make operating staff available as noted for Level 2. Costs to Designers. The principal commissioning cost incurred directly by designers is for additional on-site time for systems performance verification, if the owner has retained them to act as commissioning authority. For Level 2 HVAC commissioning, additional on-site time could result in costs of up to 0.5 percent of the mechanical cost.

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Costs to Contractors. The direct costs of Level 1 or Level 2 H V A C commissioning incurred by the contractor, including the cost of the commissioning agent’s work, is typically in the range of 1 to 4 percent of the mechanical cost. Level 3 commissioning costs are higher than those for Level 2. The exact amount depends heavily on the degree of detail in the required test protocols, number of different components requiring Level 3 testing, and a host of other factors. This cost is incurred for additional owner staff time, additional designer time, additional contractor commissioning services, and (possibly) test fees to specialized agencies certified to carry out specialized testing work. Chapter 8 provides some additional commentary in this regard, 3.3.2

Recommissioning Costs

Recommissioning costs vary greatly. It is impossible to suggest a range in a limited discussion such as this. (Refer to Chapter 9, in which recommissioning is discussed in some detail. This gives some indication of the possible tasks required in a recommissioning project.) However, it is important to note that recommissioning is driven not by its cost, but by the savings opportunities identified in the initial surveys leading to the decision to proceed.

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CHAPTER 4

AGENT AND AUTHORITY

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CHAPTER 4

AGENT AND AUTHORITY

GENERAL

Institute (NEMI) or National Training Fund (NTF) training programs, manufacturers technical training programs, or design office experience.

The use of two separate terms, commissioning agent and commissioning authority, is not common in the industry today. Both terms are used in this manual because they provide a means of describing the commissioning responsibilities of those who actually carry out commissioning and those who verify and accept the results on behalf of the owner.

4.2

Experience in either the engineering or installation and field testing of controls systems for a range of HVAC systems is also needed. Knowledge of controls is important to overall system function and is closely related to HVAC systems knowledge.

THE COMMISSIONING AGENT

Training and experience in testing and balancing of air and hydronic systems proves valuable in on-site work.

For the purposes of this manual, the commissioning agent is defined as the persons or company responsible for carrying out the detailed planning and implementation of the commissioning process. It is important to recognize that the commissioning agent's role is usually carried out by a team, rarely by one person, except on very small projects. In some respects, the term "commissioning agency" might be more appropriate; however, in this manual the term "commissioning agent" is used.

Good writing and documentation skills are essential for a number of commissioning tasks: (i) Preparation of an understandable and useful commissioning plan incorporating all the steps required, in the correct order, (2) Producing useful commissioning meeting minutes, and (3) Documenting test results as they are obtained. A knowledge of computer use for some of these tasks is becoming essential for productivity, recordkeeping, effective use of master lists, and selecting information for dissemination.

Usually, the commissioning agent's responsibilitiesare during the construction phase of a project. However, in situations where commissioning agents are appointed during the design or pre-design (program) phases, they may have input with respect to the planning of the commissioning process at those earlier times. In particular, this includes coordinating and documenting the on-site tests described in the commissioning plan.

Planning and organizational skills tie in with the writing and documentation skills just described. The ability to plan ahead and visualize the steps that must be taken in order to have a successful commissioning process is critical. This includes focusing on the details of what must be done, organizing those details into a coherent plan, which contractors can understand and follow on the jobsite, and not losing track of the overall goal. These skills also include an ability to prioritize, communicate to those involved, and follow through on required corrective actions.

(Chapters 6 through 9 describe the commissioning agent's duties and responsibilities in some detail.) The commissioning agency's function may be carried out by a separately retained company specializing in commissioning work or by properly skilled staff of the contractor carrying out the work. 4.3

Excellent communications skills, with everyone involved in the project, are necessary. These skills are important because the jobsite effectiveness of the commissioning agent often depends on good working relationships to achieve the needed cooperation. Previous jobsite experience and a considerable degree of maturity in conflict resolution are helpful in this regard, all targeted towards eliciting real cooperation and effective progress to project completion.

SKILLS AND QUALIFICATIONSCOMMISSIONING AGENT

The ideal commissioning agent has most or all of the following qualifications, experience, and skills: A good knowledge of a variety of HVAC equipment and systems is important. This knowledge needs to include an understanding of the design basics behind each system and how each is typically controlled in order to perform as designed. It can be obtained from technical school, relevant National Energy Management

Relatively few individuals have all the skills and experience outlined above. For this reason, a team approach is often be the most effective way for a commissioning agent to implement the commissioning

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process, with each member contributing some of the skills needed.

and in the context of the overall commissioning process.)

It is important to remember, however, that commissioning is primarily an organizational and planning task. Therefore, those skills are as essential to commissioningas the technical knowledge concerning the systems being commissioned.

The commissioning authoriìy is usually someone on the owner's staff, the owner's design professional, or a commissioning specialist retained by the owner specifically to represent his interests with respect to commissioning.

4.4

THE COMMISSIONING AUTHORITY

The commissioning authority is defined as the persons or company responsible, on the owner's behalf, for ensuring the commissioning process is properly camed out according to contract requirements during the construction phase. This includes witnessing functional performance tests and verifying acceptable performance. It also includes ensuring the required documentation is produced.

However, for Level 3 commissioning (Section 5.3.4), the specific types of system or installation may require very specialized knowledge. In such cases, the commissioning authority-and, for that matter, the commissioning agent-must have that knowledge to carry out their responsibilities competently. Therefore, the owner may bring in separate specialists (or require his overall commissioning authority do so) for overseeing the Level 3 commissioning work.

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(Chapters 6 through 9 describe the commissioning authority's duties and responsibilities in some detail,

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CHAPTER 5

OVERVIEW OF THE PROCESS

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5.1

OVERVIEW OF THE PROCESS SMACNA advocates the contractor commissioning option for a number of reasons:

GENERAL

There is really only one commissioning process, but it must be applied to a broad range of projects and systems. In order to be practical and economically justifiable, commissioning must be organized to accomplish its desirable results at a cost consistent with the value of the particular project. in other words, commissioning must be performed within an acceptable labor hours commitment. The value of a project-and thus the appropriate time and cost commitment-will depend on the:

0

Contractor responsibility for carrying out commissioning is consistent with the implementation of total quality management principles, as outlined in Chapter 2. Unless the commissioning process is an integral part of the contractor's work and responsibility, using it to improve planning, organization, and quality is impaired.

0

It maintains the traditional owner/designer/ contractor contractual relationships, specifically that the contractor is responsible for providing a totally complete and functional installation according to the contract documents.

Size of the project, 0

Complexity of systems, and their controls, being commissioned,

0

Degree of controls interface between different systems,

0

Existence of acceptance test procedures mandated by code or regulation, and

0

Owner's commissioning requirements.

If a third party is involved during the construction process for the purpose of commissioning, there may be a tendency for the contractor to back away from responsibilities for functional operation, letting the owner's commissioning agent discover any problems. This is inconsistent with SMACNA'S total quality goals. 0

5.2

ORGANIZATIONAL COMMISSIONING

OPTIONS

FOR

The owner is still allowed any desired degree of oversight and verification through his commissioning authority, thus ensuring requirements are met. This same oversight protects competent contractors by demanding performance to a standard of acceptance consistent with contractual requirements. Competent contractors are able to perform to the required standard. Other contractors may have a great deal of difficulty, and expend much time and money, attempting to meet the standard.

There are two organizational options for commissioning: Owner Commissioning. The owner plans and carries it out, either with his own staff or by retaining a Commissioning agency. With owner commissioning, there is an agency external to the contractor intimately involved in the construction process. This type of commissioning is advocated by many as providing a truly independent authority, who is best able to represent the owner over the whole range of design and construction. For example, the owner's commissioning personnel can also review the design, if they are independent of the designer. Contractor Commissioning. The contractor plans and carries out the commissioning process, either with a properly skilled group of his own staff or by a commissioningagency acting as a specialist sub-trade. The owner, if he has specific commissioning requirements in the contract, will have his own commissioning authority to oversee the process and verify and accept the results. The commissioning authority may be the designer, the owner's own staff, or separately retained specialists.

The descriptions of the commissioning process contained in this chapter, and in Chapters 6 through 9, are written assuming the use of the contractor commissioning option. When applicable, the descriptions outline designer and contractor responsibilities separately, as would be the case with a project designed by the owner's consultants and bid competitively to contractors. However, they are equally applicable to design-build projects. In the design-build case, however, the owner's commissioning authority may sometimes be independent of the designer.

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The process emphasizes and rewards the integrity and competence of contractors.

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5.3

LEVELS OF COMMISSIONING

5.3.1

Introduction

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The variations in project size, complexity, critical or highly specialized systems, and owner requirements suggest describing the commissioning process in terms of different "levels" of commissioning. Three different levels of commissioning are described in this manual: 1. Level 1: Basic Commissioning

2. Level 2: Comprehensive Commissioning

Identify problems as they arise and provide a mechanism for getting them corrected by whomever is responsible, with followup to prevent them from being neglected. Provide documentation showing that system installation and operation is according to requirements. Ensure the contractor is able to operate the equipment and systems to demonstrate system performance and functionality, according to contract requirements, to the designer or owner, if requested by the designer or owner.

3. Level 3: Critical Systems Commissioning These levels of commissioning are explained in Sections 5.3.2 through 5.3.4 and described in some detail in Chapters 6 through 8. This manual also includes information on recommissioning of HVAC systems in existing facilities, which is of increasing importance. Section 5.3.5 provides a brief description of the recommissioning process, and Chapter 9 describes recommissioning procedures in detail. 5.3.2

Level 1-Basic Commissioning

Competent contractors, committed to producing quality work, want to take steps to ensure they deliver on that quality commitment. Level 1 commissioning can be one tool to help them reach that goal. Generally, Level 1 commissioning is carried out by the contractor during the construction and acceptance phases of the project. Level 1 commissioning is intended to: Ensure the contractor meets a basic contractual requirement to produce a complete and fully functional installation in accordance with the contract documents. Help the contractor plan, organize, and coordinate that part of his work related to completing the installation and getting equipment and systems started properly, safely, and on schedule. Ensure that systems operation, including all control sequences, is checked out and that functional performance as specified is achieved in all respects.

5.2

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Provide a framework for giving training and demonstrations in correct systems operation to the owner's operating staff and for providing instructions and recommendations concerning the maintenance program for the completed systems. Carry out all of the preceding in the most efficient manner possible and without increasing overall contractor costs for the project (even though there is some cost for the commissioning process itself). (Refer to Chapter 6 for a detailed description of Level 1 commissioning procedures.)

In Level 1 commissioning, ihe benefits to the contractor noted in Chapter 3 have the potential to be greater than the costs incurred to plan and carry out the commissioning process. For a contractor committed to quality, Level 1 commissioning should be carried out whether or not there is any explicit commissioning requirement imposed on the contractor by the owner or the designer in the contract. 5.3.3

Level 24omprehensive Commissioning

Level 2 commissioning applies when the owner mandates commissioning requirements based on his own policies and standards or on what he has accepted as a result of recommendations from designers, contractors, or others. The designer's responsibilities with respect to commissioning are contained in the owner's contract with designer. The contractor's responsibilities with respect to commissioning are contained in the owner's contract with the contractor. If a project is being

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carried out by designlbuild, then the preceding would be combined. The owner should have a commissioning authority to ensure the contractor carries out his commissioning responsibilities properly. In addition, the owner should have some mechanism in place to ensure the designer also carries out his responsibilities. These arrangements need to be defined and communicated to all affected parties. The major differences between Level 1 and Level 2 commissioning are as follows:

ôL89350 0005526 373

Often, Level 3 commissioninggoes beyond functional performance to include what could be termed operational or environmental performance. Correct functionality is not enough. After correct functionality is achieved and verified, the specified environmental conditions must also be achieved, verified, and maintained. One example is specific room/ corridor pressure relationships in a laboratory that must be maintained during all normal lab operations. Tests might include monitoring supply/exhaustair flows and room/comdor pressures while fume hood sashes are operated and the lab entrance door is opened and closed.

Level 2 tends to have more comprehensive pre-start, start-up, and functional performance checks and tests. This is linked to the enhanced documentation requirements for Level 2 commissioning.

in Level 3 commissioning,the owner often decides to maintain direct control over the commissioning process, particularly that portion extending beyond functional performance (Section 5.2). in these circumstances, the owner will only select a commissioning agent and commissioning authority (who may be the same organization or individuals) in whom he has complete confidence. Although cost clearly is a selection criterion, knowledge, experience, effectiveness, and integrity are often be the deciding factors in selection. It is a situation in which a partnering mangement between an owner and an accomplished commissioning agent is appropriate.

Level 2 may include more detailed commissioning at the zone terminal level.

Some examples and characteristics of "critical" systems are:

Level 2 likely requires more commissioning attention to interfaces between the HVAC systems and systems installed under other divisions of the work (for example, fire alarm or security).

Fire Safety. Systems providing fire alarm signalling, fire suppression, smoke control, or evacuation or simply responding in some way to a fire condition (e.g., shut down, go to 100 percent exhaust, etc.).

(Refer to Chapter 7 for a detailed description of the Level 2 commissioning process.)

Life Safety. Systems for hospitals (particularly operating rooms or isolation areas) or laboratories, in which dysfunction could threaten the health or safety of patients, staff, or visitors.

Preparations for Level 2 start in the pre-design or design stages of the project. Level 2 has more formal and comprehensive documentation requirements. Designer and owner review of the commissioning plan should take place.

5.3.4

Level 3-Critical Systems Commissioning

Level 3 commissioning is the most detailed and exhaustive application of the commissioning process. It is carried out in those facilities for which correctly functioning and performing systems are extremely important. Level 3 commissioning is driven by either specific owner requirements or by code or regulatory requirements. in some cases, Level 3 commissioning involves acceptance test procedures that are witnessed, and the results certified, by a regulatory official independent of both owner and designer.

Automatic Backup or Standby. Systems important enough to justis. standby or redundant equipment designed for automatic activation in the event of a failure of primary equipment. The means for detecting the failure, and for responding, must both be covered.

Large Cost if Failure Occurs. Most obvious with respect to costs associated with industrial or process production shutdowns or failure to maintain product specifications, but also applicable to major computer operations and many others.

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Possible Impacts on Occupant Safety or Health. For example, critical care hospital facilities or biological containment laboratories, (Refer to Chapter 8 for additional information on Level 3 commissioning.) 5.3.5

Recommissioning

Recommissioning is authorized by a building owner who has become aware of the benefits of this process. Recommissioning can identify causes of operating problems, occupant complaints, or avoidable costs. It can then provide the means to plan, carry out, and commission corrective measures. Problems that can be identified and corrected through recommissioning include: HVAC systems not functioning correctly, 0

HVAC systems operating inefficiently, thus wasting energy and increasing cost,

0

HVAC systems zoning and layout not matching current occupancy or usage,

0

part of a building survey, the structured and organized approach inherent in the survey, analysis, and reporting phases of recommissioning can produce valuable insight into the condition and capabilities of the HVAC systems in the building. In commissioning for new construction, all the relevant documents, shop drawings, balancing reports, and other information are generally available (or will be at the appropriate time during the process). However, in recommissioning, this may not be the case. Therefore, in many cases, a major task of recommissioning is to gather the necessary data about the existing installation. Once the data is available, the planning and execution of the recommissioning process are very similar to Level 2 commissioning or, in a few cases, the more stringent Level 3. One major difference is that the building is already complete, there are not usually other trades on the job, and the building may be occupied. These factors must be accommodated in the planning process.

Reduced occupant productivity, or

The owner may retain a contractor directly as the commissioning agent, or a design professional may direct the overall process, acting as commissioning authority, through whom a commissioning agent reports. Recommissioning is particularly relevant to contractors because, if they are doing service and maintenance work in the building, they may be aware of conditions justifying some degree of recommissioning and be in a position to make recommissioning proposais to the owner for consideration.

Difficulty attracting or retaining tenants, leading to vacancy and lost revenue.

(Refer to Chapter 9 for details of a typical recommissioning process.)

Comfort needs of occupants not being met, Indoor air quality problems, Excessive and persistent occupant complaints,

0

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A prospective owner may also be interested in the problem identification phase of recommissioning. As

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CHAPTER 6

LEVEL

BASIC COMMISSIONING

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LEVEL 1, BASIC COMMISSIONING

CHAPTER 6 OVERVIEW

This chapter covers what the contractor and his commissioning agent must do to carry out basic commissioning procedures effectively. However, nearly all the tasks listed in sections 6.2 through 6.5 are carried out by the Commissioning agent, with the involvement of the HVAC contractor and his suppliers, sub-trades, and other contractors (for example, electrical), whose work must be coordinated with that of the HVAC contractor. The commissioning agent function may be carried out by a dedicated group within the W A C contractofs organization or by a separate company acting in a sub-trade relationship. The term ?commissioning agent? will be used to describe the function, regardless of whether the contractor carries it out directly or through a separate company. Much of the benefit to contractors from commissioning arises from improved planning, scheduling, and coordinating of work (Chapter 3). These benefits will only be achieved, however, if the commissioning agent makes commissioning a top priority right through to acceptance of the completed installation. Therefore, it is important that the commissioning agent be assigned to the commissioning function and not be taken away from that function to do other tasks.

6.2

PREPARATIONS

The commissioning agent?s first task is to pull together: Statement of design intent, Schedule information, List of equipment and systems needing to be commissioned, List of sub-trades, suppliers, and other contractors (most commonly the electrical contractor) who will be involved in the commissioning process, and

with the overall project schedule. Any conflicts need to be resolved, or at least identified, so they can be watched carefully.

This schedule is usually a simple bar chart. Typical events and tasks on it include: 0

Dates for completion of installation, ready for pre-start checks, often on a system-by-system basis,

0

Elapsed time allowance for pre-start checks and start-up, possibly on a system-by-system basis,

0

Time allowance for correcting any pre-start problems and rechecking,

0

Elapsed time allowance for functional performance tests, possibly on a system-by-system basis, and

0

Time allowance for correcting any functional problems and rechecking.

(Some examples are shown in Appendix A.)

Rationale: The schedule is a critical planning and communications tool. It lets each supplier, sub-trade, and other contractor know when their work must be completed on a system-by-system basis in order not to delay commissioning and final acceptance. Equipment and System Pre-Start and 6.2.3 Start-up Checklists

The commissioning agent prepares equipment and system pre-start and start-up checklists. These checklists focus on critical items that suppliers, subtrades, and other contractors must complete before start-up can occur safely and operation under control can take place. These checklists should identify installation responsibilities and will generally cover: 0

Equipment mounting and hook-up,

0

Electrical services,

0

Controls installation, including safety controls, and

All submittal data and controls sequence descriptions needed to prepare commissioning checklists. The commissioning agent prepares a commissioning schedule that identifies commissioning tasks and the estimated time each will require. This is coordinated

Any other applicable pre-start requirement, for example, pressure testing, pipe cleaning and water treatment, or boiler/gas/ electrical inspections. Appendix B contains examples of pre-start and start-up checklists for a range of equipment and

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systems. For efficiency, these checklists should be produced from master lists, with modifications to suit the project specific equipment or system. The use of computers to store masters and retrieve, edit, file, and print these lists greatly speeds their production and improves their content, consistency and legibility.

Rationale: These lists identify who must do what in sufficient detail to define responsibility. When combined with the schedule, they also pinpoint when work must be done to stay on schedule. 6.2.4

Functional Performance Checklists

The commissioning agent prepares functional performance Checklists. These checklists provide a system specific, step-by-step process to test system performance against the specified control sequences. These checklists typically cover tests of: 0

Each mode of operation, for example, unoccupied, morning start-up, and occupied,

0

The sequence of controls, for example, economizer operation and on-off, staging, or modulation of heating and cooling components to meet changing loads, and

0

Safety or emergency controls, for example, freeze protection or power failure response.

These checklists are intended to facilitate efficient, yet effective, contractor testing of systems functional performance against specified requirements; therefore, they need to cover all specified functions, but care must be taken to ensure that they are not overly complex and are easy to use on the jobsite. Appendix D contains examples of generic functional performance test checklists for a range of equipment and systems. These checklists need to be revised to cover the exact control sequences and functional requirements for the system in question because they tend to vary greatly from project to project. However, these generic checklists do include most of the common control elements which need consideration (e.g., fans, pumps, coils, dampers, controls, valves, compressors, boilers, temperatures, static pressures, etc., as applicable). Thus, they will provide a good base from which to prepare project specific lists. As with pre-start checklists, the use of computers to store masters and retrieve, edit, file, and print them greatly speeds production and improves content, consistency, and legibility.

Rationale: Working out the step-by-step procedure for testing systems operation ahead of time, and documenting it in lists, enables efficient testing in the field, makes documentation of results easy, identifies problems (and who is responsible for correcting them), and provides evidence of acceptable performance, if that is demanded by the designer or owner. 6.3

COMMISSIONING PLAN

The schedule (Section 6.2.2), the pre-start/start-up checklists (Section 6.2.3), and the functional performance test checklists (Section 6.2.4) together wiil form the commissioning plan. The timing of its preparation and the extent of its distribution is up to the contractor; however, preparation as soon as the necessary information is available is recommended.

Rationale: Early preparation, indicating elapsed time requirements and the optimum sequence of tasks, can help to identify any scheduling conflicts early, making resolution more likely. Subsequent schedule revisions are almost certain to be needed, but making revisions from a coherent schedule is much better than scrambling with no plan. Distribution to all parties with responsibilities related to the successful completion and operation of the HVAC installation is recommended.

Rationale: If everyone is not informed, there is reduced coordination. If they are informed, and make commitments accordingly, then the contractor has a better basis for demanding and getting timely performance and results from his sub-trades and suppliers. An example of a commissioning plan for the HVAC systems in a small office building is in Appendix F. This example illustrates how the various elements of documentation should be organized in the plan for use on-site during the pre-start/start-up and functional performance test phases of the commissioning process. 6.4

PRE-START CHECKS

When installation of equipment and component parts of a system, or group of systems, is or should be complete, the commissioning agent coordinates and performs pre-start checks according to the relevant checklists. The results are documented on the lists. If everything is satisfactory, then the equipment and

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system can be started up and put into operation, ready for functional performance testing. If something is not satisfactory, the deficient, faulty, or incomplete items and the required corrective actions are noted on the checklist. The commissioning agent notifies the party responsible for correcting the problem. This notification can be in the form of a copy of the checklist or an "action report" containing only items pertaining to that one party. (See Appendix C for examples.) Agreement on a deadline for completion should also be made. Commissioning agent followup is essential. Recheck are done on those items, and, if the results are satisfactory, startup takes place. 6.5

FUNCTIONAL PERFORMANCE TESTS

When equipment and system start-up has taken place, functional performance of specified controls sequences and system function can be tested. Prerequisites to functional performance testing are successful start-up, completed controls calibration, and sufficiently completed systems balancing to allow system operation. The order in which functional performance tests are carried out can be important, particularly in larger, multiple-zone systems. Generally, the zone terminal tests will be done first, then the central system, then any specified interactions with other HVAC systems, and finally any specified interactions with non-HVAC systems (often these non-HVAC systems, such as fire alarm, are in other divisions of the work). The optimum sequence of tests needs to be reflected in the functional performance test checklists. Functional performance tests are camed out according to the procedure detailed on the checklists, and the results are documented on the lists. If performance is satisfactory, the system is ready for the next in the sequence of tests, or if all have been completed, the system is ready for turnover. Some tests may need to be deferred due to weather, seasonal, or occupancy factors. For example, if the building is being completed in winter, it may be impractical to start up the refrigeration side of the HVAC equipment or to create a full cooling load. In such a case, the functional performance tests for the cooling functions may be deferred until it is feasible to obtain a full cooling load.

0005533 7 5 0

if something is not satisfactory, the deficient, faulty, or incomplete items and the required corrective actions are noted on the checklist, copies made, and the needed action communicated to the responsible party for correction. Agreement on a deadline for completion should be made. Commissioning agent followup is essential. After corrections have been made, those items are retested, and, if the results are satisfactory, the next in the sequence of tests can be camed out. Once all functional performance tests have been completed with satisfactory results, the system is ready for turnover to the owner. 6.6

OPERATIONS INSTRUCTION DEMONSTRATION

Commissioning is of little lasting benefit if the operating personnel do not understand the systems and how to operate them properly. The contractor who carries out Level 1 commissioning services should therefore include a well organized series of instruction and demonstration sessions. However, it is important that the owner is informed of the operating and maintenance requirements of the HVAC systems and encouraged to participate and to implement a proper operations and maintenance program. If appropriate, the contractor may wish to make a service contract proposal to the owner, using his commissioning expertise and performance as partial evidence of his capabilities. The instructional portion of this program should cover: Descriptions of each type of system in the building, including design intent, theory of operation, capabilities and limitations, modes of control, and sequences of operation, Particular attention to the controls system, Inspection, service, and maintenance requirements for each system, including any requirements for special skiils and knowledge which may best be met by specialized service contractors, Operational monitoring and recordkeeping, including what should be monitored, what useful information can come from monitored data, and why that information is important to analyzing system operation.

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The demonstration portion of this program should cover: 0

The operation of each system, or a typical example when there are several (or many) similar ones in the building,

0

Start-up and shut-down procedures, operation under all specified modes of control and sequences of operation, and the correct procedures under emergency (for example, power failure) or abnormal conditions, and

0

Procedures necessary for effective operational monitoring. This is particularly important in projects with DDC systems incorporating powerful trending and graphing features.

The contractor must ensure that the operations manuals are available at this time and consulted

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during the instructional sessions. This will greatly add to the professionalism of the contractor, as seen by the owner. 6.7

SUMMARY

All the checks and tests are carried out to suit the schedule requirements of the project. in larger projects, some systems may be checked, started up, operated for functional performance tests, and proven complete before some other systems are even ready for start-up. On the other hand, on a small project, the entire onsite commissioning process, as described in Sections 6.4 and 6.5, for every system in the building may be carried out in one or two days. Only completion of incomplete work and correction of deficient or faulty items would need later followup and rechecking.

