RFI 1 - Commissioning Specifications.docx

RFI #1 – Commissioning Specifications

COMMISSIONING DESIGN SPECIFICATIONS

Replace Air‑Cooled Chiller – Building 89 USDA Miami, FL

3.4 Testing and Commissioning – Design Specifications

The commissioning scope shall verify that the newly installed air‑cooled chiller system (minimum 156.2‑ton capacity, Daikin ACCH‑160T or USDA‑approved equal) operates in accordance with design intent, manufacturer requirements, project performance criteria, and USDA facility operational needs. All commissioning activities shall be performed by qualified, licensed technicians and in coordination with a factory‑authorized manufacturer’s representative. Commissioning shall confirm compliance with energy efficiency requirements, BAS integration requirements, and environmental performance criteria, including saltwater‑corrosion‑resistant construction.

3.4.1 System Startup and Performance Verification

The Contractor shall follow the commissioning sequence detailed below.

a) Manufacturer’s Representative Coordination

· Coordinate and schedule the presence of the chiller manufacturer’s certified startup technician prior to energization.

· Provide all required submittals, wiring diagrams, piping layouts, refrigerant documentation, and load conditions in advance to the representative.

· Ensure the chiller is installed per manufacturer requirements including electrical service (460V, 3‑phase, 300A), chilled-water connections, and corrosion-resistant coil coatings as required for the seacoast environment.

b) Pre‑Startup Inspection and Safety Checklist Contractor shall complete and document a comprehensive inspection addressing:

· Verification of proper mounting on existing concrete pad and structural integrity.

· Inspection of chilled water piping, including pressure testing, flushing, and foam‑glass insulation installation.

· Confirmation of correct electrical connections, circuit protection, grounding, and torque checks.

· Verification that BAS control wiring, communication cabling, and safety interlocks are properly connected.

· Refrigerant circuit integrity checks including leak testing and EPA‑compliant refrigerant handling documentation.

· Verification of clearance, airflow path, and condenser coil protection (epoxy‑coated fins).

· Review of environmental, safety, and USDA site‑access policies prior to startup.

c) Initial System Startup (With Manufacturer’s Representative)

· Conduct initial energization strictly according to manufacturer procedures.

· Verify proper operation of compressors, fans, pumps, flow switches, and safety controls.

· Confirm that chiller achieves required startup performance including fast‑recovery behavior:

· Restore to full capacity within 4 minutes after power loss.

· Achieve full capacity from standby in under 2 minutes.

d) Operational and Functional Testing Protocol The Contractor shall execute a complete functional performance test that includes:

e) Refrigeration System Performance Verification

· Confirm refrigerant levels meet manufacturer specifications.

· Validate proper operation of compressors, condenser fans, expansion valves, and sensors.

· Verify system achieves specified chilled water temperatures:

· Entering water: 54°F

· Leaving water: 44°F

· Confirm system can maintain cooling capacity at design flow:

· 350 GPM at approximately 4.97 psid.

f) Control System Functionality & Setpoint Verification

· Validate all BAS and local control setpoints including:

· Chilled water temperature control

· Lead/lag logic if applicable

· Alarm thresholds

· Low ambient lockout or fan staging (as applicable)

· Ensure control response is stable under variable load conditions.

g) Safety System Testing & Alarm Verification

· Test high/low pressure cutouts, freeze protection, motor overloads, flow switches, and emergency shutoff devices.

· Simulate alarm conditions and verify proper BAS annunciation and chiller shutdown behavior.

h) BAS Integration & Communication Verification

· Confirm full communication between chiller controller and facility BAS.

· Verify point‑to‑point communication includes:

· Status points

· Analog values

· Alarm conditions

· Command points

· Ensure BACnet or manufacturer protocol integration meets USDA cybersecurity and reliability requirements.

i) Chilled Water System Balancing

· Balance chilled water flow to achieve required 350 GPM design flow.

· Verify differential pressure, pump speed control (if VFD), and stable temperature differential.

· Ensure flow stability during load transitions.

j) Continuous Operation Test – Minimum 72 Hours

· Operate the chiller continuously for no less than 72 hours under varying load conditions.