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CHAPTER 7

LEVEL 2, COMPREHENSIVE COMMISSIONING --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

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LEVEL 2, COMPREHENSIVE COMMISSIONING

CHAPTER 7 7.1

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PROGRAM, OR PRE-DESIGN, PHASE

7.2

OVERVIEW

This Chapter provides a detailed description of typical Level 2 commissioning procedures. While Level 1 commissioning procedures occur only during the construction and acceptance phases of the project, Level 2 commissioning activities take place during all phases of the project:

The owner defines and documents his requirements for the commissioning process at the inception of the project. These usually involve some designer responsibilities, and they must be included in the designer's scope of work.

O

Program or pre-design phase.

The owner's requirements for, or related to, commissioning are usually for a process to ensure:

O

Design phase.

O

O

Construction phase.

The system design and specified equipment meets occupancy needs. This means that occupancy needs must be defined by the owner.

O

Acceptance phase (actually a subset of the construction phase).

O

The system is installed and proven to function in accordance with the design.

Typical Level 2 commissioning procedures are detailed in sections 7.2 through 7.6, presented in roughly chronological order. They assume the owner retains design professionals to undertake the design, then enters into a stipulated sum contract with a contractor for construction of the project. They also assume the HVAC systems commissioning agent will be working under the HVAC contractor's direction. Finally, the procedures assume the owner will retain either the HVAC designer or an independent agent to act as his commissioning authority. On the owner's behalf, the commissioning authority ensures that the project's commissioning requirements are carried out satisfactorily.

O

There is good documentation.

0

There is effective operator training.

When different contractural arrangements exist, or when the owner assigns responsibilities differently, corresponding adjustments must be made to the roles and responsibilities described in this Chapter. The Level 2 procedures suggested in this Chapter are for an owner wishing a comprehensive commissioning process that will ensure a facility is designed to meet the owner's program, constructed in accordance with the design, and demonstrated to function fully in accordance with the design. In addition, these procedures include demonstrations and familiarization for operations personnel (either staff or contractors), so they can operate and maintain the facility correctly. For any specific project, the owner may have individual requirements varying from those in this manual. In such cases, the necessary adjustments must be made to accommodate those requirements.

In the final analysis, the owner's goal is a successful building, which is operated effectively and efficiently. The owner's occupancy needs for the building are usually contained in a document called the functional program for the project. With respect to HVAC design and commissioning, the following items are relevant: 0

Space temperature and humidity criteria,

O

Thermal zoning criteria,

O

Illumination requirements,

0

Ventilation requirements and related indoor air quality criteria,

O

Commissioning criteria, and

0

Budget.

The owner's commissionig criteria must be defined in sufficient detail to permit the designer to include contractor commissioning scope and responsibilities in the contract documents. 7.2.1

Commissioning Criteria

The program document, or the subsequent design intent document, should contain commissioning criteria information as follows:

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7.1

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Commissioning Scope. commissioned.

What systems will be

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Commissioning Roles and Responsibilities. Who is responsible for what. This may include a preliminary event matrix and sequence of activities. Time Requirement. It should indicate, in general terms, the elapsed time period over which the on-site commissioning activities are expected to take place. This provides some indication of the likely level of effort. Commissioning Team. The commissioning team needs to be identified in generic terms. Typical members include the owner, the operator, the mechanical and electrical designers, the general contractor, the mechanical contractor (and his controls; test and balance (TAB); and other relevant sub-trades and suppliers), the electrical contractor, the commissioning agent, and the commissioning authority (who may be the mechanical designer).

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7.3.2

Design Concepts

Design concepts, which are alternate design solutions to meet the program requirements and the design intent, are also developed. They need to consider commissioning issues as well. Examples include considering access (for both commissioning and later maintenance) and keeping systems, particularly their controls, as simple and easy for the operator to understand as possible. . 7.3.3

Mechanical Drawings and Specif ¡cations

The mechanical drawings and specifications define what is to be installed. To help in commissioning, the mechanical drawings and specifications should include information to help the contractor understand how the design was intended to function dynamically.

This following information should be included: Design criteria and assumptions.

Acceptanceflerification Procedures. Such things as benchmarks, test protocols, and code requirements as they apply may be identified.

0

Operator Training and Familiarization Requirements. Documentation. This needs to include commissioning plan content and submission, documentationof on-site Commissioning checks and tests as they occur, training documentation, and the final commissioning report. The owner must set the commissioning criteria, but he may make those decisions based on recommendations from the designers, or from the construction manager or contractor, if the latter have been identified this early in the project. 7.3

DESIGN PHASE

7.3.1

Design Intent

If not included in the program document, the design intent is defined and documented, usually by the designers, prior to starting the design phase itself. Design criteria, applicable codes and standards, design assumptions, and performance standards (which may relate to the design criteria) are aU included. In addition, areas of the building or functions within requiring special attention in design or commissioning need to be identified.

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Descriptions of the various HVAC systems in the project. This information should cover system type, major components, intended operation under both full and part loads, intended operation during different seasons (or weather conditions), sequence of operations (under different modes of operation, including start-up, occupied, unoccupied, fire emergency, etc., as applicable). Flow and schematic diagrams and controls matrix keyed to the systems descriptions above.

7.3.4

Commissioning Specification

During the design phase, the fmal design is carried out and the drawings and specifications are produced. The specifications must define the commissioning procedures to be followed and all contractor commissioning responsibilities, including those of the commissioning agent. They must also provide a list of systems, subsystems, and equipment to be commissioned. Only when process and scope are both defined can contractors bid the work fairly. These specifications should include: 0

Qualifications and skills required of the commis-

. sioning agent (Section 4.3). In many cases, companies or individuals approved by the owner or designer as commissioning agents are listed.

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A definition of the roles and responsibilities of the commissioning agent.

0

Stage 3: Functional performance verification by commissioning authority, and

0

A definition of the roles and responsibilities of the various contractors and all other parties to the commissioning process as they relate to the work of the commissioing agent.

0

Stage 4: Demonstration and instruction.

A generic list of the commissioning team members. Usually, this includes the owner, mechanical and electrical design professionals, general contractor, mechanical contractor, TAB contractor, controls contractor, other mechanical sub-trades and suppliers as applicable, electrical contractor, Commissioning agent, commissioning authority, and operator. Requirements for the commissioning plan. (Refer to Section 7.4.3 for details of commissioning plan content.)

O

Submittal requirements for the commissioning plan and any other commissioning data requiring review by the designer. 0

A list of all major equipment, subsystems, and systems to be commissioned. Scope of pre-start, start-up, and functional performance tests are covered in the commissioning plan requirements, as are any special tests required by codes or standards applicable to the work.

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Applicable verification and acceptance procedures.

0

Coordination of the commissioning work with the rest of the contractors' work, particularly with respect to schedule.

A typical, comprehensive commissioning specification, including all of the preceding information, is included in Appendix E. 7.4

CONSTRUCTION PHASE

7.4.1

General

During the construction phase of the project, on-site commissioning activities will be carried out in four stages. These are: 0

Stage 1: System readiness and start-up,

0

Stage 2: Initial operation and functional performance checkout,

The details of activities in each stage are described in below and in the generic commissioning specification in Appendix D. 7.4.2

The HVAC contractor appoints the commissioning agent, subject to designer approval if required by the specification.

7.4.3

Commissioning Plan

As early as possible in the construction phase, the commissioning agent prepares a detailed commissioning plan in accordance with the specifications. The plan is circulated to the entire commissioning team for review, revised as needed, distributed to all, and revised further as circumstances (particularly scheáule) require. A typical commissioning plan contains the following sections: Scope. This section provides a brief description of the overall process and outlines communications channels. Reference Documents, This section contains a listing of specification references relevant to commissioning, along with drawing lists for HVAC, fire protection, controls, and other systems to be commissioned. The list includes submittal drawings as applicable (controls are the most common).

System Readiness. For each system to be commissioned, this section contains a brief description of the checks and tests to be carried out by the commissioning agent, with reference to specific pre-start and start-up checklists. Functional Performance Tests. For each system to be commissioned, this section lists the tests to be carried out by the commissioning agent in order to check out correct operation under all specified sequences of operation, modes of control, etc. Prerequisite activities, the personnel involved, and reference to the specific functional performance checklists or worksheets required for each system are included.

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7.3

Functional Performance Verification. This section covers the verification of systems operation by the commisssioning authority. The functional performance checklists used by the commissioning agent during the functional performance test phase, are normally used for verification purposes. The extent and detail of this part of the commissioning process is normally indicated in the specification. Demonstration and Instruction. A brief description of the content of the demonstration and instruction program for the operators. Schedule. The commissioning schedule is included in this section. It is usually a simple bar chart, organized by system (or logical groupings of systems). It also includes the time scheduled for demonstration and instruction to operators. It must be coordinated with the overall project schedule. Typical events and tasks on it include: Dates for completion of installation, ready for pre-start checks, usually on a system-by-system basis, An elapsed time allowance for pre-start checks and start-up, often on a system-by-system basis, A time allowance for correcting any pre-start problems and rechecking, An elapsed time allowance for functional performance tests, usually on a system-by-system basis, A time allowance for correcting any functional problems and rechecking, An elapsed time allowance for functional performance verification, usually for groups of systems, and A time allowance for operator instruction and demonstration. An example of a commissioning schedule is shown in Appendix A. Distribution. A list of all members of the commissioning team receiving copies of the draft plan for review and comment. They also receive a copy of the final plan and any revisions. Checklists. This section, which may be divided into subsections, comprises the specific pre-start/start-up checklists, the functional performance test Checklists, 7.4 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

8389350 0005537 179

and any related worksheets. These checklists form the bulk of the plan on most projects.

7.4.4

Commissioning Meetings

As systems installation nears completion, the commissioning agent convenes regular on-site meetings of the commissioningteam. These meetings continue until the end of the acceptance phase. Minutes are kept and distributed to all commissioning team members whether present at the meeting or not. For small projects, in which the entire pre-start, start-up, functional performance testing and verification steps may take place within a week or two, there may be only a "preparation review" meeting to ensure everything is, or will be, ready and to confirm the schedule of activities with everyone involved in the process. The parties whose attendance will be required at each step are identified at that time. Rationale: Even on small projects, good planning improves coordination, efficiency, and results. The on-site commissioning activities take place according to the commissioning plan, coordinated by the commissioning agent, and requiring the cooperation of the entire commisioning team. These activities should take place in the following stages: Stage 1: System Readiness and Start-up. This stage involves the following activities, which are described more fully in Sections 7.4.5 and 7.4.6. 0

Pre-start checks and

o Equipment and systems start-up.

Stage 2: Initial Operation and Functional Performance Checkout. This stage is carried out by the commissioning agent and the contractor. Often it is done immediately after, or even in conjunction with, equipment and systems start-up. Stage 2 is closely associated with project completion, and, therefore, its activities are described under the acceptance phase of the project (Sections 7.5.2 through 7.5.4). In general terms, this stage covers: 0

Functional performance tests for individual subsystems and systems,

0

Functional performance tests covering interfaces between systems within division 15 of the work, and

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rechecked and found satisfactory before the equipment or system progresses to the next stage. 7.5

ACCEPTANCE PHASE

Stage 3: Functional Performance Verijkation. Functional performance verification covers functional performance tests and other demonstrations of acceptable performance as required by the commissioning authority or regulatory authorities. These are described in more detail in Section 7.5.5.

The acceptance phase of a project takes place during the latter part of the construction phase and, thus, is a subset of the construction phase, but it is so crucial to the overall commissioning process that it is separately identified.

Stage 4: Demonstration and Instruction. This stage consists of instructions and demonstrations to operating staff and is described in more detail in Section 7.5.6.

In the acceptance phase, on-site commissioning activities are closely focussed on the completion of the project as a fully operational facility. As in the construction phase, the commissioning plan provides overall guidance.

7.4.5

Pre-Start Checks

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The commissioning agent cames out pre-start checks, with involvement of the contractor‘s installation personnel as appropriate. Re-start checks are really inspections to ensure the installation is complete and that everything is ready to permit a safe start-up. This stage includes controls system end-to-end point wiring checks. The pre-start checklists are used to guide the work and to document results. Examples of pre-start/start-up checklists appropriate to Level 2 commissioning are included in Appendix C. If pre-start checks identify faulty equipment, or incomplete or incorrect work, it will be documented, discussed with the responsible parties, and corrective action agreed to. Commissioning meeting minutes or separate ”action reports” document the agreement for followup. When corrected, the work will be rechecked and found satisfactory before progressing to start-up. 7.4.6

The various on-site commissioning activities taking place during the acceptance phase are summarized in 7.5.2 through 7.5.6. The sequence of tesîs-starting with individual equipment or subsystems, then progressing to systems, and fuially to interactions between systems-allows large and complex systems to be broken down into their component parts. Correct functioning of individual parts are proven first, then, as tests proceed to larger subsystems and systems, it is easier to keep track of what is being tested and diagnose any problems. Standards of detail and documentation are similar for all projects; however, for simpler systems, particularly in smaller buildings, the acceptance phase and its documentation will be correspondingly simplified. For example, it may be feasible for all functional performance tests to be carried out in a single sweep because systems interactions are minimal or nonexistent. 7.5.1

Start-up

Once equipment and systems have passed the pre-start check, start-up and initial operation can occur. The commissioning agent or, for major equipment, the manufacturer’s service technician normally do this. As with pre-start checks, the contractor‘s installation personnel are involved as appropriate. For major equipment, the manufacturer often has a specific start-up procedure. This procedure should be followed and the results documented on the manufacturer’s standard start-up form, if one exists. Any deficiencies identified at this stage are documented, discussed, and corrective action agreed to as noted under pre-start checks. Once corrected, the work is

The commissioning agent carries out the functional performance tests of each subsystem and system in accordance with the functional performance checklists. Close coordination with the controls and TAB contractors is often required to ensure all systems and controls are properly adjusted and calibrated prior to testing. All test items are documented on the checklists as they are carried out. If satisfactory results are not obtained, it is discussed with the responsible parties and corrective action agreed to. Commissioning meeting minutes or separate ”action reports,”

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document the agreement for followup. When corrected, the work is rechecked and found satisfactory before progressing further.

7.5.2

Functional Performance Tests Covering Interfaces Between Systems Within Division 15 of the Work

Once the functional performance of individual systems has been completed satisfactorily, the commissioning agent carries out tests of any specified automatic action interfaces between systems. The procedure is the same as that described in 7.5.2 for individual systems. The appropriate functional performance checklists from the commissioning plan are used. 7.5.3

Functional Performance Tests Covering Interfaces Between Systems in Different Divisions of the Work

Once the functional performance of all systems within division 15 of the work has been completed satisfactorily, the commissioning agent, in cooperation with the HVAC contractor and other involved contractors, cames out tests of any specified automatic action interfaces between systems in different divisions of the work. The procedure is the same as that described in 7.5.2 for individual systems. The appropriate functional performance checklists from the commissioning plan are used.

7.5.4

Verification of Functional Performance Tests

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The commissioning authority will verify the complete functionality of all equipment, subsystems, systems, and inter-system interactions in accordance with design requirements. Verification can take place in conjunction with the functional performance tests or as a separate, subsequent activity in which the authority witnesses a repeat of the functional performance tests (or enough of them to satisfy the authority). In either case, the commissioning agent must ensure the systems and their components are operated as directed by the commissioning authority to enable verification to the authority's satisfaction. For some systems, particularly life safety systems, codes or regulations may mandate specific acceptance tests that must be witnessed by regulatory officials as well as the commissioning authority. These tests should form part of the functional performance tests outlined in 7.5.2, 7.5.3,and 7.5.4. Documentation of verification is the responsibility of 7.6 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

the commissioning authority; however, in the event that some aspect of acceptable performance is not achieved, then re-testing (complete with documentation demonstrating acceptable performance) is the responsibility of the commissioning agent. Only then will the commissioning authority normally be willing to attempt verification of performance a second time.

7.5.5

Instruction of and Demonstrations to Operating Personnel

Commissioning is of little lasting benefit if the operating personnel do not understand the systems and how to operate them properly. A well organized series of instruction and demonstration sessions is a central part of the commissioning process. The operations manuals must be available at this time and referred to during the instructional sessions. The owner has some important responsibilities related to instruction and demonstration. If the operators will be on his own staff, they should be identified early in the construction phase, given an opportunity to observe the commissioning process during construction, and made available to participate fully in the instruction and demonstration program. If operations are going to be contracted out, the owner should make these arrangements prior to the acceptance phase of commissioning, so the service contractor may assign staff for familiarization, instruction, and demonstration as appropriate. The instructional portion of this program should cover: 0

Descriptions of each type of system in the building, including its theory of operation, capabilities and limitations, and modes of control and sequences of operation in this building.

0

Particular attention to the controls system.

0

Inspection, service, and maintenance requirements for each system, including any requirements for special skills and knowledge that may best be met by specialized service contractors. Operational monitoring and recordkeeping, including what should be monitored, what useful information can come from monitored data, and why that information in important to analyzing system operation.

The demonstration portion of this program should cover:

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emergency (for example, power failure) or abnormal conditions.

Operation of each system, or a typical example when there are several (or many) similar ones in the building. O

0

Start-up and shut-down procedures, operation under ail specified modes of control and sequences of operation, and the correct procedures under

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Procedures necessary for effective operational monitoring. This is particularly important in projects with DDC systems incorporating powerful trending and graphing features.

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S M A C N A T I T L E W H V A C C M 9 4 H 8 3 8 9 3 5 0 0 0 0 5 5 4 1 bTT

CHAPTER 8

LEVEL 3, CRITICAL SYSTEMS COMMISSIONING

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SMACNA T I T L E * H V A C C M

CHAPTER 8 8.1

LEVEL 3,CRITICAL SYSTEMS COMMISSIONING

GENERAL

Procedures for Level 3 commissioning are similar to those for Level 2 with extensions of the commissioning work, including: --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

More detailed functional performance test protocols. (Protocols are detailed step-by-step procedures for carrying out the test and documenting the results.) Maintenance of pre-defined operational or environmental conditions under specified operating conditions, loads, or other factors. 8.2

CRITICAL APPLICATIONS

Level 3 commissioning is usually required for systems in critical applications involving life safety, health risks, high value processing or research, or other applications. The common thread is that not only is correct system functional performance important, but all specified environmental criteria must be maintained under the entire range of expected loads, operations, etc. 8.3

COMMISSIONING ORGANIZATION

Because of the critical nature of Level 3 commissioning, it is likely the owner will wish to have more direct control over the process than is the case for Level 2 commissioning. This manual suggests consideration of two organizational approaches. The first approach is to use the Level 2 commissioning process up to the conclusion of functional performance testing and verification. The commissioning agent works for the contractor as described in Chapter 7. However, because of the critical nature of the systems being commissioned, the ownets commissioning authority is expected to be very detailed and diligent in verification of functional performance. The commissioning specification must indicate this, and the contractor and commissioning agent must be

prepared to carry out the necessary work. Following functional performance verification, the owner has his own commissioning agentlauthority carry out environmental performance tests to check whether or not the overall installation maintains specified conditions. In this case, the commissioning agent/ authority used by the owner is unlikely to be the same one who carried out the Level 2 portion of the work.

In the second approach, the owner uses his own staff or retains a commissioning agenvauthority directly to carry out the entire commissioning process. The owner's complete confidence in the agent's ability and integrity is usually the critical factor in selection, although cost is obviously considered. Companies interested in pursuing Level 3 commissioning work under this approach, therefore, have to convince owners of their qualifications. 8.4

Procedures for Level 3 commissioning, particularly related to environmental performance testing, are dependent entirely on the specific application. Generally speaking, these will be dictated by the owner, by a regulatory authority which in turn mandates the use of one or more published standards. Commissioning agents will have to become familiar with the requirements of any specific application. They will have to be knowledgeable in the various means of measuring, and in some cases recording, results in order to demonstrate satisfactory performance. And they will have to ensure requirements are properly defined, so the scope of work is understood by all. The user of this manual is referred to owners, published standards, published performance test protocols, and other sources of information related to commissioning various types of systems in critical applications. The references in this manual provide some guidance in this regard. It is beyond the scope of this manual to provide details in all of the specialized fields involved.

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LEVEL 3 PROCEDURES

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CHAPTER 9

RECOMMISSIONING

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CHAPTER 9 9.1

RE-COMMISSIONING

OVERVIEW

The recommissioning process for a typical project has four distinct phases: 0

Preliminary investigation,

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Survey and documentation,

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Design and installation of modifications, and

0

Actual recommissioning tests.

Typically, the commissioning agent is retained initially just to carry out a preliminary investigation. The preliminary investigation phase is required in order to determine the availability of existing doumentation and to estimate the level of effort required to: Confirm the accuracy of existing documentation,

decision whether or not to proceed are made by the owner on the basis of this, or other, information. The recommissioning proposal should break the work down into systems, floors, or other categories to the greatest extent practical. When this is done, it requires the commissioning agent to look at specifics, even at this stage of the project, and it gives the owner confidence that the commissioning agent has carried out the preliminary work in sufficient detail to have produced a workable plan. If the owner agrees to the recommissioning proposal, or the owner and commissioning agent agree on a revised scope of work, then the project proceeds to the survey and documentation, modifications (if required and agreed to by owner), and recommissioning test phases. 9.1.1

The survey and documentation phase of a recommissioning project involves:

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Carry out surveys, re-measurements of air and water flows, and other work needed to produce accurate documentation where none presently exists,

Inspections and measurements to confrm the accuracy of existing documentation Inspections and measurements necessary to produce new documentation where none presently exists, or where the existing proves to be inaccurate, and

Calculate space heating and cooling loads, outside air requirements, and any other relevant performance criteria, Identify, in general terms, any needed physical modifications to meet current occupancy and usage requirements, and Plan and carry out the necessary functional performance tests.

Section 9.2, P r e l i m i i Investigation, provides additional detail. The information gathered during the preliminary investigation enables the commissioning agent to produce a recommissioning proposal for the owner. This proposal should contain a summary of the necessary work required for boîh the survey and documentation phase and the recommissioning test phase, with estimates of fees required for each. At this stage, it is uniikely that any required modifications are defined in sufficient detail to permit the preparation of cost estimates. If the survey and documentation phase results in the definition of modifications necessary to correct system problems, then the costs of carrying these out and the

Preparation of any required new or revised documentation. Depending on the quantity and accuracy of existing documentation, the level of effort for this phase of recommissioning varies greatly. Sections 9.3, 9.4, and 9.5 provide additional details on the survey and documentation phase. 9.1.2

Modifications Phase

The survey and documentation phase results in a complete set of project documentation, sufficient to proceed with the recommissioning tests. However, it may also result in the identification of mismatches between present requirements and the existing installation. In some cases, these mismatches can be resolved by flow and controls adjustments and minor zoning modifications. In other cases, more significant modifications, involvingdesign and construction work are indicated. In the latter case, the owner has to make a decision whether to proceed with the indicated

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modifications and, in some cases, what the extent of those modifications will be. If the survey and documentation phase does not indicate any required modifications, the project proceeds to the recommissioning tests phase. During recommissioning tests, it is still possible to uncover a previously unidentified problem; therefore, even at this stage of a recommissioning project, a need for modifications of some sori might appear. 9.1.3

If complete installation and operational documentation is available, it is necessary to estimate the time and cost required to confirm its accuracy. This process is described in Section 9.3.1 If complete documentation is not available, then steps need to be taken to obtain the missing information. The time and cost required to do this needs to be estimated. These steps are described in Section 9.3.2. 9.3

SURVEY AND DOCUMENTATION PHASE

9.3.1

Confirming Existing Documentation

Re-Commissioning Tests Phase

Re-commissioning tests are comparable to the functional performance and verification tests carried out in Level 2 commissioning. A recommissioning plan should be prepared, complete with checklists, as outlined in Section 7.4.3. The difference is that pre-start/start-up checklists are normally not required. (Refer to section 9.6 for further details.) 9.2

PRELIMINARY INVESTIGATION

9.2.1

Existing Documentation

The commissioning agent's first task in recommissioning is to obtain and review all existing documentation pertaining to the HVAC systems and any related systems included in the recommissioning scope of work. This documentation should include: Installation Documents. These include as-built drawings, specifications, and operations and maintenance manuals. Design heating and cooling load data is also part of this documentation. Operational Documentation. This includes test and balance reports (including outside air flow rates), commissioning reports (if commissioning was carried out on the building previously), energy consumption and cost data, and all records pertaining to control settings and operation. In addition, available records of occupant complaints and other data that could point to systems or operational problems is useful. Service and Maintenance Records. These records include information on a preventive maintenance program or service contract scope of work, if either is in place. In addition, all inspection reports and other service and maintenance records should be available for review. This applies whether the work was done by the owner's staff, by service contractors, or by a combination of the two.

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When complete installation and operational documentation is available, the commissioning agent is fortunate indeed. However, this existing documentation may not be up to date. Therefore, the commissioning agent's next step is to carry out surveys of the building to determine the accuracy of the existing documentation. The extent of these surveys is a matter of judgment for the commissioning agent and agreement with the owner, because survey work can be time consuming and costly. Nevertheless, accurate data on existing conditions is critical to the success of any recommissioning work, so the survey scope of work must be sufficient to confirm accuracy and, if necessary, to update existing documentation to reflect current conditions. Section 9.4 discusses survey activities to confirm the accuracy of information in existing documentation. 9.3.2

Creating Required Documentation

In most cases, there is some existing documentation. This must be checked for accuracy as described in 9.3.1. When installation and operational documentation does not exist, the commissioning agent must undertake survey activities to obtain data from which the required documentation can be prepared, then prepare the documentation. Survey activities to produce data and documentation when none exists are discussed in Section 9.5. The commissioning agent must determine the scope of work involved and agree with the owner on it before proceeding.

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SURVEYS TO CONFIRM EXISTING DOCUMENTATION

9.4

When the survey work described in this section confirms the information on the existing documentation, some permanent, dated record of this c o n f i i a tion is necessary. Then, any future recommissioning will have a record of when the specific documentation’s accuracy was last confirmed. Where the survey work shows the existing documentation to be inaccurate, it must be revised, or in extreme cases new, accurate documentation must be produced. Section 9.5 provides some guidance in this regard. 9.4.1

9.4.2

Equipment Data

Equipment data is closely linked with building surveys to c o n f m drawing accuracy (Section 9.4.1). When doing these surveys, equipment must be examined and compared to that shown on the drawings, scheduled (either on the drawings or in the specifications), or identified in the operations and maintenance manuals. Data can be taken from the equipment in the field and compared later to the existing documentation. Alternatively, the existing documentation can be carried into the field and used in direct comparison. In either case, data on the existing equipment must be recorded accurately as the survey proceeds.

Drawings 9.4.3

The commissioning agent should take existing drawings on site, visually observe present field conditions, and compare them to the drawings. The initial survey should focus on major items only, such as: 0

Central heating and cooling equipment and its primary distribution systems,

0

The building envelope (important in evaluating building heating/cooling loads), and

0

Major air handling equipment and primary air distribution ducting.

The commissioning agent then carries out checks on whether local packaged heating, cooling, or terminal equipment and the zoning shown on the drawings still reflects actual field conditions. Important survey items are: Partitioning (changes indicate occupancy adjustments and a probable requirement for corresponding zoning adjustments), Zone terminal equipment and the specific spaces served, Locally packaged heating or cooling equipment and the specific spaces served, and Location of thermostats, humidistats, or DDC sensors.

If the existing test and balance (TAB) reports are more than 5 years old, it is not likely they reflect current conditions in many parts of the building, particularly if any renovations have been done. A complete re-measurement of a u and water flows is recommended in such cases (Section 9.5.3). Even if the existing TAB reports are less than 5 years old, they may still be out of date. Some flows, pressures, temperatures, etc., will need to be spot checked against those shown on the existing reports. Areas with occupant complaints should be selected for spot checking. The commissioning agent does these measurements or retains an independent TAB contractor to do so, using accepted SMACNA TAB procedures. The survey data, and whether it confirms the existing TAB reports, must be recorded accurately. 9.4.4

Space Heating and Cooling Loads

When there is any evidence of persistent occupant complaints of “too hot,” ”too cold,” “stuffy,” or others, a thermal zones analysis should be carried out, either by the commissioning agent, if qualified to do so, or by an engineer who is. This analysis involves two steps. First, the present heating and cooling loads must be calculated and compared to the installed capacity as shown on the existing documentation and confirmed by survey. Data on the building envelope, lighting, occupancy, occupant or process equipment in the space, the impact of the HVAC system on loads, and any other contributor to space heating or cooling load must be considered. The second step is to

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Test and Balance Reports

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evaluate whether the thermal zoning of the existing systems is effective. In particular, each zone should serve: Only perimeter spaces or interior spaces, but not both,

0

Perimeter space, either at a comer or on only one exposure, and Only spaces of similar occupancy, load profiles, etc. If the actual loads are greater than installed zone capacity or the thermal zoning is not according to accepted criteria, then some modifications are indicated in order to overcome comfort complaints. 9.4.5

Outside Air Ventilation

Indoor air quality (IAQ) and adequate outside air ventilation are both critical concerns for many owners. Recommissioning must address basic IAQ even in the absence of any specific IAQ complaints from ocupants. If any IAQ concerns have been raised, a detailed evaluation is even more important. The present occupancy should be confiied, contaminant sources (if any) identified, control of contaminants evaluated, the required outside air ventilation amount determined from ASHRAE Standard 62 or applicable regulations, and that amount compared to the minimum outside air ventilation quantity shown on the existing drawings or other documentation and confirmed by TAB results. If actual outside air requirements are greater than those being provided, then either control adjustments or physical modifications to provide adequate outside air are indicated. IAQ investigations often require specialized knowledge. If the surveys indicate the possibility of significant IAQ problems, the commissioning agent should recommend the owner retain an IAQ specialist for this aspect of the work. The commissioning agent should not undertake this unless staff with the requisite expertise and credentials are available. 9.5

SURVEYS TO PRODUCE NEW OR REVISED DOCUMENTATION

The procedures described in this section apply when there is no existing documentation or when existing documentation is no longer accurate. In either case, the information must be produced or updated.

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The survey activities described in Section 9.4 also apply here; however, there is in all cases the additional requirement to produce new or revised documentation. 9.5.1

Drawings

Field survey data must be collected in sufficient detail to permit the preparation of as-built drawings from scratch when none exists. If existing drawings require revision, the survey data must provide enough data to complete the revisions and confirm the accuracy of material not requiring revision.

In many cases, all the necessary data exists but on an uncoordinated set of original drawings and several sets of revision drawings. In such cases, it may be advisable to create a single, new set of as-built drawings incorporating all revisions to date as confirmed by the site survey. The new "as-builts" will be more usable than any previous drawings. There should probably be consultation and agreement with the owner as to whether computer-aided drafting (CAD) should be used to produce the new drawings to facilitate future updating. 9.5.2

Equipment Data

Missing equipment data may be difficult to replace. The starting point should be to prepare or update a complete schedule of equipment with as much information as possible about manufacturer, model number, serial number, capacity, flows, and other attributes. This information can come from nameplate data on the equipment, existing schedules (on drawings or in specifications), TAB reports, or anywhere else. Missing information may be obtainable from the equipment manufacturer. With rapidly advancing technology, equipment inventory documentation on a computer database should be considered for larger projects. Use of a bar code concept for marking equipment in the field, and having matching computer records, could also be considered. Consultation and agreement with the owner on the form of such documentation will of course be necessary. 9.5.3

Test and Balance Reports

If there are no TAB reports available, the recommissioning process needs to include a complete re-measurement of air and water flows, pressures, tempera-

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tures, etc. The commissioning agent carries this out directly, using SMACNA approved TAB procedures, or retains a separate TAB agent to do so. This would provide new TAB reports showing current conditions.

8389350 0005548 T 5 4

0

Energy savings opportunities that may have been revealed by the recommissioning survey and analysis work carried out.

0

Controls systems retrofits and upgrades. Often there are significant savings opportunities available from the improved control, monitoring, trending, and alarm reporting capabilities of modern computerized EMCS installations.

0

A recommissioning tests plan.

If there are existing TAB reports, but spot checks show they are not accurate, then re-measurement of those areas showing inaccuracies is required. Updated reports document current conditions.

9.5.4

Space Heating and Cooling Loads

Particularly in areas with persistent temperature complaints, actual space heating and cooling loads should be calculated as outlined in Section 9.4.4. These loads must be compared to present capacity, determined from whatever data is available (Section 9.5.2). 9.5.5

Outside Air Ventilation

As with heating and cooling loads, actual outside air ventilation requirements should be determined from ASHRAE Standard 62 or applicable regulations as outlined in Section 9.4.5. The comments in Section 9.4.5 concerning IAQ investigations also apply here. These requirements must be compared to present outside a u flows, determined from the updated TAB reports (Section 9.5.4). --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

9.6

ANALYSIS

The commissioning agent must analyze the results of the survey and documentation phase of the recommissioning process. From this analysis, a report should be prepared for the owner. This report contains a recommended action plan for: Replacement of equipment or controls nearing, or past, the end of their useful service life. Often, when equipment is old, it has poor reliability, service and maintenance costs are high, and energy efficiency is much lower than for available new equipment. Replacement must be justified, but frequently the savings and performance opportunities are substantial.

0

o Any modifications identified as being required in

order to have the HVAC systems meet current requirements with respect to heating or cooling capacities, thermal zoning, total air flow rates, outside air ventilation rates, exhaust requirements, or any other factor included in the owner's performance criteria for the installation.

The report must be definitive. If HVAC system modifications are required, the report should provide a detailed list of them. If it is part of the commissioning agent's scope of work, preliminary design information-including schematic diagrams or plans, where physical changes and installations are involved-should also be provided. This will require the commissioning agent to have or obtain the necessary design expertise. When the owner gives approval, the recommissioning process can proceed to the next phases.

9.7

Modifications will be required when the demands of the current use or occupancy of the building, or spaces within it, are not capable of being met by the HVAC systems as currently installed, adjusted, or operated. Modifications may be as simple as controls adjustments or adjustments to air and water flow rates. In such cases, the necessary work is usually authorized quickly, and the recommissioning tests proceed.

In other cases, relatively simple and inexpensive zoning coverage adjustments, as would be consistent with tenant improvements associated with a planned change of layout or occupancy may be required. If appropriate HVAC changes have not been made when such alterations occured in the past, this situation may be expected. Finally, if the shortcomings are significant, the requirement may be for more major renovations, even complete system replacement under some extreme circumstances. As the details of required modifications become known as a result of the survey, documentation, and analysis work, its cost is estimated as a part of that

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MODIFICATIONS

9.5

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work. It is then up to the owner to decide how much of this work to authorize. in most cases, the approved modifications should be carried out before the final recommissioning tests are done. 9.8

RE-COMMISSIONING TESTS

9.8.1

Re-commissioning Plan

As with any other commissioning activity, a wntten commissioning plan is essential if the process is going to be both effective and efficient. The recommissioning plan has the same organization as that for Level 2 commissioning (Section 7.4.3). If there are no systems modifications, it may not be necessary to have a systems readiness section. That work was covered in the survey phase. In addition, if the commissioning agent is also acting as the owner's commissioning authority, the separate functional performance verification stage may not be necessary. If there are systems modifications, checklists for pre-start checks and start-up procedures are particularly important. The reason is that planning and scheduling are particularly important on most recommissioning projects. This is because the building is likely continue to be occupied for the duration of the process; therefore, careful scheduling of the work, often after normal operating hours, is essential to minimize occupant disruption. It is important to ensure work is ready when scheduled to avoid delays and disruptions. Detailed planning and checklists, plus an effort to use them effectively, can be very beneficial. The checklists should be based on those in Appendices B and C , but adapted to include all project specific control sequences, modes, etc. 9.8.2

Re-commissioning Test Procedures

Re-commissioning test procedures are essentially the same as those described in the acceptance phase of Level 2 commissioning (Section 7.5). 9.9

DOCUMENTATION AND TRAINING

9.9.1

Operations and Maintenance Manuals

If the benefits of the recommissioning effort are to be fully realized, up-to-date operations and maintenance manuals are essential. Section 9.5 covers surveys

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necessary to produce new or revised documentation. Even if no modifications are carried out, revised or re-written manuals may be required. If modifications are undertaken, the new manuals must include complete data concerning those modifications. A complete and detailed sequence of controls must be a part of these manuals. The sequence of controls needs to cover operator procedures in categories such as: System start-up and shut-down, Procedures related to abnormal conditions, including alarm response procedures, Procedures related to emergency conditions, Recommended system monitoring and recordkeeping and how to analyze this data to evaluate ongoing equipment and system performance, and Any seasonal adjustments required or recommended 9.9.2

Retraining of Operations Personnel

Operations personnel must understand how to keep the systems operating as intended; therefore, retraining is another essential part of the recommissioning process. Often the training has to be as comprehensive as that provided for a new building. On the one hand, there may have been considerable operator turnover, and the present personnel may not have had any training. Also, the operators have been operating the systems (effectively or ineffectively) and may well have many questions arising from their experiences. The training needs to deal with these also. Training must include a review of all the documentation produced during the recommissioning process, often at great cost. The operators need instruction in what the documentation contains, how to fuid what they need, how to use it to their best advantage during their work, and, most important of all, how to go about keeping it up to date in the future. Keeping up to date includes such issues as periodic rebalancing, appropriate service and maintenance procedures, and periodic recommissioning of the facility, or parts of it, in order to c o n f m future conditions.

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APPENDICES

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COMMISSIONING SCHEDULE

APPENDIX A

The number of line items in the schedule clearly depends on the size of the project, the number and complexity of systems, and whether different parts of the building will be finished at different times. Line items for completion of ”dusty and dirty” interior finishing work are important because they link back to the general contract, and also a date before which fan systems cannot be started on many projects.

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Appendix A shows an example of a commissioning schedule. It is intended to illustrate an appropriate level of detail for Level 1 and Levei 2 commissioning and re-commissioning. A schedule for Level 3 commissioning would likely include additional verification and environmental performance test steps (Chapter 9) and might be more detailed.

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A.4 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

HVAC Systems Commissioning Manual

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

LEVEL 1 PRE-START AND START-UP CHECKLISTS

The equipment pre-start and start-up checklists included in this Appendix cover a range of equipment for typical HVAC systems. The items in each list are grouped into the following categories: Physical installation complete. Mechanical service connections. 0

Electrical service connections. Control systems complete.

These lists may seem excessively detailed; however, experience has shown they can be very useful in documenting problem areas, identifying responsibility, communicating the problem to the responsible party, and serving as followup reminders (Section 7.3).

The checklists are generic and generally include a comprehensive list of items, not all of which are applicable for every project. Therefore, the lists should be used as generic masters, to be revised to suit the needs of specific equipment and systems in specific projects. Some items will not be relevant and should be deleted from the project checklists. Other items may need to be added. It would be normal for companies offering commissioning services to come up with their own set of master checklists, stored on computer, adding to them as variations are encountered with some regularity. These can then be edited for specific projects very quickly and put into project files for printing and distribution.

TABLE OF CONTENTS CHECKLIST SMS101 SMS102 SMSlO3 SMS104 SMS10.5 SMS106 SMSlO7 SMS108 SMS1O9 SMS11O SMSlll SMS112 SMSll3 SMSll4 SMS115 SMS116 SMSll7

DESCRIPTION AIR HANDLING SYSTEM-LIQUID HEAT/ COOL AIR HANDLING SYSTEM-GAS HEAT A/C OR HEAT PUMP SYSTEM-WATER COOLED PACKAGED AIR CONDITIONING SYSTEM PACKAGED Al R CONDITIONING SYSTEM-GAS HEAT EXHAUST SYSTEM RETURN AIR SYSTEM PRESSURIZATION FAN SYSTEM HOT WATER BOILER SYSTEM-GAS HOT WATER BOILER SYSTEM-OIL CHILLER SYSTEM COOLING TOWER SYSTEM CIRCULATING PUMP SYSTEM DOMESTIC WATER HEATING SYSTEM-GAS DOMEST1C WATER HEAT1NG SYSTEM-OIL SUMP PUMP SYSTEM FIRE PUMP SYSTEM

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

B.l

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APPENDIX B

8387350 0 0 0 5 5 5 5 I194

94

SMACNA T I T L E * H V A C C M 9 4

8 3 8 9 3 5 0 0 0 0 5 5 5 6 O20 H

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST SMS101-AIR HANDLING SYSTEM - LIQUID HEAT/COOL PROJECT:

UNIT NO:

LOCATION: MAN UFACTU RER:

SERVICE: MODEL:

I

ITEM

OK

I

COMMENT

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Filters, Components - Plenums, Ducts, & Coils Clean and Clear - Fire Dampers Tested - Alignment, Belt Tension, Lubrication - Fan(@ Rotates Freely - All Dampers Open MECHANICAL SERVICE CONNECTIONS Coil piping & valves installed & tested - Condensate drains clear - Duct System Complete - Areas Clean - Misc. Components Complete (¡.e., Humidifier)

-

ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed

- Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Safety Controls Operational

- Control System Operational (or DDC Program) - Ready to Start & Run Under Control Start-up by Manufacturers Representative Mech., Elect. & Controls Contractors Present Fan Rotation Correct (Bump) Electrical Interlocks Verified Freeze Protection Operational Motor Amps - Rated - Actual Motor Volts - Rated - Actual Local Air Leakage Acceptable Vibration & Noise Level Acceptable

I

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

START-UP INSPECTION

I

GENERAL COMMENTS:

PRE-START BY: START-UP BY:

8.2 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M 9 4

8 3 8 9 3 5 0 O005557 Tb7

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START 81 START-UP CHECKLIST

-

-

SMS102 AIR HANDLING SYSTEM GAS HEAT

PROJECT: LOCATION : MANUFACTURER:

UNIT NO: SERVICE: MODEL: ITEM

I

OK

I

COMMENT

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Filters, Components - Plenums, Ducts, & Coils Clean and Clear - Fire Dampers Tested - Alignment, Belt Tension, Lubrication - Fan(s) Rotates Freely - Gas Equipment & Venting Completed MECHANICAL SERVICE CONNECTIONS

- Gas piping & valves installed & tested - Condensate drains clear

-

- Duct System Complete Areas Clean

- Micc. Components Complete (Le., Humidifier) ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed

- Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Safety Controls Operational - Control System Operational (or DDC Program) - Ready to Start & Run Under Control

- Gas Train Controls Operational START-UP INSPECTION

Start-up by Qualified Personnel (Gas Cert.) Cert.) Mech., Elect. & Controls Contractors Present Fan Rotation Correct (Bump) Electrical Interlocks Verified Firing Sequence Verified Flame Safeguard Sequence Verified Freeze Protection Operational Motor Amps - Rated - Actual Motor Volts - Rated - Actual Local Air Leakage Acceptable

PRE-START BY: START-UP BY:

DATE: DATE:

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

8.3

SMACNA

T I T L E E H V A C C M 94

= 8189350 SMACNA

0005558 9T3

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS103 AIR CONDITIONING or HEAT PUMP SYSTEM WATER COOLED

PROJECT: LOCATION: MANUFACTURER:

I

ITEM

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Filters, Components - Plenums, Ducts & Coils Clean and Clear - Fire Dampers Tested - Alignment, Belt Tension, Lubrication - Fan(s) Rotates Freely - Refrigeration Section Completed - Balance Dampers Open MECHANICAL SERVICE CONNECTIONS - Refrigerant piping & valves installed & tested - Water piping & valves installed & tested - Condensate drains clear & complete - Duct System Complete - Areas Clean - Misc. Components Complete (¡.e., Humidifier) ELECTRICAL SERVICE CONNECTIONS - Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE - Safety Controls Operational - Control System Operational (or DDC Program) - Ready to Start & Run Under Control - Integral Controls Operational

START-UP INSPECTION Start-up by Qualified Personnel (Ref. Cert.) Mech., Elect. & Controls Contractors Present Fan Rotation Correct (Bump) Electrical & Control Interlocks Verified Cooling Stages & Temperature Controls Verified Integral & Safety Controls Verified Freeze Protection Operational Motor Amps - Rated - Actual Motor Volts - Rated - Actual Local Air Leakage Acceptable Vibration & Noise Level Acceptable I

GENERAL COMMENTS:

PRE-START BY: START-UP BY:

8.4 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual

0

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA TITLE*HVACCM

8189350 0 0 0 5 5 5 9 8 3 T

94

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS104 PACKAGED AIR CONDITIONING SYSTEM

UNIT NO:

PROJECT:

ITEM

I

COMMENT

OK

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Filters, Components - Plenums, Ducts, & Coils Clean and Clear - Fire Dampers Tested - Alignment, Belt Tension, Lubrication - Fan(s) Rotates Freely - Refrigeration Section Completed

I

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

MECHANICAL SERVICE CONNECTIONS

- Refrigerant piping & valves installed & teste - Condensate drains clear - Duct System Complete - Areas Clean - Misc. Components Complete (¡.e., Humidifier) ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Safety Controls Operational - Control System Operational (or DDC Program) - Ready to Start & Run Under Control - Integral Controls Operational

1

START-UP INSPECTION Start-up by Qualified Personnel (Ref. Ce&) Mech., Elect. & Controls Contractors Present Fan Rotation Correct (Bump) Electrical & Control Interlocks Verified Cooling Stages & Temperature Controls Verified Integral & Safety Controls Verified Freeze Protection Operational Motor Amps - Rated - Actual Motor Volts - Rated - Actual _ _ Local Air Leakage Acceptable Vibration & Noise Level Acceptable GENERAL COMMENTS:

I

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

I

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

B.5

SMACNA T I T L E * H V A C C M

94

= 8189350 0005560 551 SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMSIOS PACKAGED AIR CONDITIONING SYSTEM GAS HEAT

PROJECT: LOCATION: MANUFACTURER:

UNIT NO: SERVICE:

I

ITEM

OK

I

COMMENT

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Filters, Components - Plenums, Ducts, & Coils Clean and Clear - Fire Dampers Tested - Alignment, Belt Tension, Lubrication - Fan@) Rotates Freely - Gas Equipment & Venting Complete - Refrigeration Section Completed MECHANICAL SERVICE CONNECTIONS - Refrigerant piping & valves installed & tested - Gas piping & valves installed & tested - Condensate drains clear & complete - Duct System Complete (Areas Clean) - Misc. Components Complete (¡.e., Humidifier) ELECTRICAL SERVICE CONNECTIONS - Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE - Safety Controls Operational - Control System Operational (or DDC Program) - Ready to Start & Run Under Control - Refrigeration & Gas System Controls Operational

I

I

I

START-UP INSPECTION Start-up By Qual. Personnel (Ref. & Gas Cert.) Mech., Elect. & Controls Contractors Present Fan Rotation Correct (Bump) Electrical & Control Interlocks Verified Cooling Stages & Temperature Controls Verified Firing Sequence & Flame Safety Sequences Integral & Safety Controls Verified Freeze Protection Operational Motor Amps - Rated - Actual Motor Volts - Rated - Actual Local Air Leakage Acceptable Vibration & Noise Level Acceptable GENERAL COMMENTS: PRE-START BY: START-UP BY:

B.6 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

MODEL:

rI

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

S M A C N A T I T L E U H V A C C M 94

8L89350 0 0 0 5 5 6 1 478

SMACNA

HVAC SYSTEMS COMMISSIONING - LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMSI06 EXHAUST SYSTEM

PROJECT: LOCATION: MANUFACTURER: ITEM

I

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE

- Mounting, Isolators, Filters, Components - Plenums & Ducts Clean and Clear - Fire Dampers Tested - Alignment, Belt Tension, Lubrication

4

- Fan(s) Rotates Freely - All Manual Dampers Open

MECHANICAL SERVICE CONNECTIONS

- Duct System Complete (Areas Clean) - Backdraft Dampers Free To Operate

~

I

ELECTRICAL SERVICE CONNECTIONS - Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Control System Operational (or DDC Program) - Ready to Start & Run Under Control

START-UP INSPECTION Electrical Contractor Present Fan Rotation Correct (Bump) Electrical Interlocks Verified Motor Amps - Rated - Actual Motor Volts - Rated - Actual Local Air Leakage Acceptable Vibration & Noise Level Acceptable

GENERAL COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

8.7

SMACNA T I T L E * H V A C C M

94

m

8389350 0005562 324

SMACNA

m

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMSlO7 RETURN AIR SYSTEM

UNIT NO:

PROJECT: LOCATION: MANUFACTURER:

SERVICE MODEL:

I

ITEM

OK

I

COMMENT

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE

- Mounting, Isolators, Filters, Components - Plenums & Ducts Clean and Clear

- Fire Dampers Tested

- Alignment, Belt Tension, Lubrication - Fan(c) Rotates Freely MECHANICAL SERVICE CONNECTIONS

- Duct System Complete (Areas Clean)

- Return & Exhaust Dampers Operational ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed

- Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Control System Operational (or DDC Program) - Supply Fan Interlocks Operational - Ready to Start & Run Under Control

START-UP INSPECTION Electrical Contractor Present Fan Rotation Correct (Bump) Electrical Interlocks Verified Supply Fan Interlock Verified Motor Amps - Rated - Actual Motor Volts - Rated - Actual Local Air Leakage Acceptable Vibration & Noise Level Acceptable

-

GENERAL COMMENTS:

PRE-START BY: START-UP BY:

B.8

DATE: DATE:

HVAC Systems Commissioning Manual

0

First Edition

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

8 3 8 9 3 5 0 0005563 260 H

94

SMACNA T I T L E * H V A C C M

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS108 PRESSURIZATION FAN SYSTEM PROJECT: LOCATION : MANUFACTU RER:

UNIT NO: SERVICE: MODEL: ITEM

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Filters, Components - Plenums & Ducts Clean and Clear - Alignment, Belt Tension, Lubrication - Fan(s) Rotates Freely

I

OK

I

COMMENT

I

MECHANICAL SERVICE CONNECTIONS - Duct System Complete (Areas Clean) - Outdoor Air Dampers Operational ELECTRICAL SERVICE CONNECTIONS - Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

I

- Control System Operational (or DDC Program) - Fire System Interlocks Operational - Ready to Start & Run Under Control

START-UP INSPECTION Electrical Contractor Present Fan Rotation Correct (Bump) Electrical Interlocks Verified Fire System Interlocks Verified Motor Amps - Rated - Actual Motor Volts - Rated - Actual Local Air Leakage Acceptable Vibration & Noise Level Acceptable I

DATE: DATE:

PRE-START BY: START-UP BY:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

GENERAL COMMENTS:

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

B.9

SMACNA T I T L E r H V A C C M 9 4

= BLB9350 SMACNA

0005564 I T 7 H

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS109 HOT WATER BOILER SYSTEM GAS

PROJECT: LOCATION: MANUFACTURER:

UNIT NO: SERVICE:

I

ITEM

OK

I

MODEL: COMMENT

I PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE

- Mounting, Isolators, Components - Burner & Gas Train

- Breeching & Combustion Air - Boiler Inspection & Chemical Treatment MECHANICAL SERVICE CONNECTIONS

- Water Piping & Valves Installed & Tested - Gas Piping & Valves Installed & Tested - Valves Positioned For Start-up

ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Control System Operational (or DDC Program) - Integral Controls Operational - Ready to Start & Run Under Control START-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Start-up By Manufacturers Representative Mech., Elect. & Controls Contractors Present Firing Sequences Verified Pump & Flow Interlocks Verified Safeîy Controls 8 Flame Safeguards Verified Pressure & Temperature Gauges Checked Water Temperature Maintained Low Water Cutout Verified Safety Relief Valve Tested Water Temperature Maintained Combustion Efficiency & Capacity Test Vibration & Noise Level Acceptable GENERAL COMMENTS: PRE-START BY: START-UP BY:

B.10 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

94

= 8389350

0 0 0 5 5 6 5 033

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS110 HOT WATER BOILER SYSTEM OIL

UNIT NO: SERVICE:

PROJECT: LOCATION: MANUFACTURER: ITEM

MODEL:

I

OK

I

COMMENT

PR E-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Components

- Burner & Oil System - Breeching & Combustion Air - Boiler Inspection & Chemical Treatment MECHANICAL SERVICE CONNECTIONS - Water Piping & Valves Installed & Tested - Oil Piping & Valves Installed & Tested - Valves Positioned For Start-up

1

ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Control System Operational (or DDC Program) - Integral Controls Operational - Ready to Start & Run Under Control

START-UP INSPECTION Start-up by Manufacturer's Representative Mech., Elect. & Controls Contractors Present Firing Sequences Verified Pump & Flow Interlocks Verified Safety Controls & Flame Safeguards Verified Pressure & Temperature Gauges Checked Water Temperature Maintained Low Water Cutout Verified Safety Relief Valve Tested Water Temperature Maintained Combustion Efficiency & Capacity Test Vibration & Noise Level Acceptable GENERAL COMMENTS:

I

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

B.11

BL89350 0005566 T ï T H

SMACNA T I T L E * H V A C C M 94 --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

SMACNA HVAC SYSTEMS COMMISSIONING

- LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST SMSI77

- CHILLER SYSTEM

UNIT NO: SERVICE:

PROJECT: LOCATION: MAN UFACTURER:

MODEL:

I

ITEM

OK

I

COMMENT

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Components - Preheating & Lubrication - Control Panel - Refrigerant Charge MECHANICAL SERVICE CONNECTIONS

- Condenser & Chilled Water Piping & Valves - Valves Positioned for Start-up

4

ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed

- Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE - Control System Operational (or DDC Program)

- Integral Controls Operational

- Ready to Start & Run Under Control START-UP INSPECTION

Start-up By Manufacturer's Representative Certificate / Log Provided Mech., Elect. & Controls Contractors Present Pump & Flow Interlocks Verified Safety Controls Verified Pressure & Temperature Gauges Checked Water Temperature Maintained Motor Amps - Rated - Actual Motor Volts - Rated - Actual Vibration & Noise Level Acceptable NOTE: This checklist is suitable to prepare most types of chillers for start-up. Start-up Technician should follow manufacturer's equipment specific checklist and submit copy for report. GENERAL COMMENTS:

PRE-START BY: START-UP BY:

6.12 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

8189350 O005567 906

94

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS112 COOLING TOWER SYSTEM

PROJECT: LOCATION: MANUFACTURER: ITEM

I

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

I

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

PR E-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Components - Alignment, Belt Tension, Lubrication - Fan(s) Rotates Freely

MECHANICAL SERVICE CONNECTIONS

- Piping & Valves Completed & Tested - Valves Positioned For Start-up - Water treatment system installed ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly)

CONTROL SYSTEMS COMPLETE - Control System Operational (or DDC Program) - Control Interlocks Operational - Ready to Start & Run Under Control

START-UP INSPECTION Mech., Elect. & Controls Contractors Present Pump & Fan Rotation Correct (Bump) Electrical & Control Interlocks Verified Level Control Tested & Adjusted Capacity Controls Verified Motor Amps - Rated - Actual Motor Volts - Rated - Actual Vibration & Noise Level Acceptable I

GENERAL COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

B.13

8 3 8 9 3 5 0 0005568 8 4 2 M

SMACNA T I T L E U H V A C C M 9 4

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST SMS113

- CIRCULATING PUMP SYSTEM

PROJECT: LOCATION : MANUFACTURER:

I

ITEM

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

I PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE

- Mounting, Isolators, Components - Alignment, Lubrication - Pump(s) Rotates Freely

MECHANICAL SERVICE CONNECTIONS

- Piping & Valves Completed & Tested - Valves Positioned for Start-up

- Strainer(s) Clean ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed

- Disconnect Switch Installed

- Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Control System Operational (or DDC Program) - Control Interlocks Operational

- Ready to Start & Run Under Control START-UP INSPECTION

Mech., Elect. & Controls Contractors Present Pump Rotation Correct (Bump) Electrical & Controls Interlocks Verified Check Valve Tested System Pressure Acceptable Motor Amps - Rated - Actual Motor Volts - Rated - Actual Vibration & Noise Level Acceptable

PRE-START BY: START-UP BY:

8.14 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

HVAC Systems Commissioning Manual

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

S M A C N A TITLE*HVACCM 9 4

8189350 000.5569 7 8 9

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS114 DOMESTIC WATER HEATING SYSTEM GAS

PROJECT: LOCATION : MANUFACTURER: ITEM

I

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

I PR E-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE Mounting, Isolators, Components - Burner & Gas Train - Breeching & Combustion Air

-

MECHANICAL SERVICE CONNECTIONS - Water Piping & Valves Installed & Tested

- Recirculation Pump Operational - Gas Piping & Valves Instatled & Tested - Valves Positioned For Start-up --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

ELECTRICAL SERVICE CONNECTIONS - Electrical Connections Completed

- Disconnect Switch Installed

- Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Control System Operational (or DDC Program) - Integral Controls Operational - Ready to Start & Run Under Control START-UP INSPECTION Start-up by Qualified Personnel (Gas Cert.) Mech., Elect. & Controls Contractors Present Firing Sequences Verified Safety Controls & Flame Safeguards Verified Safety Relief Valve Tested Temperature Gauges Checked Water Temperature Maintained Water Recirculation Verified Combustion Efficiency & Capacity Test

GENERAL COMMENTS:

DATE: DATE:

PRE-START BY: START-UP BY:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

B.15

SMACNA T I T L E * H V A C C M

9 4 M 8389350 0 0 0 5 5 7 0 4 T O W

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS115 DOMESTIC WATER HEATING SYSTEM OIL

PROJECT:

UNIT NO:

LOCATION : MANUFACTURER:

SERVICE: MODEL: ITEM

COMMENT

PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE - Mounting, Isolators, Components - Burner & Oil System - Breeching & Combustion Air

MECHANICAL SERVICE CONNECTIONS - Water Piping ¿? Valves Installed & Tested

- Recirculation Pump Operational - Oil Piping ¿ Valves i Installed ¿? Tested - Valves Positioned For Start-up ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

- Control System Operational (or DDC Program) - Integral Controls Operational - Ready to Start & Run Under Control

START-UP INSPECTION Start-up by Qualified Personnel Mech., Elect. & Controls Contractors Present Firing Sequences Verified Safety Controls & Flame Safeguards Verified Safety Relief Valve Tested Temperature Gauges Checked Water Temperature Maintained Water Recirculation Verified Combustion Efficiency & Capacity Test

GENERAL COMMENTS:

PRE-START BY: START-UP BY:

B.16 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS116 SUMP PUMP SYSTEM

UNIT NO: SERVICE:

PROJECT: LOCATION: MAN UFACTURER: ITEM

I

OK

I

MODEL: COMMENT

I PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE

- Mounting, Isolators, Components - Alignment, Lubrication

- Pump(s) Rotates Freely - Control Panel

MECHANICAL SERVICE CONNECTIONS

- Piping & Valves Completed & Tested - Valved Positioned For Start-up ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed - Disconnect Switch Installed - Overload Heaters in Place (Sized Correctly) CONTROL SYSTEMS COMPLETE

- Control System Operational

- Ready to Start & Run Under Control

START-UP INSPECTION Mech. & Elect. Contractors Present Pump Rotation Correct (Bump) Float Switches Verified Level Alarms Tested Motor Amps - Rated - Actual Motor Volts - Rated - Actual Vibration & Noise Level Acceptable

I

GENERAL COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

B.17

SMACNA T I T L E * H V A C C M

8 1 8 9 3 5 0 0 0 0 5 5 7 2 273

94

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 1

EQUIPMENT PRE-START & START-UP CHECKLIST S M S í í 7 FIRE PUMP SYSTEM

-

PROJECT: LOCATION : MANUFACTURER:

UNIT NO: SERVICE:

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

I

ITEM

OK

I

MODEL: COMMENT

I PRE-START-UP INSPECTION PHYSICAL INSTALLATION COMPLETE

- Mounting, Isolators, Components - Alignment, Lubrication - Purnp(s) Rotates Freely - Control Panel MECHANICAL SERVICE CONNECTIONS - Piping & Valves Completed & Tested - Valves Positioned For Start-up ELECTRICAL SERVICE CONNECTIONS

- Electrical Connections Completed

- Disconnect Switch Installed

- Overload Heaters in Place (Sized Correctly)

CONTROL SYSTEMS COMPLETE

- Control System Operational - Ready to Start & Run Under Control

START-UP INSPECTION Start-up by Manufacturer's Representative Mech. & Elect. Contractors Present Pump Rotation Correct (Bump) Electrical Interlocks Verified Check Valve Tested StatVStop Operation Verified Motor Amps - Rated __ Actual Motor Volts - Rated - Actual Vibration & Noise Level Acceptable

I

GENERAL COMMENTS:

PRE-START BY: START-UP BY:

B.18 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

APPENDIX C

94

= 8289350

0005573 L O T

LEVEL 2 PRE-START AND START-UP CHECKLISTS

The equipment pre-start and start-up checklists included in this Appendix cover a range of equipment for typical HVAC systems. They are similar to those for Level 1 commissioning but are set up so each item has "checkmark documentation instead of just categories of items.

applicable for every project. Therefore, the lists should be used as generic masters, to be revised to suit the needs of specific equipment and systems in specific projects. Some items will not be relevant and should be deleted from the project checklists. Other items may need to be added.

These lists may seem excessively detailed; however, experience has shown they can be very useful in documenting problem areas, identifying responsibility, communicating the problem to the responsible party, and serving as followup reminders (Section 7.3).

It would be normal for companies offering commissioning services to come up with their own set of master checklists, stored on computer, adding to them as variations are encountered with some regularity. These can then be edited for specific projects very quickly and put into project files for printing and distribution.

The checklists are generic and generally include a comprehensive list of items, not all of which are

TABLE OF CONTENTS CHECKLIST

SMS201 SMS202 SMS203 SMS204 SMS205 SMS206 SMS207 SMS208 SMS209 SMS21O SMS211 SMS212 SMS213 SMS214 SMS215 SMS216 SMS217 SMS218 SMS219 SMS220 SMS221 SMS222 SMS223 SMS224 SMS225 SMS226 SMS227 SMS228 SMS229 SMS230 SMS231 SMS232 SMS233

DESCRIPTION

AIR HANDLING UNIT-LIQUID HEATKOOL AHU CNV RETURN FAN-LIQUID HEATKOOL AIR HANDLING UNIT-GASHEAT PACKAGED AIR CONDITIONING UNIT PACKAGED AIR CONDITIONING UNIT-GAS HEAT AIR CONDITIONING UNIT-WATER COOLED HEAT PUMP UNIT-WATER COOLED MAKE-UP AIR UNIT-LIQUID HEATKOOL MAKE-UP AIR UNIT-GAS HEAT FAN COIL UNIT EXHAUST FAN RETURN FAN PRESSURIZATION FAN HYDRONIC HEATING SYSTEM-GENERAL HOT WATER BOILER-GAS FIRED HOT WATER BOILER-OIL FIRED STEAM BOILER-GAS FIRED STEAM BOILER-OIL FIRED CONDENSATE RETURN CHILLED WATER SYSTEM-GENERAL CHILLER-GENERAL CHILLER-AIR COOLED AIR COOLED CONDENSING UNIT COOLING TOWER CIRCULATING PUMP DOMESTIC WATER SYSTEM-GENERAL DOMESTIC HOT WATER TANK-GAS FIRED DOMESTIC HOT WATER TANK-HEAT EXCHANGER SUMP PUMP FIRE PROTECTION SYSTEM-GENERAL FIRE PUMP/JOCKEY PUMP AIR COMPRESSOR FUEL OIL SYSTEM-GENERAL

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

c.1

SMACNA T I T L E M H V A C C M 9 4

8 1 8 9 3 5 0 0 0 0 5 5 7 4 O46

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST SMS201 AIR HANDLING UNIT LIQUID HEATICOOL

-

-

PROJECT: LOCATION: MANUFACTURER:

UNIT NO: SERVICE: MODEL:

I

ITEM

OK

I

COMMENT

PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Heating Coil Clean and Clear - Piping Complete Cooling Coil Clean and Clear - Piping Complete Condensate Drains Clear Humidifier Section Installation Completed Safety Controls Operational Building & Fan Room Clean For Start-up Duct Cleaning Completed Control System Completed (End to End Checks)

START-UP INSPECTION Start-up By Manufacturer's Representative Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Freeze Protection Operational Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated - Actual Motor Volts - Rated - Actual Final Operating Filters Installed COMMENTS:

PRE-START BY: START-UP BY:

c.2 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

S M A C N A T I T L E U H V A C C M 94

= ALB9350

SMACNA

0005575 T A 2

=

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS202 AIR HANDLING UNIT C/W RETURN FAN LIQUID HEAT/COOL

PROJECT: LOCATION: MANUFACTURER:

I

ITEM

OK

UNIT NO: SERVICE: MODEL: COMMENT

I

PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Heating Coil Clean and Clear - Piping Complete Cooling Coil Clean and Clear - Piping Complete Condensate Drains Clear Humidifier Section Installation Completed Safety Controls Operational Building & Fan Room Clean For Start-up Duct Cleaning Completed Control System Completed (End to End Checks)

1-

I

I

START-UP INSPECTION Start-up By Manufacturer's Representative Fan Rotation Correct (Both Fans) Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Freeze Protection Operational Local Air Leakage Acceptable Vibration & Noise Level Acceptable SF Motor Amps - Rated - Actual SF Motor Volts - Rated - Actual RF Motor Amps - Rated - Actual RF Motor Volts - Rated - Actual

~

I

PRE-START BY: START-UP BY:

DATE: DATE:

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

c.3

S M A C N A TITLE*HVACCM 94

= ôLô9350 0005576 919 SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS203 AIR HANDLING UNIT GAS HEAT

PROJECT: LOCATION: MANUFACTURER:

I

ITEM

UNIT NO: SERVICE: MODEL: OK

]

I

I

I

I

COMMENT

PRE-START-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Duct System Installation Completed Equipment Secure / Shipping Bolts Removed Vibration Isolators Adjusted Equipment Guards Freedom of Rotation Lubrication Completed Plenum Free of Loose Material / Coils Clean Balance & Fire Dampers in Start-up Position Temporary Start-up Filters Installed Overload Protection Heater Size Electrical Connections / Local Disconnect Safety Controls Operational Burner Controls Complete and Operational Gas Piping Tested & Purged Combustion Air Inlet Unobstructed Gas Venting Completed Gas Pressure Confirmed

FURNACE START-UP INSPECTION Fan Rotation Correct Motor Amps (Rated ) Motor Voltage (Rated ) Electrical Interlocks Damper Interlocks Operating Temperature Controls Checked Qualified Personnel (Cert. No. ) Firing Sequence Verified Flame Safeguard Sequence Verified Combustion Efficiency Test (Report Attached) Volume / Capacity Test (Report Attached)

COMMENTS:

PRE-START BY: START-UP BY:

c.4 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS204 PACKAGED AIR CONDITIONING UNIT

PROJECT: LOCATION: MANUFACTURER:

UNIT NO:

SERVICE: MODEL: ITEM

COMMENT

PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators & Seismic Restraints Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Cooling Coil Clean and Clear - Piping Complete Condensate Drains Clear & Complete Safety Controls Operational Building & Fan Room Clean For Start-up Control System Completed (End to End Checks)

START-UP INSPECTION Start-up By Manufacturer's Representative Fan Rotation Correct Electrical Interlocks Verified Damper Controls Operational Temperature Controls Operational Hot Gas Bypass Control Verified Cooling Stages Verified Motor Amps - Rated - Actual Motor Volts - Rated - Actual Final Operating Filters Installed Safety Controls Verified

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

c.5

S M A C N A TITLE*HVACCM 94

8 1 8 9 3 5 0 0005578 791

SMACNA HVAC SYSTEMS COMMISSIONING

- LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS205 - PACKAGED AIR CONDITIONING UNIT GAS HEAT

PROJECT: LOCATION : MANUFACTURER:

I

ITEM

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators & Seismic Restraints Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Burner Controls Complete & Operational Gas Piping Tested & Purged Gas Pressure Confirmed Combustion Air and Venting Unobstructed Cooling Coil Clean and Clear - Piping Complete Condensate Drains Clear & Complete Safety Controls Operational Building & Fan Room Clean For Start-up Duct Cleaning Completed Control System Completed (End to End Checks)

I

START-UP INSPECTION

PRE-START BY: START-UP BY:

C.6 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Start-up By Manufacturer's Representative Fan Rotation Correct Electrical Interlocks Verified Damper Controls Operational Temperature Controls Operational Firing Sequence Verified Flame Safeguard Sequence Verified Combustion Efficiency Test Report Attached Volume / Capacity Test Report Attached Motor Amps - Rated - Actual Motor Volts - Rated - Actual

DATE: DATE:

HVAC Systems Commissioning Manual

0

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

74

=

8 1 8 9 3 5 0 0005577 628

SMACNA

=

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS206 AIR CONDITIONING UNIT WATER COOLED

PROJECT: LOCATION: MANUFACTURER:

I

ITEM

OK

I

I

UNIT NO: SERVICE: MODEL: COMMENT

I

PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Piping Complete Cooling Coil Clean and Clear - Piping Complete Condensate Drains Clear & Complete Safety Controls Operational Building 8 Fan Room Clean For Start-up Duct Cleaning Completed Control System Completed (End to End Checks)

START-UP INSPECTION Start-up By Manufacturer's Representative Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Freeze Protection Operational Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated - Actual Motor Volts - Rated - Actual Final Operating Filters Installed Water Control Valve Operational Manufacturer's Start-up Checklists Attached

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT ~

c.7

SMACNA T I T L E x H V A C C M '74

818'7350 0 0 0 5 5 8 0 3 4 T

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS207 HEAT PUMP UNIT WATEWCOOLED

PROJECT: LOCATION: MANUFACTURER:

I

ITEM

OK

I

I

I

I

I

UNIT NO: SERVICE: MODEL: COMMENT

PRE-START-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Piping Complete Coil Clean and Clear - Piping Complete Condensate Drains Clear & Complete Safety Controls Operational Building & Fan Room Clean For Start-up Duct Cleaning Completed Control System Completed (End to End Checks)

START-UP INSPECTION Start-up By Manufacturer's Representative Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Freeze Protection Operational Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated - Actual Motor Volts - Rated - Actual Final Operating Filters Installed Water Control Valve Operational Manufacturer's Start-up Checklists Attached COMMENTS:

PRE-START BY: START-UP BY:

C.8 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

= 8389350 0005583

SMACNA T I T L E * H V A C C M 9 4

SMACNA

28b

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS208 MAKE-UP AIR UNIT LIQUID HEAT/COOL

PROJECT: LOCATION: MANUFACTURER:

UNIT NO: SERVICE: MODEL: ITEM

I

OK

I

COMMENT

PRE-START-UP INSPECTION

t

~~

I

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Heating Coil Clean and Clear - Piping Complete Cooling Coil Clean and Clear - Piping Complete Condensate Drains Clear Humidifier Section Installation Completed Outdoor Air Damper End Switch Operational Safety Controls Operational Building & Fan Room Clean For Start-up Duct Cleaning Completed Control System Completed (End to End Checks)

START-UP INSPECTION Start-up By Manufacturer's Representative Outdoor Air Damper Wide Open Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Freeze Protection Operational Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated - Actual Motor Volts - Rated - Actual -

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

c.9

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS209 MAKE-UP AIR UNIT GAS HEAT

PROJECT: LOCATION : MANUFACTURER:

UNIT NO: MODEL:

I

ITEM

OK

I

COMMENT

PR E-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Burner Controls Complete & Operational Gas Piping Tested & Purged Gas Venting Completed Gas Pressure Confirmed PSI) Outdoor Air Damper End Switch Operational Safety Controls Operational Building & Fan Room Clean For Start-up Duct Cleaning Completed Control System Completed (End to End Checks)

START-UP INSPECTION Start-up By Qualified Personnel (Cert. No. Outdoor Air Damper Wide Open Fan Rotation Correct Electrical Interlocks Verified Firing Sequence Verified Freeze Protection Operational Flame Safeguard Sequence Verified Combustion Efficiency 8 Capacity Test Reports Motor Amps - Rated - Actual Motor Volts - Rated - Actual -

PRE-START BY: START-UP BY:

c.1o Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

SERVICE:

S M A C N A TITLE*HVACCM 9 4

8 1 8 9 3 5 0 0 0 0 5 5 8 3 O59

SMACNA

=

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST SMS210 - FAN COIL UNIT

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

PROJECT: LOCATION : MANUFACTURER:

UNIT NO: SERVICE: MODEL: ITEM

PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Piping Complete Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors 8 Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Cooling Coil Clean and Clear - Piping Complete Condensate Drains Clear Safety Controls Operational Building & Fan Room Clean For Start-up

I

OK

1

COMMENT

H

START-UP INSPECTION Fan Rotation Correct Electrical Interlocks Verified Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated - Actual Motor Volts - Rated - Actual Final Operating Filters Installed

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

c.11

SMACNA T I T L E * H V A C C M

94

8189350 0 0 0 5 5 8 4 T95

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST SMS211- EXHAUST FAN PROJECT: LOCATION : MANUFACTU R ER:

UNIT NO: SERVICE: MODEL:

I

ITEM

OK

I

COMMENT

PRE-START-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Backdraft Dampers Free to Operate Electrical Connections Complete Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Building & Fan Room Clean For Start-up

START-UP INSPECTION Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated - Actual Motor Volts - Rated Actual

-

I

I

COMMENTS:

PRE-START BY: START-UP BY:

c.12 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

94

= 8389350

0005585 923

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS212 RETURN FAN

LOCATION:

UNIT NO: SERVICE:

MANUFACTURER:

MODEL:

PROJECT:

ITEM PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Supply Fan Interlock Completed Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Building & Fan Room Clean For Start-up

I

OK

I

COMMENT

I

START-UP INSPECTION Fan Rotation Correct Electrical Interlocks Verifiei Supply Fan Interlock Verified Fan Status Indicators Verified (Local / Remote) Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated - Actual Motor Volts - Rated - Actual -

COMMENTS:

DATE: DATE:

PRE-START BY: START-UP BY:

HVAC Systems Commissioning Manual

First Edition

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

c.13

~~~~~

8 3 8 9 3 5 0 0 0 0 5 5 8 6 868

SMACNA T I T L E * H V A C C M 9 4

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS213 PRESSURIZATION FAN

PROJECT: LOCATION : MANUFACTURER:

UNIT NO: SERVICE:

I

ITEM

I

OK

I

MODEL: COMMENT

I

PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenums Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Outdoor Air Dampers Operational Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Building & Fan Room Clean For Start-up

START-UP INSPECTION Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated - Actual Motor Volts - Rated - Actual

Id====I

I

COMMENTS:

PRE-START BY: START-UP BY:

C.14 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

94

8389350 0005587 ï T 4

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS214 HYDRONIC HEATING SYSTEM GENERAL UNIT NO: SERVI CE: MODEL:

PROJECT: LOCATION: MANUFACTURER: ITEM

I

OK

I

COMMENT

PRE-START-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

System Pressure Tested (Hrs) Water Make-up Station Installed Fill Pressure Set (PSI) Safety Relief Valve Setting ( PSI) Safety Relief Valve Capacity ( BTU) Backflow Preventer Installed Expansion Tank On Line Sight Glass Installed Air Vents Installed (High Points in System) Pressure & Temperature Gauges Installed Chemical Pot Feeder tnstalled Pumps Ready to Start - Checklists Completed Boilers Ready to Start - Checklists Completed Manufacturers Rep. On Site For Start-up Control System Completed (End to End Checks)

CHEMICAL CLEANING 81 TREATMENT Cleaning Carried Out By Qualified Personnel Valves Positioned For Full Circulation City Water Circulated ( HRS) System Drained - Strainers Cleaned Cleaning Solution Circulated (HRS) Cleaning Solution Drained - Strainers Cleaned 2nd City Water Circulation (Stable PH & TDH) Corrosion Inhibiter Added Per Manuf. Instruc. System Valves Cycled During Flushing All Low Points Blown Down During Flushing Chemical Cleaning Report Attached Final PH = Final TDH = Chemical Concentration = -PPM

I COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

C.15

SMACNA T I T L E U H V A C C M 94

= 8387350

0 0 0 5 5 8 8 630

SMACNA

=

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS215 HOT WATER BOILER GAS FIRED

PROJECT: LOCATION : MANUFACTURER:

UNIT NO: SERVICE: MODEL: ITEM

COMMENT

PRE-START-UP INSPECTION Installation Complete Including Breeching Equipment & Piping Identification Electrical Connections I Voltage Checked Safety Controls Complete & Operational Sensor & Gage Locations Noted Burner Controls Complete & Operational Gas Piping Tested & Purged Combustion Air Inlet Unobstructed Gas Venting Completed Gas Pressure Confirmed = Boiler Water Temperature Setpoint = Boiler Inspection Certificate No. Chemical Treatment Completed

BOILER START-UP INSPECTION

I

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Qualified Personnel (Cert. No. 1 Firing Sequence Verified Flame Safeguard Sequence Verified Automatic Shutdown Verified Safety Shutdown Verified Low Water Cut-Out Tested Safety Relief Valve Tested Water Temperature Maintained Pump Interlock Operational Combustion Efficiency Test (Report Attached) Volume / Capacity Test (Report Attached) Manufacturer's Representative Present

I

COMMENTS:

PRE-START BY: START-UP BY:

C.16 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E M H V A C C M 9 4

m

8189350 0005589 577

SMACNA HVAC SYSTEMS COMMISSIONING

m

- LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS216 HOT WATER BOILER OIL FIRED PROJECT: LOCATION: MANUFACTURER:

UNIT NO: SERVICE: MODEL: ITEM

I

OK

I

I

COMMENT

I

PRE-START-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Installation Complete Including Breeching Equipment & Piping Identification Electrical Connections / Voltage Checked Safety Controls Complete & Operational Sensor & Gage Locations Noted Oil Burner Controls Complete & Operational Oil Piping Tested & Purged Combustion Air Inlet Unobstructed Boiler Water Temperature Setpoint = Boiler Inspection Certificate No. Chemical Treatment Completed

BOILER START-UP INSPECTION Qualified Personnel (Cert. No. ) Firing Sequence Verified Flame Safeguard Sequence Verified Automatic Shutdown Verified Safety Shutdown Verified Low Water Cut-Out Tested Safety Relief Valve Tested Water Temperature Maintained Pump Interlock Operational Combustion Efficiency Test (Report Attached) Volume / Capacity Test (Report Attached) Manufacturer's Representative Present

PERFORMANCE TESTS COMPLETED CONSULTANT VERIFICATION COMPLETED DEMONSTRATION COMPLETED

COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

C.17

B L B ï 3 5 0 0005590 2 9 9

SMACNA T I T L E * H V A C C M 94

SMACNA HVAC SYSTEMS COMMISSIONING

- LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS217 STEAM BOILER GAS FIRED

PROJECT: LOCATION: MANUFACTURER:

I

ITEM

I

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

I

PRE-START-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Installation Completed Including Breeching Equipment & Piping Identification Electrical Connections / Voltage Checked Safety Controls Complete & Operational Sensor & Gage Locations Noted Burner Controls Complete & Operational Gas Piping Tested & Purged Combustion Air Inlet Unobstructed Gas Venting Completed Gas Pressure Confirmed = Syphons at Gauges and Instruments Feed Water System Operational Surface and/or Bottom Blowdown Piping Compl. Safety Valve Installed Boiler Inspection Certificate No. Chemical Treatment Completed

BOILER START-UP INSPECTION Qualified Personnel (Cert. No. .._.) Firing Sequence Verified Flame Safeguard Sequence Verified Automatic Shutdown Verified Safety Shutdown Verified Pump Interlock Operational Combustion Efficiency Test (Report Attached) Volume / Capacity Test (Report Attached) Manufacturer's Start-up Sheets Attached Manufacturer's Representative Present

I COMMENTS:

PRE-START BY: START-UP BY:

C.18 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA TITLE*HVACCM

8289350 0005593 225

94

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS218 STEAM BOILER OIL FIRED

PROJECT: LOCATION : MANUFACTURER: ITEM

I

UNIT NO: SERVICE: MODEL: OK

I

I

I

I

I

COMMENT

PRE-START-UP INSPECTION Installation Completed Including Breeching Equipment & Piping Identification Electrical Connections / Voltage Checked Safety Controls Complete & Operational Sensor & Gage Locations Noted Oil Burner Controls Complete & Operational Oil Piping Tested & Purged Combustion Air Inlet Unobstructed Syphons at Gauges & Instruments Feed Water System Operational Surf. and/or Bottom Blowdown Piping Complete Safety Valve Installed Boiler Inspection Certificate No. Chemical Treatment Completed

BOILER START-UP INSPECTION Qualified Personnel (Cert. No. ) Firing Sequence Verified Flame Safeguard Sequence Verified Automatic Shutdown Verified Safety Shutdown Verified Pump Interlock Operational Combustion Efficiency Test (Report Attached) Volume / Capacity Test (Report Attached) Manufacturer's Start-up Sheets Attached Manufacturer's Representative Present

COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

c.19

S M A C N A T I T L E x H V A C C M 9 4 W B L 8 9 3 5 0 0 0 0 5 5 9 2 Ob1

SMACNA

=

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS219 CONDENSATE RETURN UNIT

PROJECT: LOCATION : MANUFACTURER:

UNIT NO: SERVICE: MODEL:

I

ITEM

OK

I

COMMENT

PRE-START-UP INSPECTION Mountings Checked - Pump & Motor Alignment By Millwright or Installer Seismic Restraints Installed Equipment Guards Installed Pumps Rotate Freely Pump & Motor Lubricated Shaft Gland Lubricated Local Valving Set For Normal Operation Tank Clean & Free of Debris Electrical Connections Completed Overload Heaters in Place (Sized Correctly) Control Panel Complete ¿ Activated i Electrical Interlocks - Stop/Start

START-UP INSPECTION Pump Rotation Correct Electrical Interlocks Verified Pump Status Indicators Verified (Local / Remote) Check Valve Operation Tested Float Switches Operating Level Alarms Tested Motor Amps - Rated - Actual Motor Volts - Rated - Actual Pump Flow Rate GPM Manufacturer's Start-up Checklists Attached

~

COMMENTS:

PRE-START BY: START-UP BY:

c.20

DATE: DATE:

HVAC Systems Commissioning Manual --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E x H V A C C M 9 4

8189350 0 0 0 5 5 9 3 T T B

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST SMS220 - CHILLED WATER SYSTEM - GENERAL

PROJECT: LOCATION: MANUFACTURER: ITEM

II

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

I

PRE-START-UP INSPECTION System Pressure Tested ( Hrs) Water Make-up Station Installed Fill Pressure Set (PSI) Safety Relief Valve Setting ( PSI) BTU) Safety Relief Valve Capacity ( Backflow Preventer Installed Expansion Tank On Line Sight Glass Installed Air Vents Installed (High Points in System) Pumps Ready To Start - Checklists Completed Chillers Ready To Start - Checklists Completed Chillers Controls Activated Manufacturer's Rep. On Site for Start-up Control System Completed (End to End)

CHEMICAL CLEANING & TREATMENT Cleaning Carried Out By Qualified Personnel Valves Positioned For Full Circulation City Water Circulated ( Hrs) System Drained - Strainers Cleaned Cleaning Solution Circulated ( Hrs) Cleaning Solution Drained - Strainers Cleaned 2nd City Water Circulation (Stable PH & TDH) Corrosion Inhibiter Added Per Manuf. Instruc. Chemical Cleaning Report Attached Final PH = Final TDH = Chemical Concentration = -PPM

I

COMMENTS:

DATE: DATE:

PRE-START BY: START-UP BY:

HVAC Systems Commissioning Manual

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

c.21

SMACNA T I T L E * H V A C C M

8389350 0005594 4 3 4

94

SMACNA

m

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS221- CHILLER GENERAL

PROJECT: LOCATION: MANUFACTURER:

I

ITEM

I

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

I

PRE-START-UP INSPECTION Installation Completed Equipment & Piping Identification Electrical Connections / Voltage Checked Safety Controls Complete & Operational Sensor & Gage Locations Noted Chiller Controls Complete & Operational Local Valving & Piping Correct Electrical Interlocks Completed Chilled Water Temperature Setpoint = Overload Protection Heater Size: Chemical Treatment Completed

i

CHILLER START-UP INSPECTION Start-up By Manufacturer's Representative Certificate / Log Provided Safety Cutout - Flow Safety Cutout - Temperature Safety Cutout - Pressure Electrical Interlocks Tested Pressure & Temperature Gauges Checked Water Temperature Maintained Pump Interlock Operational Motor Amps - Rated - Actual Motor Volts - Rated - Actual Manufacturer's Start-up Sheets Attached NOTE: This checklist is suitable to prepare most types of chillers for start-up. Start-up Technician should follow manufacturer's equipment specific checklist and submit CODY for report.

COMMENTS:

PRE-START BY: START-UP BY:

c.22 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

t

I

DATE: DATE:

HVAC Systems Commissioning Manual --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA TITLE*HVACCM

94

m ôL89350

0 0 0 5 5 9 5 870

SMACNA

m

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS222 CHILLER AIR COOLED

UNIT NO: SERVICE:

PROJECT: LOCATION: MAN UFACTU RER:

MODEL: ITEM

I

OK

I

COMMENT

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators & Seismic Restraints Installed Equipment Connections I Voltage Checked Fans Rotate Freely Fans & Motors Lubricated Oil Levels Checked Outdoor Coil Clean & Clear Safety Controls Complete & Operational Chiller Controls Complete & Operational Local Valving & Piping Correct Electrical Interlocks Completed Chiller Water Temperature Setpoint = Overload Protection Heater Size: Chemical Treatment Completed Condensate Drains Clear Leak Tests Complete

CHILLER START-UP INSPECTION Start-up By Manufacturer's Representative High & Low Pressure Cutouts Tested Capacity Control Verified Head Pressure Control Verified Hot Gas Bypass Tested Electrical Interlocks Tested Pressure & Temperature Gauges Checked Water Temperature Maintained Pump Interlock Operational Motor Volts - Rated - Actual Motor Amps - Rated - Actual Comp. Volts - Rated - Actual Comp. Amps - Rated - Actual Manufacturer's Start-up Sheets Attached I

I

COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

C.23

BLB9350 0 0 0 5 5 9 6 7 0 7

SMACNA T I T L E 8 H V A C C M 94

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST SMS223 AIR COOLED CONDENSING UNIT

-

PROJECT: LOCATION: MANUFACTURER:

I

ITEM

I

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

I

PRE-START-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Piping Complete Fans Rotate Freely Fans, Motors i3 Linkages Lubricated Electrical Connections Completed Disconnect Switch Installed Overload Heaters in Place (Sized Correctly) Outdoor Coil Clean and Clear Condensate Drains Clear Safety Controls Operational Leak Tests Completed Oil Levels Checked

START-UP INSPECTION Start-up By Qualified Personnel Manufacturer's Start-up Checklists Attached Crankcase Heater Energized for 24 Hours Electrical Interlocks Verified High i3 Low Pressure Cut-Outs Tested Capacity Control Verified Low Ambient Control Verified Head Pressure Control Verified Vibration i3 Noise Level Acceptable Motor Amps - Rated - Actual Actual Motor Volts - Rated Comp. Amps - Rated - Actual Comp. Volts - Rated - Actual Thermostat Verified - Setpoint = Mode Switches Verified (Cooling, Heating, Auto) Time Clock Set

-

COMMENTS:

PRE-START BY: START-UP BY:

C.24

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

94

m

8387350 0005597 6 4 3

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST SMS224- COOLING SYSTEM

UNIT NO: SERVICE: MODEL:

PROJECT: LOCATION : MANUFACTURER: ITEM PR E-START-UP INSPECTION Mountings Checked - Pump & Motor Alignment By Millwright or Installer Seismic Restraints Installed Equipment Guards Installed Pumps & Fans Rotate Freely Pumps, Fans, & Motors Lubricated Electrical Interlocks / Starters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters Size

I

OK

I

COMMENT

1

START-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Pump & Fan Rotation Correct Electrical Interlocks Verified Status Indicators Verified (Local/Rernote) Level Control Tested Tower Blowdown Vibration & Noise Level Acceptable Motor Amps - Rated - Actual Motor Volts - Rated - Actual Start-up By Manuf. Rep. (Checklists Attached) Controls Adjusted Log Provided

I

I

COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

C.25

S M A C N A T I T L E r H V A C C M 94

8LB7350 0005598 58T

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST SMS225 CIRCULATING PUMP

-

PROJECT: LOCATION : MANUFACTURER:

I

ITEM

I

UNIT NO: SERVICE: MODEL: OK

]

COMMENT

I

PRE-START-UP INSPECTION Mountings Checked - Pump & Motor Alignment By Millwright or Installer Seismic Restraints Installed Equipment Guards Installed Pump Rotate Freely Pump & Motor Lubricated Shaíî Gland Lubricated Local Valving Set For Normal Operation Pressure Gauges in Supply and Return Piping Electrical Connections Completed Disconnect Switch Installed Overload Heaters Installed (Sized Correctly)

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

START-UP INSPECTION Pump Rotation Correct Electrical Interlocks Verified Pump Status Indicators Verified (Local/Remote) Check Valve Operation Tested System Static Pressure Vibration & Noise Level Acceptable Motor Amps - Rated Actual Motor Volts - Rated - Actual -

-

COMMENTS:

PRE-START BY: START-UP BY:

C.26 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual

0

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

74

m

8389350 0 0 0 5 5 9 9 4 L b M

SMACNA

HVAC SYSTEMS COMMISSIONING - LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS226 DOMESTIC WATER SYSTEM GENERAL

UNIT NO: SERVICE:

PROJECT: LOCATION : MANUFACTURER: ITEM

I

OK

I

MODEL: COMMENT

PRE-START-UP INSPECTION Water Piping Pressure Test (Report Attached) System Flushed & Cleaned

REPORTS & CHECKLISTS RECEIVED Booster Pump Manufacturer's Checklists Attached Booster Pump Commissioning Checklist DHW Tank Manufacturer's Checklist Attached DHW Tank Commissioning Checklist Fixture Checklist Heat Tape Verification Report Attached --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

C.27

S M A C N A T I T L E * H V A C C M 94 W 8189350 0 0 0 5 6 0 0 T 6 8

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS227- DOMESTIC HOT WATER TANK GAS FIRED

PROJECT: LOCATION: MANU FACTURER:

UNIT NO:

SERVICE: MODEL: ITEM

COMMENT

PRE-START-UP INSPECTION Installation Completed Including Breeching Electrical Connections / Voltage Checked Safety Controls Complete & Operational Sensor & Gage Locations Noted Burner Controls Complete & Operational Gas Piping Tested & Purged Combustion Air Inlet Unobstructed Gas Venting Completed Gas Pressure Confirmed = Water Heater Temperature Setpoint = Gas Piping Identified

WATER HEATER START-UP INSPECTION Qualified Personnel (Cert. No. ) Firing Sequence Verified Flame Safeguard Sequence Verified Automatic Shutdown Verified Safety Shutdown Verified Recirculation Pump Operational Safety Valve Tested Water Temperature Maintained Combustion Efficiency Test (Report Attached) Volume / Capacity Test (Report Attached) Manufacturer's Start-up Sheets Attached Heat Tracing Mega Test Certificate Attached 49C Hot Water At All Remote Branch Outlets

I

I

COMMENTS:

PRE-START BY: START-UP BY:

C.28 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

HVAC Systems Commissioning Manual

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

94

B L B 9 3 5 0 0005bOL 9 T 4

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS228 DOMESTIC HOT WATER TANK HEAT EXCHANGER

PROJECT: LOCATION: MANUFACTURER:

UNIT NO: SERVICE: MODEL:

PRE-START-UP INSPECTION Installation Completed Safety Controls Complete & Operational Sensor & Gage Locations Noted Controls Complete & Operational Water Heater Temperature Setpoint =

WATER HEATER START-UP INSPECTION Recirculation Pump Operational Safety Valve Tested Control Valve Modulation Verified Water Temperature Maintained

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

I

COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

C.29

SMACNA T I T L E * H V A C C M

94

= 8189350 0 0 0 5 6 0 2 SMACNA

830

=

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST SMS229 - SUMP PUMP PROJECT: LOCATION: MANUFACTURER:

I

ITEM

I

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

I

PRE-START-UP INSPECTION Mountings Checked - Pump ¿ Motor i Alignment By Millwright or Installer Seismic Restraints Installed Equipment Guards Installed Pump Rotates Freely Pump & Motor Lubricated Shaft Gland Lubricated Local Valving Set For Normal Operation Sump Clean & Free Of Debris Electrical Connections Completed Overload Heaters Installed (Sized Correctly) Control Panel Complete & Activated Electrical Interlocks - Stop/Start

START-UP INSPECTION Pump Rotation Correct Electrical Interlocks Verified Pump Status Indicators Verified (LocaVRemote) Check Valve Operation Tested Float Switches Operating Level Alarms Tested Motor Amps - Rated - Actual Motor Volts - Rated - Actual Pump Flow Rate GPM Manufacturer's Start-up Checklists Attached

I

I

I

COMMENTS:

PRE-START BY: START-UP BY:

C.30

DATE: DATE:

HVAC Systems Commissioning Manual 0 First Edition --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

SMACNA T I T L E * H V A C C M 74

m

8389350 0005603 777

SMACNA

m

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS230 - FIRE PROTECTION SYSTEM GENERAL

PROJECT: LOCATION: MANUFACTURER:

UNIT NO: SERVICE:

MODEL: ITEM

I OK

I

I

I

COMMENT

PRE-START-UP INSPECTION Piping Pressure Test (Report Attached) Contractor's Letter of Assurance (Attached)

REPORTS & CHECKLISTS RECEIVED

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Fire Pump Manufacturer's Start-up Report Fire Pump Commissioning Checklist Fire Pump Flow Test Data Sheet Standpipe Flow Test Data Sheet Sprinkler System Commissioning Checklist Fire Protection Points Checklist DDC Auxiliary Functions Operational Checklist Pressurization Fan Verification Checklist

COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

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C.31

8 3 8 9 3 5 0 0 0 0 5 6 0 4 603

SMACNA T I T L E U H V A C C M 9 4

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST SMS231- FIRE PUMP / JOCKEY PUMP

PROJECT: LOCATION: MANUFACTURER:

I

ITEM

I

OK

I

UNIT NO: SERVICE: MODEL: COMMENT

I

PRE-START-UP INSPECTION Mountings Checked - Pump 8 Motor Alignment By Millwright or Installer Seismic Restraints Installed Equipment Guards Installed Pump Rotates Freely Pump & Motor Lubricated Shaft Gland Lubricated Packing Glands Adjusted Accessories Installed Local Valving Set For Normal Operation Water In System Electrical Connections Completed Overload Heaters Installed (Sized Correctly) Electrical Disconnect Cut In Pressure

START-UP INSPECTION Pump Rotation Correct Electrical Interlocks Verified Pump Status Indicators Verified (LocaVRemote) Check Valve Operation Tested Jockey Pump Relief Valve Tested FIRE PUMP Motor Amps - Rated - Actual Motor Volts - Rated - Actual Pump Flow Rate Manufacturer's Test Sheets Attached

COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

C.32 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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First Edition

SMACNA TITLEUHVACCM 94

8189350 0005605 5 4 T

SMACNA

=

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

SMS232 AIR COMPRESSOR

PROJECT:

UNIT NO:

LOCATION: MAN UFACTURER:

SERVICE: MODEL:

I

ITEM

OK

I

COMMENT

I PRE-START-UP INSPECTION Mountings Checked - Compressor & Motor Alignment By Millwright or Installer Seismic Restraints Installed Equipment Guards Installed Relief Valve Installed Oil Level Checked & Correct Pressure Settings - ON -OFF Air Driers Installed (Quantity -) Automatic & Manual Drains Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters Installed (Sized Correctly) Water Solenoid & Flow Regulating Valve In Place Identification Complete Manufacturer's Rep On Site For Start-up Manufacturer's Start-up Checklists Attached

START-UP INSPECTION Compressor Rotation Correct Status Indicators Verified (LocaURemote) Cylinder Unloaders Verified Alternator Operation Verified Relief Valve Tested Tank Pressure Control Verified Voltage - Rated - Actual Amperage - Rated - Actual Start-up By Qualified Personnel

COMMENTS:

PRE-START BY: START-UP BY:

DATE: DATE:

HVAC Systems Commissioning Manual --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

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c.33

SMACNA T I T L E * H V A C C M 9 4

8 3 8 9 3 5 0 0005bOb 486 M

SMACNA HVAC SYSTEMS COMMISSIONING

- LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

-

SMS233 FUEL OIL SYSTEM GENERAL

MODEL:

I

ITEM

OK

I

COMMENT --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

II

UNIT NO: SERVICE:

PROJECT: LOCATION: MANUFACTURER:

PRE-START-UP INSPECTION Oil Storage Tank Mountings Checked Oil Storage Tank Seismic Restraints in Place Day Tank Mountings Checked Day Tank Seismic Restraints In Place Local Piping Correct - No Leakage Pressure Gauges In Place Level Meter Installed And Operational Fill ¿ Venti Lines Completed Anti Syphon Valve In Place Whistle Alarm at Fill Pipe Fuel Piping Test Report Attached Fire Marshall Inspect Report Attached Fuel Pump Start-up Checklist Completed Pump Discharge Pressure 10 PSI Pump Discharge Relief Valve Operational Day Tank Flow Switch Operation Verified

I

%

1

I

I

COMMENTS:

START-UP BY:

c.34 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE:

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First Edition

APPENDIX D

94

BLBï3.50 0005607 312

=

FUNCTIONAL PERFORMANCE TEST CHECKLISTS

As with pre-staflstart-up checklists, the functional performance test checklists are generic for each of the various types of systems included in them. However, while pre-start/start-up checklists are generic for equipment, the functional performance checklists are for systems and the control sequences specified for them. There is a great deal more variability in system controls than there is in equipment checkout. Therefore, for a number of the more common systems, a set of four documents is provided: A generic functional performance test checklist for the system. This covers a common range of items relevant to many projects, but not all. An example of a system control sequence description for the system.

A verification procedure suggesting how the various tests may be carried out in the field by the commissioning and controls specialists. These examples illustrate how the generic, or master, checklists are intended to be used. Note that the threepart document is not provided for all the systems covered by generic functional performance checklists. Like pre-start/start-up checklists, it would be normal for companies offering commissioning services to come up with their own set of master functional performance checklists, stored on computer, adding to them as variations are encountered with some regularity. These can then be edited for specific projects very quickly and put into project files for printing and distribution.

A specific functional performance test checklist corresponding to the control sequence example. It is, in fact, how the generic checklist would be adapted for the specific control specification in the example.

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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D. 1

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SMACNA TITLE*HVACCM

S M A C N A TITLEmHVACCM 94

8389350 O005608 2 5 9

TABLE OF CONTENTS

SMCO1 SMCOIA1 SMCO1A2 SMCOIA3 SMCOI B I SMCOI €32 SMCOI B3 SMCOlCl SMCO1C2 SMCOI C3 SMCOP SMC02A1 SMC02A2 SMC02A3 SMC02B1 SMC02B2 SMC02B3 SMCOS SMC03A1 SMC03A2 SMC03A3 SMC04 SMCOS SMCOG SMC07 SMC08 SMCOS

D.2 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DESCRIPTION AIR HANDLING SYSTEM - GENERIC CHECKLIST SAMPLE-AH SYSTEM-ELECTRIC CONTROLS SEQUENCE OF OPERATION ACTUAL CHECKLIST VERIFICATION PROCEDURE SAMPLE-AH SYSTEM-VAV WITH DDC CONTROLS SEQUENCE OF OPERATION ACTUAL CHECKLIST VERIFICATION PROCEDURE SAMPLE-ROOFTOP A/C UNIT-GAS HEAT SEQUENCE OF OPERATION ’ ACTUAL CHECKLIST VERIFICATION PROCEDURE HYDRONIC HEATING SYSTEM-GENERIC CHECKLIST SAMPLE-HYDRONIC SYSTEM - ELECTRIC CONTROLS SEQUENCE OF OPERATION ACTUAL CHECKLIST VERIFICATION PROCEDURE SAMPLE-HYDRONIC SYSTEM-DDC CONTROLS SEQUENCE OF OPERATION ACTUAL CHECKLIST VERIFICATION PROCEDURE CHILLED WATER SYSTEM-GENERIC CHECKLIST SAMPLE-CH ILLED SYSTEM-DDC CONTROLS SEQUENCE OF OPERATION ACTUAL CHECKLIST VERIFICATION PROCEDURE EXHAUST FANS-GENERIC CHECKLIST PRESSURIZATION FANS-GENERIC CHECKLIST FORCE FLOW/UNIT HEATERS-GENERIC CHECKLIST VAV BOXE -GENERIC CHECKLIST CONTROL VALVES-GENERIC CHECKLIST FAN SYSTEM FIRE ALARM SHUTDOWN CHECKLIST

HVAC Systems Commissioning Manual

0

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

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CHECKLIST

SMACNA T I T L E * H V A C C M

94

= 8189350

0 0 0 5 6 0 9 L95

m

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION CHECKLIST

-

SMCO1 AIR HANDLING SYSTEM

SYSTEM::

PROJECT: LOCATION:

SERVICE:

, I

ITEM SYSTEM OFF Sensor Locations & Supports Checked Installation Complete Damper Positions Checked & Stroked DAY MODE START-UP SEQUENCE Fan Interlocks Start-Stop Sequences Mixing Damper Sequences

TEST

I

COMMENT

I

OK

TEMPERATURE CONTROL Mixed Air Temperature Control Supply Air Temperature Control Cooling Supply Air Temperature Control Heating Minimum Outdoor Air Control High & Low Limits Verified

-

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

STATIC PRESSURE CONTROL Static Pressure Maintained at Setpoint Supply I Return Fan Tracking Pressure & Volume Sensors Calibrated Pressure High Limit Verified

NIGHT MODE OPERATION Start-Stop Sequences Mixing Damper Sequences Temperature Control Sequences SAFETY & MISC. CONTROLS Freeze Protection Verified Fire Alarm Shutdown

COMMENTS:

TEST 1 BY: TEST 2 BY: VERIFIED BY:

DATE: DATE: DATE:

-

HVAC Systems Commissioning Manual First Edition Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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D.3

SMACNA T I T L E * H V A C C M

8 3 8 9 3 5 0 0005bLO 907 D

94

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM SEQUENCE OF OPERATION SMCOlA1 -AIR HANDLING SYSTEM ELECTRIC CONTROLS

-

IPRO.IECT:: I

~

LOCATION:

SYSTEM: SERVICE:

sample Project Mechanical Room

AHU-1 Main Floor

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

THE FOLLOWING IS A SAMPLE OF A TYPICAL SEQUENCE OF OPERATION AS SPECIFIED BY THE DESIGN CONSULTANT

AIR HANDLING UNIT AH-1

1.

Dayhiight mode selected by time clock.

2.

When supply fan stops outdoor and relief dampers close, return damper opens (normal position).

3.

Freeze-stat (hard wired) located downstream of heating coil shuts down the unit

DAY MODE 1.

Supply fan started by time clock.

2.

Room thermostat resets discharge air temperature through mixing dampers, and heating coil 3 way valve in sequence to maintain discharge temperature.

3.

Minimum outdoor air position shall be 50%.

4.

Mixed air shall be maintained at 54°F except in heating mode when dampers shall return to minimum position.

UNOCCUPIED MODE 1.

System off by time clock.

0.4

-

HVAC Systems Commissioning Manual First Edition

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT ~~~

~

SMACNA TITLE*HVACCM

74

= ôLô93.50 00056LL

ô43

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION CHECKLIST SMCOIA2 AIR HANDLING SYSTEM ELECTRIC CONTROLS

-

-

PROJECT: LOCATION:

Sample Project

UNIT NO:

Mechanical Room

SERVICE:

I

ITEM

OK

SYSTEM OFF Sensor Locations & Supports Checked Installation Complete Damper Positions Checked & Stroked

I

AHU-1 Main Floor COMMENT

I

I Dampers in Full Recirc Position

NORMAL START-UP SEQUENCE Timeclock Start/Stop Checked Mixing Dampers Modulate Fan Runs Continuously in Occupied Mode

t --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

TEMPERATURECONTROL Mixed Air Temp Control (Setpoint = 54°F) Room Thermostat Resets SA Temperature Dmprs & Htg. Valve Seq. To Maint. SA Temp Dampers To Min. OSA On Heating Demand Min OSA 50% (Adjustable)

UNOCCUPIED MODE System off

SAFETY CONTROLS Low Temperature Shutdown Fan Off/Full Recirc

-

Hardwired Freeze Thermostat

I

I

GENERAL: COMMENTS:

TEST 1 BY: TEST 2 BY: VERIFIED BY:

DATE: DATE: DATE:

.

HVAC Systems Commissioning Manual First Edition Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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D.5

S M A C N A TITLE*HVACCM

94

= 8389350

O005632 ï 8 T

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM SEQUENCE OF OPERATION SMCOlA3 -AIR HANDLING SYSTEM ELECTRIC CONTROLS

-

PROJECT: LOCATION:

SYSTEM: SERVICE:

Sample Project Mechanical Room

AHU-1 Main Floor

SYSTEM OFF 1. Check static items listed on verification checklist. 2. Stroke Dampers ¿? Control Valves by resetting associated controller setpoints. NORMAL START-UP SEQUENCE 1. Verify start-up of system by adjusting timeclock. Ensure Timeclock is programmed. 2. Witness mixing dampers modulating to control position on startup. TEMPERATURECONTROL 1. Verify mixing damper control at setpoint (measure temperature of mixed air). 2. Verify SA Temp. reset by manipulating room thermostat setpoint and witnesses risehall in SA temperature. 3. Verify sequencing by cycling from cooling demand (dampers 100% open) to heating demand (dampers at minimum ¿? heating valve open) by manipulating room temperature setpoint. 4. Balancing Contractor to verify and demonstrate Minimum damper position using temperature calculation to airflow measurement.

-

SAFETY CONTROLS 1. Simulate freeze condition (manipulate setpoint of freeze thermostat) and witness shutdown. Reset freeze thermostat and witness restart of system.

D.6 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

.

HVAC Systems Commissioning Manual First Edition Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

I

UNOCCUPIED MODE 1. Adjust timeclock and witness system off dampers to OFF position.

SMACNA T I T L E * H V A C C M

9Y

8389350 0005633 b3b

SMACNA HVAC SYSTEMS COMMISSIONING --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

CONTROL SYSTEM SEQUENCE OF OPERATION SMCOlBl- AIR HANDLING SYSTEM VAV WITH DDC CONTROLS

-

PROJECT: LOCATION:

SYSTEM: SERVICE:

Sample Project Mechanical Room I

AHlJ-2 Office VAV System

THE FOLLOWING IS A SAMPLE OF A TYPICAL SEQUENCE OF OPERATION AS SPECIFIED BY THE DESIGN CONSULTANT AIR HANDLING UNIT AH-2 1.

StarüStop the supply fan and return fan on schedule. Before start-up, open the outdoor air dampers to minimum position. Provide gradual (ramped) start for both fans.

2.

Supply air volume shall modulate to maintain the required static pressure. The return volume will be based on supply volume less all calculated exhaust fan flows less 10%.

3.

Module the mixing dampers to provide the required supply air temperature. Do not use the mixed air temperature sensor for mixing damper control.

4.

When the mixing dampers are at minimum outdoor air position, heating mode is enabled. Turn on the heating coil pump and modulate the 3 way control valve to maintain the required supply air temperature.

5. When the mixing dampers are at 100% outdoor air position, cooling mode is enabled. Modulate the 3 way control valve to maintain the required supply air temperature. 6.

When the outdoor air temperature is below 39"F, turn on the heating coil pump and modulate the 3 way control valve to maintain the required plenum temperature as sensed by the mixed air temperature sensor.

7.

The low temperature switch on the downstream side of the heating coil will stop the supply fan and close the outdoor air damper. Hardwire the sensor to the fan with manual reset and also send an alarm to the system.

8.

Reset the required supply air temperature from the zone temperatures.

-

HVAC Systems Commissioning Manual First Edition Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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D.7

SMACNA T I T L E * H V A C C M

94

m

8 3 8 7 3 5 0 O005634 5 5 2

m

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION CHECKLIST SMCOl82 AIR HANDLING SYSTEM VAV WITH DDC CONTROL

-

PROJECT: LOCATION: SERVICE:

-

Sample Project Mechanical Room 1 Office VAV System

UNIT NO: AHU-2

I

ITEM SYSTEM OFF Sensor Locations & Supports Checked Installation Complete Damper Positions Checked & Stroked End to End Checks Completed

OK

I

COMMENT

t ~

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

NORMAL START-UP SEQUENCE SF i 3 RF StarVStop By Daily Schedule OSA Damper To Min Pos. Before Fan Start Static Pressure Control Verified Return Fan Tracking Verified Mixing Dampers Modulate to Maintain SAT Mixing Dampers Min. Pos. Verified SAT Reset By Zone Temps SF & RF Fan Status Verified HEATING MODE Heating Mode Enabled When OSA Dmpr at Min Coil Pump Energized Heating Valve Modulates t o Maintain SAT

~~

Ramped Start Sequence

1

I I

I

Set Point = In. volume= CFM (90% (SF CFM-EFCFM) Not MAT

~~

Setpoint =

t

COOLING MODE Cooling Mode Enabled When OSA Dmpr at 100% Cooling Valve Modulates To Maintain SAT SAFETY CONTROLS If OSA c39 Htg. Pump On & Htg Valve Modulates To Maintain Plenum At Setpoint Freeze Protection Manual Reset

-

SF Off; OSA Dmpr Closed; System Alarm

COMMENTS:

TEST1 BY: TEST 2 BY: VERIFIED BY:

D.8 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE: DATE:

HVAC Systems Commissioning Manual First Edition Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

SMACNA T I T L E * H V A C C M

7 4 H 838’7350 000.5635 4’79 H

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION PROCEDURE SMCOIS3 AIR HANDLING SYSTEM VAV WITH DDC CONTROLS

-

I

PROJECT: LOCATION:

-

SYSTEM: SERVICE:

Sample Project Mechanical Room 7

AHU-2 Office VAV System

CONTROLS CONTRACTOR & COMMISSIONING AGENT WORK TOGETHER TO CARRY OUT THE FOLLOWING SYSTEM TESTS SYSTEM OFF 1. Check static items listed on verification checklist. 2. Stroke Dampers & Control Valves by resetting associated controller setpoints. 3. Confirm that Controls Contractor has completed End to End Checks NORMAL START-UP SEQUENCE 1. Verify start-up of system by simulating start time. Ensure Daily Schedule is programmed. 2. Witness mixing dampers open to minimum OSA position on before fan startup. 3. Verify Supply Fan Speed Control (Or VAV Damper) modulates to maintain system static pressure at setpoint. (Record Setpoint) 4. Verify Return Fan Speed Control (Or VAV Damper) modulates to maintained specified volume differential. 5. Verify Mixing Damper Controls To Supply Air Temperature Setpoint. Test by manually adjusting setpoint and watching dampers adjust to suit. 6. Verify Mixing Damper Min. Position (Adjust SAT setpoint & determine volume OSA using temperature differential calculation or flow measuring device). 7. Examine SAT reset algorithm in DDC program and test by manually adjusting zone setpoints as required to cause new SAT Setpoint calculation. 8. Verify that correct fan status is displayed by DDC system. HEATING MODE 1. Verify heating mode enabled by adjusting SAT Setpoint to drive dampers to min. position. 2. Verify Coil Pump starts when heating mode enabled. 3. Witness heating valve modulation to maintain SAT setpoint. COOLING MODE 1. Verify cooling mode enabled by adjusting SAT Setpoint to drive dampers to 100% OSA. 2. Witness cooling valve modulation to maintain SAT setpoint.

1

SAFETY CONTROLS 1. Simulate freeze condition (manipulate setpoint of freeze thermostat) and witness shutdown. 2. Reset freeze thermostat and witness restart system. 3. Verify Plenum temperature control by simulating 39°F OSA (with Fan On and Off) (Record Plenum Setpoint)

HVAC Systems Commissioning Manual First Edition --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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D.9

SMACNA TITLE*HVACCM

94

H 8389350 00056Lb 325

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM SEQUENCE OF OPERATION SMCOlC1- ROOFTOP A/C UNIT GAS HEAT

-

PROJECT: LOCATION:

Sample Project Roof

SYSTEM: SERVICE:

AHU-3

Offices

THE FOLLOWING IS A SAMPLE OF A TYPICAL SEQUENCE OF OPERATION AS SPECIFIED BY THE DESIGN CONSULTANT AIR HANDLING UNIT AH-2 1.

Daymight mode selected by time clock. Fan shall run continuously in Day Mode. System is off at night.

2.

Unit shall be complete with economizer and enthalpy controller. Minimum outdoor air 10%.

3.

Integral freeze-stat shuts down the unit.

4.

A call for cooling sequences the economizer and 2 compressors to maintain room temperature at setpoint.

5.

A call for heating sequences the economizer to minimum position and modulates gas heat to maintain room temperature at setpoint.

6.

Unit is interlocked to shut down on fire alarm.

D.10 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

.

HVAC Systems Commissioning Manual First Edition --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

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SMACNA T I T L E * H V A C C M

94

8389350 0 0 0 5 6 3 7 261

=

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION CHECKLIST SMCOICZ ROOFTOP A/C UNIT GAS HEAT

-

-

PROJECT: Sample Project LOCATION: Roof Offices SERVICE:

SYSTEM: AHU-3

I

ITEM PRELIMINARY CHECKS Sensor Locations & Supports Checked Installation Complete Damper Positions Checked & Stroked

OK

I

COMMENT

I Ensure dampers seal on closure I

NORMAL START-UP SEQUENCE Unit Startistop With Timeclock ) Economizer control verified (SP = Min. OSA damper control verified (SP=lO%) Enthalpy Control Verified COOLING CONTROL Room Thermostat Verified Cooling Stage 1 Economizer Verified Cooling Stage 2 Comp 1 Verified Cooling Stage 3 Comp 2 Verified Head Pressure Control Verified

-

-

-

HEATING CONTROL Economizer t o Min Pos. Gas Ignition Sequence On Heat Demand Gas Modulation To Maintain Setpoint

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

SAFETY i3 MISC. CONTROLS Freeze-stat verified (SP=35"F) Fire Alarm Shutdown verified Air proving switch verified High limit burner control verified

Continuous Fan Operation

t t t Manual Reset

COMMENTS:

TEST 1 BY: TEST 2 BY: VERIFIED BY:

DATE: DATE: DATE:

HVAC Systems Commissioning Manual First Edition Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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D.11

SMACNA T I T L E m H V A C C M 94

8389350 0005638

LTB

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION PROCEDURE SMCOlC3 ROOFTOP A/C UNIT GAS HEAT

-

PROJECT: LOCATION:

Sample Project Roof

-

SYSTEM: SERVICE:

AHU-3 Offices

SYSTEM OFF 1. Check static items listed on verification checklist. 2. Stroke Dampers by resetting associated controller setpoints. NORMAL START-UP SEQUENCE 1. Verify start-up of system by adjusting timeclock. Ensure Timeclock is programmed. 2. Witness mixing dampers modulating to control position on startup. 3. Balancing Contractor to verify and demonstrate Minimum damper position using temperature calculation or airflow measurement. COOLING CONTROL 1. Verify cooling sequence by adjusting thermostat and observing sequence. 2. Verify head pressure control with refrigeration contractor. HEATING MODE 1. Verify heating sequence by adjusting thermostat and observing sequence. 2. Ensure stable control is obtained by monitoring gas valve position. SAFETY CONTROLS 1. Simulate freeze condition (manipulate setpoint of freeze thermostat) and witness shutdown. 2. Reset freeze thermostat and witness restart of system. 3. Verify air proving switch by shutting down fan while system is heating. 4. Verify high limit burner control (assistance may be required from gas installer).

D.12 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

-

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94

SMACNA T I T L E * H V A C C M

8 3 8 9 3 5 0 0 0 0 5 6 1 9 034 9

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION CHECKLIST SMCO2 HYDRONIC HEATING SYSTEM

-

SYSTEM:: SERVICE:

PROJECT: LOCATION: ITEM

1

TEST

I

COMMENT

I

OK

SYSTEM OFF Sensor Locations & Supports Checked Installation Complete Control Valves Checked & Stroked BOILER CONTROL LeadLag Boiler Sequences Verified Firing Sequences - Modulation Maintains Setpnt Supply Water Temperature Reset Verified Integral Control Functions Verified Circulation Pump Sequences Verified

~

PRIMARY PUMP CONTROL Leadliag Pump Sequences Verified Pump OrúOff Control Sequences Verified

' Radiation Circuit, Coil Circuit etc.

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

SECONDARY CIRCUIT CONTROL LeadRag Pump Sequences Verified Pump On/Off Control Sequences Verified Loop Water Temperature Reset Verified Control Valve Modulates To Maintain Setpoint Pressure Differential Sequence Verified

Boiler Low Flow Limit Verified Integral Boiler Safety Controls Verified

I

I

Manufacturer's Start-uD Checklists

I

GENERAL COMMENTS:

I

TEST 1 BY: TEST 2 BY: VERIFIED BY:

DATE: DATE: DATE:

.

HVAC Systems Commissioning Manual First Edition Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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D.13

S M A C N A T I T L E * H V A C C M 7 4 H ALA7350 O005620 8 5 6

SMACNA HVAC SYSTEMS COMMISSIONING CONTROLSYSTEMSEQUENCEOFOPERATION SMCOIAI HYDRONIC HEATING SYSTEM ELECTRIC CONTROLS

-

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

PROJECT: LOCATION:

-

SYSTEM: SERVICE:

Sample Project Mechanical Room

Heating Heating

THE FOLLOWING IS A SAMPLE OF A TYPICAL SEQUENCE OF OPERATION AS SPECIFIED BY THE DESIGN CONSULTANT

HEATING WATER CONTROL

1.

System shall be a primary / secondary pump system.

2.

Lead primary pump shall run continuously. Lag pump shall start if additional demand is incurred.

3.

The boilers shall start from the flow switch mounted on the boiler discharge.

4.

The secondary pumps shall run continuously.

5.

An outdoor thermostat shall modulate a 3 way valve between the primary and secondary system and shall reset water temperature from 200°F at 20°F outside to 120°F at 55°F outside.

D.14 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

-

HVAC Systems Commissioning Manual First Edition Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

SMACNA T I T L E * H V A C C M

94

m

8 3 8 9 3 5 0 O005623 7 9 2

m

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION CHECKLIST SMC02A2 HYDRONIC HEATING SYSTEM ELECTRIC CONTROLS

-

-

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I

SYSTEM: Heating

PROJECT: Sample Project LOCATION: Mechanical Room SERVICE: Heating

I

SYSTEM OFF Sensor Locations & Supports Checked Installation Complete Control Valves Checked & Stroked

I

I

1

PUMP CONTROL

I

P-1 & P-2 Leadliag Operation Verified

P-3 On Continuously P-4 On Continuously

I

BOILER CONTROL 6-1 Activated By Flow Switch At Discharge 8-2 Activated By Flow Switch At Discharge

I

I

1 Lead Pump On Contin. Lag Pump On With High Demand

-

I I

'

II

I I

HEATING WATER TEMPERATURE CONTROL OSA Temp Reset Of Control Valve

I

Schedule = OSA 20°F-550FMWT200°F-120°F

I I

1

II

I

t

I

I

I

I

I I

GENERAL: COMMENTS:

TEST 1 BY: TEST 2 BY: VERIFIED BY:

DATE: DATE: DATE:

HVAC Systems Commissioning Manual . First Edition Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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D.15

SMACNA TITLE*HVACCM

94

8 1 8 9 3 5 0 O005622 6 2 9

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION PROCEDURE SMCO2A3 HYDRONIC HEATING SYSTEM ELECTRIC CONTROLS

-

PROJECT: LOCATION:

-

Sample Project Mechanical Room

CYSTEM: SERVICE:

Heating Heating

SYSTEM OFF 1. Check static items listed on verification checklist. 2. Stroke Control Valves by resetting associated controller setpoints. PUMP CONTROL 1. Control Contractor to demonstrate Lead/Lag operation. 2. Simulate high demand (setpoint adjustment) and ensure lag pump energizes. 3. Ensure P-3 & P-4 run continuously. Note Switch Location BOILER CONTROL 1. Ensure boiler integral controls were checked (Start-up Checklist) 2. Simulate No Flow Condition (Close valve or Stop Pump) and ensure boilers shutdown. HEATING WATER TEMPERATURE CONTROL 1. Simulate OSA Temperature change and witness reset of supply water temperature.

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D.16 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

-

HVAC Systems Commissioning Manual First Edition Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

SMACNA T I T L E * H V A C C M

8389350 0005623 565

94

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM SEQUENCE OF OPERATION SMC02Bl- HYDRONIC HEATING SYSTEM - DOC CONTROL

I

PROJECT: LOCATION:

Sample Project Boiler Room

SYSTEM: SERVICE:

Hot Water Heating Building Heating

THE FOLLOWING IS A SAMPLE OF A TYPICAL SEQUENCE OF OPERATION AS SPECIFIED BY THE DESIGN CONSULTANT BOILER SYSTEM 1.

2.

3.

4.

When heat is called for, start the lead primary heating water pump. If the lead pump does not start, start the lag pump and send an alarm to the system. The lead pump shall be the pump with the lowest totalized run time. When flow i s established start the lead boiler. If the lead boiler does not start, start the lag boiler and send an alarm to the system. The lead boiler shall be the boiler with the lowest totalized run time. The required boiler feedback to determine whether the boiler is on is to be taken from the gas valve. Start the lead pump of the associated secondary loop which requires heating (heating coils or radiation). If the lead pump does not start, start the lag pump and send an alarm to the system. The lead pump shall be the pump with the lowest totalized run time. Modulate the boiler gas valve to maintain the required supply water temperature setpoint. The setpoint shall be determined in the following way: .1 Radiation & Heating Coil loops: - Determine the maximum value of all radiation control valve controllers (MAX-RAD-VALVE) and heating coil control valve controllers (MAX-COI L-VALVE) Use the larger of these values as the input to the boiler controller, with a setpoint of 90% (BOILER-COILVALVE). This will have the end result of supplying the heating water system with the lowest temperature water required to satisfy the systems heating demand. .2 Minimum return water temperature: Obtain the minimum recommended return water temperature from the boiler manufacturer. Use this as the setpoint to another boiler controller, with an input from the return water temperature sensor (BOILER-COS-MIN). .3 Use the maximum controller value (BOILER-Col-VALVE) and (BOILER-CO2-MIN) with a high limit of 194°F to control the boiler. Modulate the 3 way control valve on the radiation secondary loop to maintain the required water temperature. Use a similar method as the boiler control by using the MAX-RAD-VALVE as the input to the controller, and 90% as the setpoint. This will have the end result of maintaining the minimum supply water temperature to satisfy the radiation loop heating demand. When heating mode is disabled, shut off the boilers. Shut off the secondary loop pumps as required. Maintain primary loop pumping for 2 hours after boiler shut-off.

-

-

' 5.

6.

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.

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D.17

SMACNA T I T L E * H V A C C M

8 1 8 9 3 5 0 O005624 4 T 1

94

=

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION CHECKLIST SMCO2B2 HYDRONIC HEATING SYSTEM DOC CONTROL

-

-

PROJECT: Sample Project LOCATION: Boiler Room

I

ITEM

OK

I

COMMENT

SYSTEM OFF Sensor Locations & Supports Checked Installation Complete Valve Positions Checked & Stroked End To End Checks Completed BOILER CONTROL Lead Boiler On With Primary Pump Flow Lead Boiler Failure Alarm Verified Boiler Modulates t o Maintain SWT Setpoint SWT Reset By Rad or Coil Demand

SWT Low Limit Verified (Setpoint = 3 SWT High Limit Verified (Setpoint = 194°F) RADIATION TEMPERATURE CONTROL Rad Water Temp Reset By Valve Pos Demand Rad Valve Modulates To Maintain Setpoint

-

PRIMARY PUMP CONTROL P-20,21 Lead Pump On With SWT Demand Lead Pump Failure Alarm Verified Pump Off After Boiler Off For 2 Hours

Lead = Boiler with Lowest Totalized Run Lag Boiler Starts Alarm Indicated

-

I

90% of MAX (MAX-COIL-VALVE, MAX-RAD-VALVE) Min. Recommended Return Water Temp

1 90% Of MAX-RAD-VALVE

Lead = Pump with Lowest Totalized Run Lag Pump Starts Alarm Indicated

-

-

COIL LOOP PUMP CONTROL P-22.23 Lead Pump On With Demand (Coil Valve Pos.) Lead Pump Failure Alarm Verified

Lead = Pump with Lowest Totalized Run Lag Pump Starts - Alarm Indicated

RAD LOOP PUMP CONTROL - P-24,25 Lead Pump On With Demand (Rad Valve Pos.) Lead Pump Failure Alarm Verified

Lead = Pump with Lowest Totalized Run Lag Pump Starts - Alarm Indicated

GENERAL COMMENTS:

TEST 1 BY: TEST 2 BY: VERIFIED BY:

D.18

DATE: DATE: DATE:

-

HVAC Systems Commissioning Manual First Edition

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT ~~~~

~

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SYSTEM: Hot Water Heating SERVICE: Building Heating

~~

SMACNA T I T L E * H V A C C M

94

=

8 3 8 9 3 5 0 0 0 0 5 6 2 5 338

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION PROCEDURE SMC02B13 HYDRONIC HEATING SYSTEM DOC CONTROL

-

I

PROJECT: LOCATION:

Sample Project Boiler Room

-

SYSTEM: SERVICE:

Hot Water Heating Building Heating

CONTROLS CONTRACTOR 81 COMMISSIONING AGENT WORK TOGETHER TO CARRY OUT THE FOLLOWING SYSTEM TESTS SYSTEM OFF 1. Check static items listed on verification checklist. Stroke Control Valves by resetting associated controller setpoints. 2. 3. Confirm that Controls Contractor has completed End to End Checks.

RADIATION TEMPERATURE CONTROL 1. Examine Radiation loop reset algorithm and test by manually adjusting appropriate setpoint. 2. Verify that valve controls to loop temperature setpoint. (Test by manually adjusting set point) PRIMARY PUMP CONTROL 1. Examine pump control algorithm and starüstop lead pump by manually adjusting appropriate setpoint. 2. Manually fail lead pump and verify alarm and lag pump startup. 3. Simulate boilers off for 2 hours and witness pump stop. COIL LOOP PUMP CONTROL 1. Examine pump control algorithm and starüstop lead pump by manually adjusting appropriate setpoint. 2. Manually fail lead pump and verify alarm and lag pump startup. RAD LOOP PUMP CONTROL 1. Examine pump control algorithm and starüstop lead pump by manually adjusting appropriate setpoint. 2. Manually fail lead pump and verify alarm and lag pump startup.

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D.19

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BOILER CONTROL 1. Manually starüstop primary pump and verify lead boiler interlock. Manually fail lead boiler and verify alarm and lag boiler startup. 2. 3. Verify that boilers control to SWT setpoint. (Test by manually adjusting setpoint) 4. Examine SWT reset algorithm and test by manually adjusting appropriate setpoint. 5. Test SWT low limit (Setpoint should be confirmed with manufacturer) by adjusting setpoints as required to simulate a call for a lower than minimum setpoint. 6. Test SWT high limit by adjusting setpoints as required to simulate a call for a higher than maximum setpoint.

SMACNA T I T L E E H V A C C M 94

m

ôLô9350 0005626 274

m

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION CHECKLIST SMC03 CHILLED WATER SYSTEM

-

I

PROJECT: LOCATION:

SYSTEM:: SERVICE: ITEM

TEST

COMMENT

OK

SYSTEM OFF Sensor Locations & Supports Checked Installation Complete Control Valves Checked & Stroked --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

CHILLER CONTROL StarüStop Sequences Verified Capacity Control Sequences Verified Chilled Water Temperature Reset Verified Integral Control Functions Verified Condenser Pump Interlock Sequences Verified

i I

I

I

I

I

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COOLING TOWER CONTROL StatüStop Sequences Verified DamDers & Fans Modulate To Maintain Setpnt.

CHILLED WATER CIRCUIT CONTROL LeadRag Pump Sequences Verified Pump OniOff Control Sequences Loop Water Temperature Reset Verified

SAFETY & MISC CONTROLS Chilled Water Low Limits Verified Condenser Water Low Flow Limit Verified Integral Chiller Safety Controls Verified

Manufacturer's Start-up Checklists

GENERAL COMMENTS:

I

TEST 1 BY: TEST 2 BY: VERIFIED BY:

D.20 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE: DATE:

-

HVAC Systems Commissioning Manual First Edition Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

SMACNA T I T L E * H V A C C M

94

8389350 0 0 0 5 b 2 7 L O O

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM SEQUENCE OF OPERATION SMCO3A1- CHILLED WATER SYSTEM DDC CONTROLS

-

PROJECT: LOCATION:

Sample Project Boiler Room

SYSTEM: SERVICE:

Cbilíed Water Building Cooler

THE FOLLOWING IS A SAMPLE OF A TYPICAL SEQUENCE OF OPERATION AS SPECIFIED BY THE DESIGN CONSULTANT CHILLERS 81 COOLING TOWER

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1.

When cooling is called for, start the chiller and condenser water pumps. The condenser water pumps are to run in parallel. When flow is established, the chiller may be started.

2.

When the chiller has started, start the main chilled water pumps. These pumps also run in parallel. The pump speed shall be set to maintain the required system pressure as measured by the two end of loop water differential pressure sensors.

3.

Modulate the chilled water temperature (CHWS) to maintain the required chilled water supply temperature setpoint. The setpoint shall be determined in the following way: .1 Determine the maximum cooling value of all cooling coil control valve controllers. .2 Use this value as the input to the chiller controller, with a setpoint of 90% (CHILLER-Col-VALVE). This will have the end result of supplying the chilled water system with the warmest temperature water required to satisfy the systems cooling demand.

4.

Modulate the cooling tower control damper and alternate the fan motors to maintain the required condenser water return temperature. The first stage of condenser water cooling will be the small fan in combination with the modulating damper. When the damper is fully open, and further cooling is required, start the large fan motor and continue to modulate the fan capacity damper.

.

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D.21

SMACNA T I T L E M H V A C C M 94

8 3 8 9 3 5 0 0005b28 047

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION CHECKLIST SMC03A2 CHILLED WATER SYSTEM DDC CONTROL

-

I

PROJECT: LOCATION:

-

SYSTEM: Chilled Water SERVICE: Building Cooling

Sample Project Boiler Room

I

ITEM

I

OK

I

COMMENT

I

SYSTEM OFF Sensor Locations & Supports Checked Installation Complete Valve Positions Checked & Stroked End to End Checks Complete CHILLER CONTROL Chiller Start with Cond. Water Flow Pump Energized By CHWS Demand CHWS Reset By Coil Valve Positions CHWS Low Limit Verified (Setpoint = 3

P-33, 35A, 358 ON 90% of MAX-CCOIL-VALVE

CHILLED WATER LOOP PUMP CONTROL Both pumps On/Off With Chiller Pump Speed Adjusted To Maintain System ) Pressure at Setpoint (Setpoint =

P-34A, 348 Run in Parallel

I

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COOLING TOWER CONTROL Damper & Fans Modulate t o Maintain Condenser Water Return Temp. at Setpoint

Stage l=Fan 1 + Damper Modulation Stage 2=Fan 1 + Fan 2 + Damper Modulation

t I

I

r

TEST 1 BY: TEST 2 BY: VERIFIED BY:

D.22

DATE: DATE: DATE:

.

HVAC Systems Commissioning Manual First Edition

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT ~~

~

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GENERAL COMMENTS:

SMACNA T I T L E W H V A C C M 94

m

8 3 8 9 3 5 0 0 0 0 5 6 2 9 T83

m

SMACNA HVAC SYSTEMS COMMISSIONING CONTROL SYSTEM VERIFICATION PROCEDURE SMCO3A3 CHILLED WATER SYSTEM DDC CONTROL

-

I

PROJECT: LOCATION:

Sample Project Boiler Room

-

SYSTEM: SERVICE :

Chilled Water Building Cooling

CONTROL CONTRACTOR & COMMISSIONING AGENT WORK TOGETHER TO CARRY OUT THE FOLLOWING SYSTEM TESTS SYSTEM OFF 1. Check static items listed on verification checklist. 2. Stroke Control Valves by resetting associated controller setpoints. 3. Confirm that Controls Contractor has completed End to End Checks. CHILLER CONTROL 1, Manually starüstop condenser pumps and verify chiller interlock. 2. Examine cooling demand algorithm and starüstop condenser pumps by manually adjusting appropriate setpoint. 3. Verify that chiller controls to CHWS setpoint. (Test by manually adjusting setpoint) 4. Examine CHWS reset algorithm and test by manually adjusting appropriate setpoint. 5. Test CHWS low limit (Setpoint should be confirmed with manufacturer) by adjusting setpoints as required to simulate a call for a lower than minimum setpoint. CHILLED WATER LOOP PUMP CONTROL 1. Verify that both pumps starüstop with chiller. 2. Verify that pump speed controllers modulate to maintain system pressure setpoint. (Manually adjust setpoint and observe reset. Record setpoint.)

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D.23

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COOLING TOWER CONTROL 1. Verify stages sequence as specified by manually adjusting water temperature setpoint. 2. Ensure stable control by returning setpoint to normal and observing stability. (Record Setpoint.)

SMACNA T I T L E * H V A C C M

74

8L87350 0005630 7 T 5

SMACNA HVAC SYSTEMS COMMISSIONING

CONTROL SYSTEM VERIFICATION CHECKLIST

-

SMC04 EXHAUST FANS

I

PROJECT: LOCATION:

SYSTEM: SERVICE:

I

GENERAL COMMENTS:

I

TEST1 BY: TEST 2 BY: VERIFIED BY:

D.24

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Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

DATE: DATE: DATE:

-

HVAC Systems Commissioning Manual First Edition Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

SMACNA T I T L E w H V A C C M 94

m 8189350

0005b31 631

SMACNA HVAC SYSTEMS COMMISSIONING

CONTROL SYSTEM VERIFICATION CHECKLIST

-

SMCOS PRESSURIZATION FANS

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PROJECT: LOCATION:

SYSTEM: SERVICE:

I

GENERAL COMMENTS:

I

DATE: DATE: DATE:

TEST1 BY: TEST 2 BY: VERIFIED BY:

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.

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m

SMACNA T I T L E * H V A C C M

94

8l189350 0 0 0 5 6 3 2 5 7 8

SMACNA HVAC SYSTEMS COMMISSIONING

CONTROL SYSTEM VERIFICATION CHECKLIST

-

SMC06 FORCE FLOW / UNIT HEATERS

PROJECT: LOCATION: I

UNIT NUMBER

SYSTEM: SERVICE: LOCATION

AMPERAGE RATED/ACT.

FAN OPERATION

VALVE OPERATION

CONTROL OPERATION

I

I

I

I

I

I

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TEST1 BY: TEST 2 BY: VERIFIED BY:

D.26 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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GENERAL

DATE: DATE: DATE:

.

HVAC Systems Commissioning Manual First Edition Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

SMACNA T I T L E x H V A C C M 9 4

BLB9350 0005633 404

SMACNA HVAC SYSTEMS COMMISSIONING

CONTROL SYSTEM VERIFICATION CHECKLIST

-

SMC07 VAV BOXES

I

PROJECT: LOCATION:

SYSTEM: SERVICE:

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I

GENERAL COMMENTS:

I

TEST 1 BY: TEST 2 BY: VERIFIED BY:

DATE: DATE: DATE:

-

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D.27

SNACNA T I T L E * H V A C C M

94

8 3 8 9 3 5 0 0 0 0 5 6 3 4 340

SMACNA HVAC SYSTEMS COMMISSIONING

CONTROL SYSTEM VERIFICATION CHECKLIST

-

SMCOB CONTROL VALVES

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PROJECT: LOCATION:

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SYSTEM: SERVICE:

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GENERAL COMMENTS:

TEST 1 BY: PRE-START BY: START-UP BY:

D.28

DATE: DATE: DATE:

.

HVAC Systems Commissioning Manual First Edition --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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SMACNA T I T L E * H V A C C M

i

94

81189350 O005635 2 8 7

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HVAC Systems Commissioning Manual First Edition Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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D.29

SMACNA T I T L E * H V A C C M

APPENDIX E 1.

GENERAL

1.1

Overview

94

8 3 8 7 3 5 0 0 0 0 5 6 3 6 113 W

SAMPLE SPECIFICATION: COMMISSIONING OF HVAC SYSTEMS

This section of the specification describes the process for commissioning HVAC systems, defines the responsibilities of the commissioning agent and contractor, and outlines the duties of other members of the commissioning team.

o The contractor's representative(s)

The controls contractor's representative(s) The sheet metal contractor's representative

0

The fire protection contractor's representative The electrical contractor's representative(s)

The commissioning process shall be applied to all equipment, components, and systems as listed in Section 3, including specified interfaces to and from equipment and systems provided under other divisions. 1.2

The mechanical engineer's representative 0

The electrical engineer's representative

0

The architect's representative

Subcontractors

The appropriate Subcontractors shall be responsible for cooperating and coordinating their work with the commissioning agent. They shall also be responsible for carrying out all the physical activities required for physical installation of components and systems, and for operating them during the commissioning process. 1.3

The general contractor's representative(s)

The owner's representative(s). NOTE: Add to or delete from this list as applicable for the specific project. 2.2

Commissioning Responsibilities

2.2.1

Commissioning Agent

Commissioning Agent

The commissioning agent shall be a sub-trade to the contractor or, subject to pre-bid approval by the engineer, a specific commissioning group within the contractor's staff.

The commissioning agent shall: 0

Plan, organize, and implement the commissioning process as specified herein,

Approved commissioning agents are: Prepare the commissioning plan and ensure its distribution for review and comment,

NOTE: Include list of approved companies. 0

Revise the commissioning plan as required during consmc tion,

0

Chair commissioning meetings and prepare and distribute minutes to all commissioning team members, whether or not they attended the meeting,

If outside air temperature, lack of full occupancy, or other factors prevent full performance testing of some functions, then testing, verifying and documenting the performance of these functions shall be carried out at an appropriate, and mutually agreed upon, time during the 12 months after substantial completion.

Coordinate commissioning activities among all contractors, sub-trades, and suppliers, 0

Carry out all required system readiness checks and document the results as the checks are done,

0

In cooperation with the controls contractor, ensure all control point checkouts are carried out and the results documented as the checks are done,

2. THE COMMISSIONING PROCESS 2.1

The Commissioning Team

The commissioning team shall consist of 0

The commissioning agent

Observe or verify all start-ups and initial system

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E.l

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The owner's designated representatives must have the opportunity to observe any or all of the systems functional performance tests as an important element in the operator familiarization and instruction process.

SMACNA T I T L E m H V A C C M 94

operations tests and checks, which shall encompass all specified functional performance tests, ensuring the results are documented as the tests and checks are done, At the direction of the engineer, ensure equipment and systems are operated for functional performance verification purposes,

8 3 8 9 3 5 0 0005b37 05T

2.2.4

Ensure all required instruction and demonstrations are provided to the owner's designated operating staff.

2.2.2

Owner

The owner will ensure the availability of operating staff for all scheduled instruction and demonstration sessions. This staff will possess sufficient skills and knowledge to operate and maintain the installation following attendance at these sessions.

2.3 0

Commissioning Phases

The on-site commissioning process shall be organized and carried out in four phases, as follows: e Phase 1-system

Contractor

=

readiness and start-up,

Phase 2-initial operation,

0

The contractor, and all his sub-trades and suppliers, shall cooperate with the commissioning agent in carrying out the commissioning process. In this context, the contractor shall:

Each phase is applicable to each separate system and its components, as listed in Section 3, including all related controls and specified interfaces to other divisions.

e Provide equipment and systems start-up as

2.4

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Within one (I) month of the award of the contract, the contractor shall submit the name of the commissioning agent firm, along with the name of the individual who will be the agent's commissioning coordinator for this project.

Phase 3-functional performance verification, and Phase Uemonstration and instruction.

Commissioning Plan

required, 0

Operate equipment and systems as required for both initial systems operations and final functional performance tests, Attend commissioning meetings, and attend to action items arising from them, as required to allow the commissioning process to proceed on schedule,

e Provide instruction and demonstrations for the

owner's designated operating staff, in conjunction with the commissioning agent, in order to meet all specified requirements in this regard.

2.2.3

Engineer

The engineer will review the commissioning pian. He will also participate, as appropriate, in on-site commissioning meetings. During the functional performance phase of the commissioning process, the engineer will be on site to review commissioning documentation, witness functional performance tests, and verify acceptable performance or to declare performance unacceptable, as the case may be.

Within two (2) months of award of contract, the commissioning agent shall review design intent and intended commissioning procedures with the engineer. Within three (3) months of award of contract, but in no event less than three (3) months before scheduled date of substantial completion, the commissioning agent shall submit a detailed commissioning plan to the engineer. The commissioning plan shall contain the information necessary to document the commissioning process as it progresses from pre-start checks, to start-up and initial operation, and finally to functional performance verification of all systems. The commissioning plan must include detailed checklists relevant to guiding the carrying out and documenting of phases 1,2, and 3 of the commissioning process. The design of these checklists should be such that the items to be checked, or the steps to be taken in functional performance testing, are clearly listed. The plan will thus streamline the process and make documentation of it efficient and easy. The commissioning plan shall also contain a schedule of commissioning work, integrated with the general contractor's overall project schedule. This schedule shall show:

HVAC Systems Commissioning Manual

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~

First Edition

SMACNA T I T L E a H V A C C M 94

= 8389350

required startup reports completed and submitted.

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Completion dates for each system or systems in each area of the building, Dates for controls installation completion and point checkout, Dates for carrying out phases 1 and 2 commissioning work for each system or group of systems, Submission dates for the documentation required by the engineer prior to phase 3 verification, and Dates for carrying out phase 3 commissioning work.

2.5

Phase 1-Systems Readiness and Startup

Before starting any equipment or systems, complete the system readiness or pre-start checks in the commissioning plan and document the results. The following conditions and items shall be completed as applicable:

All checks shall be documented on the relevant checklists as they are carried out. Deficiencies or incomplete work shall be corrected, and the checks repeated until the installation is ready for operation, before proceeding to phase 2 of the process. 2.6

Work carried out during this phase of commissioning shall include the following, as applicable (note that not all these activities are a direct part of the commissioning process, but they all need to be carried out during or prior to this phase of commissioning): Air systems balancing, including positioning of all balance dampers, adjustments to diffusers, registers, and grilles,

specified, found to be tight, with reports submitted,

Hydronic systems balancing, including positioning of all balance valves,

e Piping systems have been flushed and cleaned as

specified, any required reports submitted, and then filled or charged as applicable,

Correction of problems revealed during balancing, including changes to fan speeds or blade pitch as necessary,

e Equipment has been lubricated to specification,

Setting up and calibrating all automatic temperature controls devices, including adjustments to control valves and damper actuators,

Air system cleaning is complete, and particulate filters have been installed,

e Vibration isolation and seismic restraints have

been installed to specification and adjusted,

Setting up or programming controls for accurate response and precise sequencing to meet specified performance,

e Equipment drives have been aligned,

e Electrical services have been installed and

With commissioning agent verifying, the balancing contractor, and controls contractor working together, setting up air Rows and controls calibrations for variable volume terminal units and air valves where applicable,

checked, e Control point checkouts have been completed, e Safety controls have been installed and operation

checked, and

Ensuring fmal adjustments to vibration isolation and seismic restraints are carried out as necessary, and

e Major equipment start-up has been carried out by

manufacturers representatives when specified (refer to equipment specification sections), and

Checking operation of all fire dampers,

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Phase 2-Initial Operation

In phase 2 of the commissioning process, the contractor, with the commissioning agent verifying, completes the testing, balancing, and calibration of all components and systems. They also operate all systems through all specified modes of operation, and test system responses to specified abnormal or emergency conditions.

e Piping systems have been pressure tested as

e

0005638 T96

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SMACNA

T I T L E * H V A C C M 9 4 m 8 3 8 9 3 5 0 0005639 9 2 2 M

As was done in phase 1, all checks and tests shall be documented on the relevant checklists as they are carried out. Deficiencies or incomplete work shall be corrected, and the checks or tests repeated until correct installation and function has been confirmed and the installation is ready for engineer verification. 2.7 Phase Verification

3-Functional

Demonstration and instruction shall cover all equipment and systems, and their controls. Detailed requirements are listed in the following sections of the specifications: 0

Performance

All equipment and systems shall be operated through the entire specified sequence of operations, as directed by the engineer for witnessing and verifying acceptable operation. During this phase of commissioning, the following checks and tests may be required by the engineer and shall be allowed for: Checking the location and accessibility of all access panels,

Section 1563 @ @, Controls Section 15@ @ @, Demonstration and Instruction to Owner/User.

3. EXECUTION The following systems shall be commissioned: NOTE: The lists following must be edited to suit the scope of work within each project. Delete items that are not applicable and add new items that are part of the project. 3.1

HVAC Systems

Hot Water, Glycol Solution, Chilled Water, and --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Operation of all controls system devices, both sensors and actuators, Proper physical response of all controlled devices and components to setpoint changes or other relevant adjustments, Operation of randomly selected fire or smoke dampers, Demonstration of acceptable noise and vibration levels from any equipment, under its full range of operational conditions, Operation of equipment and systems under every specified mode of operation and sequence of control, Operation of equipment and systems under normal, abnormal, and emergency conditions, Once acceptable performance of HVAC systems has been verified, then operation under specified interfaces to/from equipment and systems provided under other divisions. 2.8

Demonstration and Instruction

The formal demonstration and instruction for operating staff shall commence once the Phase 3 commissioning is complete and substantial completion achieved.

E.4 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Condenser Water Piping Systems. Installation checks; pressure tests; expansion tanks; flow balancing verification. Duct Systems. Installation checks; flow balancing verification; leak testing as applicable. Chiller(s). Installation checks; checkout and start-up by manufacturefs representative; performance measurements, including capacity, evaporator and condenser flows, motor amperage, and controls operation (e.g., staging and capacity modulation). Cooling Tower(s). Installation checks; checkout and start-up by manufacturer's representative in conjunction with chiller; performance measurements, including sound, capacity, motor amperage, pan heater operation, makeup water, overflow, and capacity controls. Closed-Circuit Heat Rejector(s) or Evaporative Condenser(s). As for cooling tower. Refrigeration Compressor/Condensing Unit(s). Installation checks; checkout and start-up by manufacturer's representative as specified; performance measurements, including capacity, evaporator and condenser pressures, motor current draw, and controls operation. Boiler(s). Installation checks; boil out and chemical treatment; checkout and start-up by manufacturers representative; performance measurements, including

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94

combustion efficiency, capacity test, burner, and controls operation.

Pumps. Checks on alignment, rotation, motor current draw, flows, and pressures. Hydronic Heating. Installation checks; performance measurements and adjustments, including flows, capacity, and control responses. Supply, Return, Reliefi and Exhaust Fans. Checks on installation (including dampers and other accessories), rotation, motor current draw, and air flows and pressures. Air Handling Units (Packaged, Rooftop, and Built-up). Installation checks; checkout and start-up by manufacturer's representative for large factory

8389350 0005640 6 4 4

fabricated units; capacity tests for heating, cooling, air flow, and static pressures; operation of all controls.

Air Terminal Devices. Installation checks; for variable air volume (VAV) units, flow adjustments and calibration coordinated with controls and air balancing; controls operation, including flow modulation, reheat, controls responses. Fan-Coil Units. Installation checks; performance and controls checks. Controls and EMCS. Installation and operation of all devices; complete operation of all controls sequences in coordination with commissioning of all controlled systems. 3.2

Other Systems

NOTE: Add additional systems, such as plumbing, fire protection, etc., as applicable to the particular project. Format of lists would be similar to that in 3.1.

HVAC Systems Commissioning Manual

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

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E.5

SMACNA T I T L E * H V A C C M

94

BLB9350 0005641 580

SAMPLE REPORT

APPENDIX F

The commissioning plan as discussed in this manual is in fact composed of the same documents as appear in this sample report with the exception that the checklists have not been filled in. The plan would also contain a copy of the commissioning schedule (see Appendix A) in place of the general comment page.

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Appendix F shows an example of a commissioning report. Typically, the report is submitted at the conclusion of the project and includes all of the completed checklists along with copies of supplementary reports or checklists supplied by manufacturers' and suppliers' start-up specialists. In addition, any specific comments pertaining to concerns or outstanding work is included for reference.

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

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F.l

SMACNA T I T L E * H V A C C M 9 4

=

8 3 8 7 3 5 0 O005642 417

HVAC SYSTEMS COMMISSIONING REPORT FOR

SAMPLE PROJECT

Prepared for: Client Name Address Telephone Number

Date Prepared

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

F.2 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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8389350 0005643 353

HVAC SYSTEMS COMMISSIONING REPORT SAMPLE PROJECT

A.

GENERAL COMMENTS

B.

EQUIPMENT LIST

C.

START-UP CHECKLISTS

D.

CONTROL SYSTEM CHECKLISTS

E.

MANUFACTURERS CHECKLISTS AND START-UP REPORTS

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT ~~

~~

~~

~~

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

INDEX

F.3

SMACNA TITLE*HVACCM

9 4 W 8389350 0 0 0 5 6 4 4 2 9 T W

HVAC SYSTEMS COMMISSIONING REPORT SAMPLE PROJECT GENERAL COMMENTS 1.

The following items were incomplete or unresolved at the time of preparation of this report: o HOA for boilers to be installed. 0

DDC lighting controls incomplete.

0

Fire alarm fan shutdown not verified.

F.4

HVAC Systems Commissioning Manual

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT ~~

First Edition

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

9

9 4 W 8489350 0005645 126

SMACNA T I T L E * H V A C C M

m

HVAC SYSTEMS COMMISSIONING REPORT SAMPLE PROJECT EQUIPMENT LIST EQUIPMENT NAME

UNIT NO.

LOCATION

AREASERVED

AIR HANDLING UNIT

AHU-1 AHU-2 EF-1 EF-2 EF-3

MECH ROOM 201 MECH ROOM 201 MECH ROOM 201 JANITOR 127 CORRIDOR 152

CLASSROOMS GYMNASIUM GYM CHANGEROOMS JANITOR 127 WASHROOMS

VAR IOUS MECH ROOM 201 MECH ROOM 201 MECH ROOM 201 MECH ROOM 201 VAR IOUS SUPPLY DUCTS

HEAT1NG HEATING WATER PRIMARY HEAT LOOP PRIMARY HEAT LOOP AHU-1 COIL VAR IOUS VARIOUS

VARIOUS

VAR IOUS

MECH ROOM 201

DHW

EXHAUSTFAN

HYDRONIC HEATING SYSTEM B-1 BOILER P-1 PUMP P-2 P-3 RADIATION PANELS REHEAT COILS DOMESTIC WATER SYSTEM DOMESTIC WATER DHWT-1 HEATER

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

-

~

~

~

~

~

_

_

_

SMACNA TITLE*HVACCM

94

8 3 8 9 3 5 0 0 0 0 5 6 4 6 O62

SMACNA HVAC SYSTEMS COMMISSIONING LEVEL 2

-

EQUIPMENT PRE-START 81 START-UP CHECKLIST

-

A fR HANDLfNG UN/T LfQUfD HEA r/cOOL

UNIT NO: AHU-7 SERVICE: Classrooms MODEL: P-36

PROJECT: Sample Project LOCATION: Mech Room 201 MANUFACTURER: Tri Metal

I

ITEM

OK

I

COMMENT

PRESTART-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenum Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters In Place (Sized Correctly) Heating Coil Clean and Clear - Piping Complete Cooling Coil Clean and Clear - Piping Complete Condensate Drains Clear Humidifier Section Installation Completed Safety Controls Operational Building & Fan Room Clean For Start-up Duct Cleaning Completed Control System Completed (End To End

OK OK

Pillow Blocks Pre-lubed, Motor Pre-lubed Fire Dam ers Positioned

OK OK OK NIA NIA N/A

CC143 (80.6

- 86.5 FLA)

I I

OK OK OK

START-UP INSPECTION Start-up By Manufacturer's Representative Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local I Remote) Freeze Protection Operational Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated 83 Actual 73/73/69 Motor Volts - Rated 200 Actual 204/2041203 Final Operating Filters Installed GENERAL COMMENTS:

PRESTART BY: START-UP BY:

F.6 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

SMC

mr:

OK OK

D.D.C. F.A. Shutdown Not Complete HandIOfflAuto & D.D.C. Control

OK

OK OK OK

I

OK

I

DATE: DATE:

511fc14

5/1/44

HVAC Systems Commissioning Manual

0

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

NIA OK OK

S M A C N A TITLE*HVACCM

9 4 I8 3 8 7 3 5 0 0 0 0 5 6 4 7 T T î I

SMACNA

HVAC SYSTEMS COMMISSIONING - LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

AIR HANDLING UNIT LIQUID HEAT/COOL

UNIT NO: AHU-2 SERVICE: Gymnasium MODEL: P-24

PROJECT: Sample Project LOCATION: Mech Room 201 MANUFACTURER: Tri Metal

I

ITEM

OK

I

COMMENT

PRESTART-UP INSPECTION OK

Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints installed Equipment Guards installed Pulleys Aligned and Belt Tension Correct Plenum Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Temporary Start-up Filters Installed Electrical Connections Completed Disconnect Switch Installed Overload Heaters In Place (Sized Correctly) Heating Coil Clean and Clear - Piping Complete Cooling Coil Clean and Clear - Piping Complete Condensate Drains Clear Humidifier Section Installation Completed Safety Controls Operational Building & Fan Room Clean For Start-up Duct Cleaning Completed Control System Completed (End To End

NIA OK OK OK OK

I Pre-Lubed

OK OK OK

AR55 (60 AMP)

OK OK NIA

OK OK OK OK

I I

START-UP INSPECTION Start-up By Manufacturer's Representative Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Freeze Protection Operational Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated 28 Actual 18/18/18 Motor Volts - Rated 200 Actual 208 Final Operating Filters Installed GENERAL COMMENTS:

PRESTART BY: START-UP BY:

A

OK

OK

I D.D.C. F.A. Shutdown Not Complete I Hand/Off/Auto & D.D.C. Control

OK OK OK

I I

OK

I

I

DATE: DATE:

'

SMC:

HVAC Systems Commissioning Manual --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

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511 194

511 I94

F.7

SMACNA TITLE*HVACCM

= 8389350

94

0005648 935 M

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST EXHAUST FAN

UNIT NO: EF-7 SERVICE: Gymnasium Changerooms

PROJECT: Sample Project LOCATION: Mech Room 201 MANUFACTUR ER: Delhi

MODEL:

1

ITEM

OK

1

209 COMMENT

PRESTART-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenum Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Backdrafi Dampers Free To Operate Electrical Connections Completed Disconnect Switch Installed Overload Heaters In Place (Sized Correctly) Building & Fan Room Clean For Start-up

OK OK OK OK OK OK OK OK NIA

OK OK

None

I I A4.79 (3.46-3.70 AMPS)

NIA

START-UP INSPECTION Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated 3.6 Actual 2.412.4 Motor Volts - Rated 208 Actual 204

OK OK

I

I

OK OK OK

COMMENTS:

PRESTART BY:

mr.

DATE:

511 m4

START-UP BY:

wr.

DATE:

511 144

F.8 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

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First Edition

S M A C N A T I T L E W - H V A C C M 9 4 I8 1 8 9 3 5 0 0 0 0 5 6 4 9 871

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST EXHAUST FAN UNIT NO: EF-2

PROJECT: Sample Project LOCATION: Janitor 127 MANUFACTU RER: Penn

SERVICE: Janitor 727

MODEL:

I

ITEM

OK

I

N/A N/A

I None I None

Z-8 COMMENT

PRESTART-UP INSPECTION Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenum Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Backdraft Dampers Free To Operate Electrical Connections Completed Disconnect Switch Installed Overload Heaters In Place (Sized Correctly) Building & Fan Room Clean For Start-up

OK OK OK OK

Direct Drive

Pre-lubed

START-UP INSPECTION Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Local Air Leakage Acceptable Vibration & Noise Level Acceptable Motor Amps - Rated 1.9 Actual 1.7 Motor Volts - Rated 115 Actual 117

Fan

PRESTART BY: START-UP BY:

+

c/#@#&

Q JI

OK

nnCTimF!.k

DATE: DATE:

SMC

CMC

HVAC Systems Commissioning Manual

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

e

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

3

1 194

3

1 194

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

COMMENTS:

OK OK OK OK

F.9

8389350 0005650 593

SMACNA T I T L E x H V A C C M 9 4

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST EXHAUST FAN UNIT NO: E f - 3 SERVICE: Health ¿? Washroom MODEL: 209

PROJECT:

Sample Project LOCATION: Corridor 752 MANUFACTURER: Delhi

I

ITEM

OK

I

COMMENT

Mountings Checked (Shipping Bolts Removed) Vibration Isolators Installed Seismic Restraints Installed Equipment Guards Installed Pulleys Aligned and Belt Tension Correct Plenum Clear and Free of Loose Material Fans Rotate Freely Fans, Motors & Linkages Lubricated Fire & Balance Dampers Positioned Backdraft Dampers Free To Operate Electrical Connections Completed Disconnect Switch Installed Overload Heaters In Place (Sized Correctly) Building & Fan Room Clean For Start-up

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

PRESTART-UP INSPECTION

OK OK OK

OK OK N/A

I

Pre-lubed

I Not Accessible

OK OK OK

A11.9 (8.16-8.96 AMPS)

START-UP INSPECTION Fan Rotation Correct Electrical Interlocks Verified Fan Status Indicators Verified (Local / Remote) Local Air Leakage Acceptable Vibration 8 Noise Level Acceptable Motor Amps - Rated 7.2 Actual 5.1 Motor Volts - Rated 1 15 Actual 117

OK

OK OK OK

I

I

GENERAL COMMENTS:

PRESTART BY: START-UP BY:

F.10 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

SMC

mc

DATE: DATE:

5/1IQ4

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E * H V A C C M

94 I8 3 8 9 3 5 0 O005653 4 2 T

SMACNA HVAC SYSTEMS COMMISSIONING

- LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

HYDRONIC HEATING SYSTEM GENERAL

UNIT NO: Various SERVICE: Heating System MODEL: Various

Sample Project Various MANUFACTURER: Various PROJECT: LOCATION:

ITEM

I

OK

I

I

COMMENT

I

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

PRESTART-UP INSPECTION System Pressure Tested Water Make-up Station Installed Fill Pressure Set (10 Ib. PSI) Safety Relief Valve Setting (30 PSI) Safety Relief Valve Capacity (535,000 BTU) Backflow Preventer Installed Expansion Tank On Line Sight Glass Installed Air Vents Installed (High Points in System) Pressure & Temperature Gauges Installed Chemical Pot Feeder Installed Pumps Ready To Start - Checklists Completed Boilers Ready To Start - Checklists Completed Manufacturer's Rep. On Site For Start-up Control System Completed (End to End Checks)

CHEMICAL CLEANING & TREATMENT Cleaning Carried Out By Qualified Personnel Valves Positioned For Full Circulation City Water Circulated ( HRS) System Drained - Strainers Cleaned Cleaning Solution Drained - Strainers Cleaned 2nd City Water Circulation(Stab1e PH & TDH) Corrosion Inhibiter Added Per Manuf. Instruc. System Valves Cycled During Flushing All Low Points Blown Down During Flushing Chemical Cleaning Report Attached Final PH = Final TDH = Chemical Concentration = PPM

OK OK OK OK N/A OK OK OK

Diaphragm Type Exp. Tank

OK OK NO

OK See Chem Treatment Report OK

OK OK OK

OK See Chem Treatment Report See Chem Treatment Report See Chem Treatment Report

COMMENTS:

PRESTART BY: START-UP BY:

*

:-

Wr.

DATE: DATE:

SMC

HVAC Systems Commissioning Manual

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

21 1 ~

4

5 1 1 194

F.11

SMACNA T I T L E * H V A C C M

74

= 8189350

SMACNA HVAC SYSTEMS COMMISSIONING

0005652 366

M

- LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

HOT WATER BOILER GAS FIRED

UNIT NO: B-1 SERVICE: Heating System MODEL: MR- 7685

PROJECT: Sample Project LOCATION : Mech Room 201 MANUFACTURER: Multi Temp

1

ITEM

OK

I PRESTART-UP INSPECTION Installation Completed Including Breeching Equipment & Piping Identification Electrical Connections / Voltage Checked Safety Controls Complete & Operational Sensor & Gage Locations Noted Burner Controls Complete & Operational Gas Piping Tested & Purged Combustion Air Inlet Unobstructed Gas Venting Completed Gas Pressure Confirmed = 11 in W.C. Boiler Water Temperature Setpoint = 160 Boiler Inspection Certificate No. HW 76320B.C. Chemical Treatment Completed BOILER START-UP INSPECTION Qualified Personnel (Cert. No. 46578) Firing Sequence Verified Flame Safeguard Sequence Verified Automatic Shutdown Verified Safety Shutdown Verified Low Water Cut-Out Tested Safety Relief Valve Tested Water Temperature Maintained Pump Interlock Operational Combustion Efficiency Test (Report Attached) Volume / Capacity Test (Report Attached) Manufacturer's Start-up Sheets Attached Manufacturer's Representative Present

COMMENT

I

OK OK OK OK OK OK - . OK

OK OK

OK OK OK

OK OK OK OK _ ..

OK OK OK

OK OK OK NO

Start-up By Contractor Forces

DATE: DATE:

CMC

PRESTART BY: START-UP BY:

I

SMC

511 IQ4 QA

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

F.12 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA T I T L E U H V A C C M 9 4

= 8389350

O005653 2 T 2

SMACNA

m

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST CIRCULATING PUMP PROJECT: Sample Project Mech Room 201 LOCATION: MANUFACTURER: Bell & Gossett

UNIT NO: P-7 SERVICE: Primary Heating Loop

MODEL:

I

ITEM

OK

BUSC

I

COMMENT

I

I PRESTART-UP INSPECTION Mountings Checked - Pump & Motor Alignment By Millwright or Installer Seismic Restraints Installed Equipment Guards Installed Pump Rotates Freely Pump & Motor Lubricated Shaft Gland Lubricated Local Valving Set For Normal Operation Pressure Gauges in Supply and Return Piping Electrical Connections Completed Disconnect Switch Installed Overload Heaters Installed (Sized Correctly)

OK NIA OK

I

OK OK OK

I I I

None

Sealed Bearings

None

OK OK

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

AR 11.2 (7.97-8.69 AMPS) TRNR 15 Fuses

START-UP INSPECTION OK

Pump Rotation Correct Electrical Interlocks Verified Pump Status Indicators Verified (LocaVRemote) Check Valve Operation Tested System Static Pressure Vibration & Noise Level Acceptable Motor Amps - Rated 8.2 Actual 8.2/8.1/7.8 Motor Volts - Rated 208 Actual 208

OK

12 PSI Differential

OK

1

nff if OAT > fì5F

t -e H

COMMENTS:

7M

PRESTART BY: START-UP BY:

I

i

i

DATE: DATE:

SMC

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

3

1 /QA

3

1/QA

F.13

SMACNA T I T L E * H V A C C M

8389350 0 0 0 5 6 5 4 1 3 9

94

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST CIRCULATING PUMP UNIT NO: P-7 SERVICE: Primary Heating Loop MODEL: 80SC

PROJECT: Sample Project Mech Room 201 LOCATION: MANUFACTURER: Bell & Gossett

I

ITEM

OK

I

COMMENT

PRESTART-UP INSPECTION --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Mountings Checked - Pump & Motor Alignment By Millwright or Installer Seismic Restraints Installed Equipment Guards Installed Pump Rotates Freely Pump & Motor Lubricated Shaft Gland Lubricated Local Valving Set For Normal Operation Pressure Gauges in Supply and Return Piping Electrical Connections Completed Disconnect Switch Installed Overload Heaters Installed (Sized Correctly)

I

N/A OK OK OK OK OK

None

I

Sealed Bearings

None OK OK

AR 11.2 (7.97-8.69 AMPS) TRNR 15 Fuses

START-UP INSPECTION Pump Rotation Correct Electrical Interlocks Verified Pump Status Indicators Verified (Local/Remote) Check Valve Operation Tested System Static Pressure Vibration & Noise Level Acceptable Motor Amps - Rated 8.2 Actual 7.4/7.5/7.6 Motor Volts - Rated 208 Actual 210

COMMENTS:

HP3

PRESTART BY: START-UP BY:

F.14 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

SMr:

wr:

OK OK OK OK OK OK OK

26 PSI

12 PSI Differential

I

will shiit nff if OAT > G S F nftnr -n

DATE: DATE:

SI1 IQA

3

HVAC Systems Commissioning Manual

1/Q4

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

SMACNA

TITLEIHVACCM 94

ôL89350 0 0 0 5 b 5 5 0 7 5 M

SMACNA HVAC SYSTEMS COMMISSIONING

- LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST CIRCULATING PUMP UNIT NO: P-3 SERVICE: AHU-7 Heating Coil

PROJECT: Sample Project LOCATION: Mech Room 201 MANUFACTURER: Bell ¿? Gossett ITEM

MODEL:

I

OK

80BF

I

COMMENT

PRESTART-UP INSPECTION

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Mountings Checked - Pump & Motor Alignment By Millwright or Installer Seismic Restraints Installed Equipment Guards Installed Pump Rotates Freely Pump & Motor Lubricated Shaft Gland Lubricated Local Valving Set For Normal Operation Pressure Gauges in Supply and Return Piping Electrical Connections Completed Disconnect Switch Installed Overload Heaters Installed (Sized Correctly)

OK OK N/A OK

I

None

OK

OK OK

I

Sealed Bearings

OK None

OK OK

AR 5.3

OK OK OK OK OK

26 PSI

START-UP INSPECTION Pump Rotation Correct Electrical Interlocks Verified Pump Status Indicators Verified (LocaVRemote) Check Valve Operation Tested System Static Pressure Vibration & Noise Level Acceptable Motor Amps - Rated 4.0 Actual 3.4/3.8/3.7 Motor Volts - Rated 208 Actual 210

10 PSI Differential

OK _ _ _ ~

~~

COMMENTS:

PRESTART BY: START-UP BY:

e

SMr:

DATE: DATE:

mr:

HVAC Systems Commissioning Manual

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

5/1/44

F.15

S M A C N A T I T L E P H V A C C M 9 4 W 8 3 8 9 3 5 0 0005b5b T O 1

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST DOMESTIC WATER SYSTEM GENERAL

-

Sample Project PROJECT: Various LOCATION: MANUFACTURER: Various

UNIT NO: Various SERVICE: Domestic Water

MODEL:

I

ITEM

OK

I

Various COMMENT

PRESTART-UP INSPECTION Water Piping Pressure Test (Report Attached) System Flushed & Cleaned

OK OK

REPORTS i% CHECKLISTS RECEIVED

NIA

OK OK --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Booster Pump Manufacturer's Checklist Attached Booster Pump Commissioning Checklist DHW Tank Manufacturer's Checklist Attached DHW Tank Commissioning Checklist Fixture Checklist Heat Tape Verification Report Attached

SOMMENTS:

PRESTART BY: START-UP BY:

F.16 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

SMr.

DATE: DATE:

HVAC Systems Commissioning Manual

511 Ici4 511IC14

.

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA TITLE*HVACCM

9 4 W 8189350 0005657 948 W

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST

-

DOMESTIC WATER TANK GAS FIRED

UNIT NO: SERVICE: MODEL:

PROJECT: Sample Project LOCATION: Mech Room 201 MANUFACTURER: A. O. Smith ITEM

I

OK

PRESTART-UP INSPECTION Installation Completed Including Breeching Electrical Connections / Voltages Checked Safety Controls Complete & Operational Sensor & Gage Locations Noted Burner Controls Complete & Operational Gas Piping Tested & Purged Combustion Air Inlet Unobstructed Gas Venting Completed Gas Pressure Confirmed = Water Heater Temperature Setpoint = 120C Gas Piping Identified

I

DHWT-1 Domestic Water Heating BT 8939 COMMENT

I

I

OK

I

N/A

I None required

OK OK OK

OK OK NfA

WATER HEATER START-UP INSPECTION --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Qualified Personnel (Cert. No. 45678) Firing Sequence Verified Flame Safeguard Sequence Verified Automatic Shutdown Verified Safety Shutdown Verified Recirculation Pump Operational Safety Valve Tested Water Temperature Maintained Combustion Efficiency Test (Report Attached) Volume / Capacity Test (Report Attached) Manufacturer's Start-up Sheets Attached Heat Tracing Mega Test Certificate Attached

OK

OK OK

VI.

OK OK

150 PSI 210 F 200,000 BTU/HR

COMMENTS:

PRESTART BY: START-UP BY:

DATE: DATE:

SMC SMC

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

511IC44

3

1 194

F.17

SMACNA TITLE*HVACCM

8389350 0005658 8 8 4

94

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2 CONTROL SYSTEM VERIFICATION CHECKLIST AIR HANDLING SYSTEM

Sample Project Mech Room 209

PROJECT: LOCATION:

SYSTEM: AHU-7 SERVICE: Classrooms

I

ITEM

'

OK

SYSTEMOFF

~

I

COMMENT

I

Sensor Locations & Supports Checked ' Installation Complete Damper Positions Checked & Stroked End To End Checks Completed

I

OK OK OK OK

I I

Requires guards Return air damper will not close all the way

NORMAL START-UP SEQUENCE StartíStop Supply & Ret. Fans By Weekly Sched Damper minimum position verified

OK OK

Setpoint = 40%

I

TEMPERATURE CONTROL

1

SAT Reset by room sensors Heating sequences verified SAT maintained at setpoint

I

OK OK OK

I

OK OK

PUMP CONTROL

I

Hottest zone

I Dampers / Coil Pump / Heating Valve I Setpoint = 54F SAT maintained OAT temp. I

Pump on continuously if OAT e 40F If Fans off and OAT < 40F Htg Valve Open 100% Pump On/Off with heating demand

I Whether Fans on or fans off I

OK

I

UNOCCUPIED MODE

Fan On - Full Heat if RT c56F System Off if RT >62F

OK OK

SAFETY & MEC. CONTROLS Freezestat verified (Setpoint = 36F) Manual over-ride verified

OK OK

I

I

I

DDC Alarm - Manual reset ON=System On For Time (Initial Time = 0-255 min.) OFF=System Off: EF2 On - override buttons not terminated

GENERAL COMMENTS:

I

TEST 1 BY: TEST 2 BY: VERIFIED BY:

F.18 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

i

)

*

SMV

DATE: DATE: DATE:

3

1 /QA 511 íìlQ4

HVAC Systems Commissioning Manual --`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA TITLE*HVACCM

94

8 1 8 9 3 5 0 0 0 0 5 6 5 9 710

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

EQUIPMENT PRE-START & START-UP CHECKLIST AIR HANDLING SYSTEM

SYSTEM: AHU-2 SERVICE: Gymnasium

Sample Project Mech Room 201

PROJECT: LOCATION:

I

ITEM

OK

I

COMMENT

I SYSTEM OFF Sensor Locations & Supports Checked Installation Complete Damper Positions Checked & Stroked End To End Checks Completed

OK OK

I

I

NORMAL START-UP SEQUENCE StarVStop Supply & Ret. Fans By Weekly Sched Damper minimum position verified

OK

Setpoint = 40%

OK OK OK

Hottest zone Dampers / Coil Pump / Heating Valve Setpoint = 54F SAT maintained OAT temp.

TEMPERATURECONTROL SAT Reset by room sensors Heating sequences verified SAT maintained at setpoint

~

PUMP CONTROL Whether Fans on or fans off

OK OK

Pump on continuously if OAT < 40F If Fans off and OAT < 40F Htg Valve Open 100% Pump On/Off with heating demand

-

UNOCCUPIED MODE Fan On - Full Heat if RT 62F

OK

SAFETY i% MISC. CONTROLS

OK

Freezestat verified (Setpoint = 36F) Manual over-ride verified

OK

I

I I I

I

DDC Alarm - Manual reset ON=Svctem On For Time (Initial Time = 0-255 m h ì OFF=Svctem Off: EF2 On - override buttons not terminated

I GENERAL COMMENTS:

TEST 1 BY: TEST 2 BY: VERIFIED BY:

DATE: DATE: DATE:

SMC

SMV

511 194 511 n / q A

~~

% 6-

HVAC Systems Commissioning Manual

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

F.19

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

OK

SMACNA T I T L E * H V A C C M

94

8389350 0005660 432

SMACNA

-

HVAC SYSTEMS COMMISSIONING LEVEL 2

CONTROL SYSTEM VERIFICATION CHECKLIST EXHAUST FANS

I

PROJECT: LOCATION:

SYSTEM: Various SERVICE: Exhaust Fans

mr:

DATE: DATE: DATE:

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Sample Project Various

I

GENERAL COMMENTS:

I

TEST1 BY: TEST 2 BY: VERIFIED BY:

F.20 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

SMV

511 IQ4

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

94

First Edition

SMACNA TITLE*HVACCM

74

8389350 0 0 0 5 6 6 1 3 7 9

SMACNA HVAC SYSTEMS COMMISSIONING

CONTROL SYSTEM VERIFICATION CHECKLIST CONTROL VALVES

I

PROJECT: LOCATION:

SYSTEM: SERVICE:

Sample Project Supply Ducts

I

STROKE

I

PIPING

I

I

LEAK

I

CONTROL

I

CHECKED

DATE: DATE: DATE:

TEST 1 BY: TEST 2 BY: VERIFIED BY:

HVAC Systems Commissioning Manual

First Edition

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Reheat Coils Reheat

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

F.21

SMACNA T I T L E * H V A C C M 74

m 8389350

0 0 0 5 6 6 2 205

m

SMACNA HVAC SYSTEMS COMMISSIONING

CONTROL SYSTEM VERIFICATION CHECKLIST CONTROL VALVES

I

PROJECT: LOCATION:

Sample Project Various

SYSTEM: SERVICE:

Radiation Perimeter Heat

SERVICE RM-103 RM-105W RM-105E

STROKE CHECKED OK OK OK

PIPING CHECKED OK OK OK

LEAK CHECK OK OK OK

CONTROL OPERATION OK OK OK

CHECKED BY SMC SMC SMC

CV-RP28 CV-RP29

RM-142 RM-133

OK OK

OK OK

OK OK

OK OK

SMC SMC

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

VALVE NUMBER CV-RP1 CV-RP2 CV-RP3

I

GENERAL COMMENTS:

I

TEST 1 BY: TEST 2 BY: VERIFIED BY:

F.22 Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

8 3 8 7 3 5 0 0005bb3 141

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

SMACNA T I T L E a H V A C C M 9 4

INDEX

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

SMACNA T I T L E * H V A C C M

94

8387350 0005664 O 8 8

INDEX Acceptance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2, 5.1, 5.3, 7.1 Balancing Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 2.1, 3.1, 5.1, 5.3, 7.1, 7.2, 7.4 Building Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 Callbacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checklists 1.1, 6.2, 6.3, 7.4-7.6, D.l Functional Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 6.1, 6.2, 7.3-7.5, 9.2, 9.6, B.l, C.l Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1, 6.2, 7.3-7.5, 9.2, 9.6, B.l, C.l Commissioning 5.2, 7.1, 7.4-7.6, 9.6 Acceptance Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3 Acceptance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Agent Duties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1,6.1-6.3 2.2, 4.1, 7.2, 7.3 Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1, 4.2, 5.3, 7.2 Authority . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 2.2, 3.4, 4.1, 4.2, 5.1, 5.3, 5.4, 7.1-7.6, 8.1, 9.6 3.1,3.2,5.2,6.3 Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3,5.4,9.6 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2,5.2,5.3,7.1 Comprehensive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 4.1, 4.2, 7.1, 7.3, 7.5, 7.6 Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1, 5.3, 5.4, 9.1-9.3, 9.5, 9.6 2.2, 3.2, 3.4, 5.2 Contractors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 Designers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Owners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 3.1-3.4, 5.3, 8.1, 9.5 Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1, 7.1, 7.2, 8.1, 9.1, 9.4, 9.5 3.4, 5.2, 6.3, 7.1, 7.3-7.7 Demonstration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Event Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 Functional Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1, 3.4, 5.2, 6.3, 6.4, 7.3-7.6, 9.6 Levels . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 2.2, 3.1, 3.3, 3.4, 4.2, 5.2-5.4, 6.3, 7.1, 8.1, 9.2, 9.6 Meetings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4-7.6 5.1,8.1 Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Tests . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 3.2, 4.2, 5.3, 6.1-6.3, 7.3-7.6, 8.1, 9.1 Performance Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1, 3.4, 7.3-7.6, 8.1, 9.2, 9.6 Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 3.2, 4.1, 5.3, 6.2, 7.2-7.6, 9.2, 9.6 Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2, 5.2, 6.1-6.4, 7.1, 7.2, 8.1 Process . . . . . . . . . . . . 1.1, 2.1, 2.2, 3.1-3.4, 4.1, 4.2, 5.1-5.4, 6.2, 7.1, 7.3-7.6, 8.1, 9.1, 9.4-9.6 7.1,7.2 Program Document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 Program Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2,7.3 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Responsibilities . . . . . . . . . . . . . . . . . . . . . . . 2.1, 2.2, 3.2, 4.1, 4.2, 5.1-5.3, 6.1-6.3, 7.1-7.3, 7.6 A.l Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 2.2, 7.1-7.3, 8.1, 9.1, 9.2, 9.5 2.2,7.2-7.4,8.1 Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1,7.2-7.4 Team . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Team Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2,7.2-7.4 Tests . . . . . . . . . . . . . . 1.1, 1.2, 3.1, 3.4, 4.1, 4.2, 5.1, 5.3, 6.1-6.3, 7.2-7.6, 8.1, 9.1, 9.2, 9.5, 9.6 Deferred . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 6.3 Seasonal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3, 3.4,6.2,7.2 5.1 Verification Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2,2.1,3.1,3.2,3.4 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3,7.5 6.2 Emergency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HVAC Systems Commissioning Manual

--`,`,``,`,,``,``,`,,``,`,`,,,-`-`,,`,,`,`,,`---

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

First Edition

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

1.1

SMACNA T I T L E * H V A C C M

9 4 W 8189350 0005665 T L 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1,6.2 Sequence of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1,6.2,9.6 Sequences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3 Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3,7.2,9.5 Temperature Control Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 3.3, 9.5 8.1 Critical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2, 6.3, 7.1, 7.3-7.7, 8.1 Demonstrating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Design Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 3.1,7.2 Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1, 3.1, 3.2, 6.1, 6.3, 7.1, 7.2 Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1,5.3,7.1,7.2 Documentation . . . . . . . . . . . . . . . . . . 1.1, 2.1, 3.1, 3.2, 4.1, 4.2, 5.2, 5.3, 6.2, 7.2, 7.5, 7.6, 9.1-9.6 Energy Cost-Savings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3, 9.5 Conservation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 9.2 Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1-3.3, 5.1, 5.2, 5.4, 6.1, 7.4 HVAC Contractors . . . . . . . . . . . . . 1.1, 2.1, 2.2, 3.1-3.4, 4.1, 5.1, 5.2, 5.4, 6.1-6.4, 7.1, 7.3, 7.5, 7.6, 8.1 Systems . . . . . . . . . . . . . . . 1.1, 1.2, 2.1, 2.2, 3.1, 3.3, 4.1, 4.2, 5.2-5.4, 6.1-6.3, 7.1, 7.2, 9.2, 9.5 Zoning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2, 3.3, 5.3, 5.4, 6.3, 7.1, 9.1, 9.3-9.5 Indoor Air Quality (IAQ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 2.1, 3.1, 5.4, 7.1, 9.4 IAQCriteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 3.1, 5.4, 7.2, 8.1, 9.2, 9.6 Cost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1,3.2,9.5 Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1, 3.3, 5.2,6.3,9.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1,6.3,7.6 6.2,7.2 Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . National Energy Management Institute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1 4.1 National Training Fund . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Occupant Complaints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3,5.4,9.2, 9.3 1.1,2.1, 3.1, 3.3, 5.4 Discomfort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Productivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2,3.3,5.4 1.1,3.1 Operating Costs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3, 6.3, 6.4, 7.7 Operations Instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1, 3.4, 5.2, 6.3, 6.4, 7.3-7.6, 9.6 5.3 Partnering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Performance Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 6.2, 6.3, 7.3-7.6 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1,8.1 Functional . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 2.1, 3.2, 4.2, 5.2, 5.3, 6.1-6.3, 7.3-7.6, 8.1, 9.2 Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2,5.3 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1, 3.2, 4.2, 5.3, 6.1-6.3, 7.3-7.6, 8.1, 9.2 2.1, 3.4, 7.3-7.6, 8.1, 9.2, 9.6 Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1,3.2,6.1,7.4 Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1,6.3,7.4 Pre-Start Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1, 5.2, 5.4, 6.2, 9.2 Recommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1, 3.3, 3.4, 5.2, 9.1-9.6 Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4,9.3,9.5 Cooling Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1-9.3,9.5 Documentation 9.1-9.3 Confirming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Creating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1,9.2, 9.4,9.6 9.1-9. Existing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

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Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

HVAC Systems Commissioning Manual Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

First Edition

SMACNA TITLE*HVACCM

94

m

81893.50 0 0 0 5 b b b 950

m

Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2-9.5 9.1, 9.5, 9.6 Modifications Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4,9.5 Outside Air Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Plan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1,9.2,9.6 9.6 Retraining Operations Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Space Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1, 9.3, 9.5 Survey Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4, 9.1-9.6 Test and Balance Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2-9.5 Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.1, 9.2, 9.5,9.6 9.1,9.2,9.6 Tests Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F.1 Report. Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Samples F.l Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E.l Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Schedule. Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A.l Shutdown Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4,7.7, 9.6 3.2 Sick Building Syndrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smoke Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. l . 2.1,5.3 E.l Specification. Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2, 7.7, 9.6 Start-up Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Systems. Critical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2,5.3,8.1 2.2, 4.1, 7.2, 9.2-9.5 Testing and Balancing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1,5.1 Total Quality Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3,7.1, 9.4,9.5 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HVAC Systems Commissioning Manual Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

.

First Edition

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Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT

1.3

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SMACNA T I T L E * H V A C C M

94

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8389350 0005667 8 9 7 M

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SHEET METAL AND AIR CONDITIONING CONTRACTORS NATIONAL ASSOCIATION, INC.

Copyright SMACNA Provided by IHS under license with SMACNA No reproduction or networking permitted without license from IHS

Licensee=Army Hdqrtrs/7838506107 Not for Resale, 09/13/2005 03:14:03 MDT