· Monitor and log:

· Leaving/entering water temperatures

· Ambient conditions

· Refrigerant pressures

· Compressor staging

· Power consumption/performance

· BAS trend data

· Correct deficiencies identified during runtime.

k) Documentation of Test Results & Performance Data

· Record all measurements, test results, and corrective actions.

· Provide calibrated instrument readings for verification.

· Submit a commissioning log for USDA review.

l) Comprehensive Commissioning Report The final report shall include:

· System performance verification against design criteria.

· Confirmation of compliance with Energy Star efficiency requirements.

· Verification of corrosion‑resistant construction and environmental suitability.

· BAS integration summary and point‑to‑point verification.

· Completed checklists and test forms.

· Refrigerant handling certification and EPA‑608 documentation.

· As‑built configuration of programming parameters and setpoints.

m) Manufacturer Startup Certification & Warranty Activation

· Provide official startup certification signed by the manufacturer’s representative.

· Ensure all warranties for equipment, installation, and workmanship are activated and transmitted to USDA.

· Provide 24/7 troubleshooting contact information per SOW requirements.

1) Commissioning Checklist (fillable) Project: Replace Air‑Cooled Chiller – Building 89, USDA Miami, FL Chiller: Daikin ACCH‑160T (or USDA‑approved equal, ≥156.2‑ton) Electrical: 460V, 3‑Phase, 300A service Design Water Temps/Flow: 54°F entering / 44°F leaving; 350 GPM @ ~4.97 psid Environmental: Seacoast corrosion‑resistant construction; epoxy‑coated condenser fins Duration: Continuous operation test ≥72 hours Cover Page Fields

· Date: _______

· Cx Agent / Lead Technician: __________________

· Manufacturer Rep (Name/Company): __________________

· USDA Site Contact (AO): Karla Agurto

· Instrument Calibration Due Dates Verified: ☐ Yes ☐ No

· Weather/Ambient (start): ____ °F | Relative Humidity: ____ %

A. Pre‑Startup Safety & Readiness

· ☐ Job Hazard Analysis reviewed; PPE verified

· ☐ Site access and security procedures reviewed (badge, hours, restricted areas)

· ☐ Lockout/Tagout cleared; energized equipment boundaries defined

· ☐ Permits/approvals confirmed

· ☐ Manufacturer’s installation checklist completed and on file

· ☐ Installation on concrete pad verified (level, anchorage, vibration isolation)

· ☐ Clearances and airflow paths unobstructed

· ☐ Seacoast protection present (epoxy‑coated fins; accessories per submittals)

· Notes: ____________________________________________ B. Mechanical (Piping & Hydronics)

· ☐ Chilled water supply/return connections tight; leak-free

· ☐ Hydrostatic pressure test completed: ____ psi, duration ____

· ☐ System flushed/cleaned; strainers cleaned

· ☐ Foam‑glass insulation installed; vapor‑tight; matches existing

· ☐ Differential pressure across chiller at design: ~4.97 psid (record actual: ___)

· ☐ Flow measured: target 350 GPM (record actual: ___)

· Notes: ____________________________________________ C. Electrical

· ☐ 460V 3‑Phase service verified; voltage balance within tolerance

· ☐ 300A feeder, OCPD, grounding verified; torque values recorded

· ☐ Control power and transformers checked

· ☐ Conduit and wiring methods compliant; old wiring removed

· Notes: ____________________________________________ D. Controls & BAS Integration

· ☐ BAS network connected; addressing verified

· ☐ Point‑to‑point check complete (see Table in Section 3)

· ☐ Command and feedback agreement verified

· ☐ Trend logging enabled for critical points

· ☐ Cybersecurity requirements met (per USDA policies)

· Notes: ____________________________________________ E. Refrigerant & Environmental Compliance

· ☐ EPA Section 608 documentation (recovery/handling) on file

· ☐ Leak test performed; results: __________________

· ☐ Refrigerant charge within manufacturer spec: ______

· Notes: ____________________________________________ F. Safety & Protections

· ☐ High/low pressure cutouts tested

· ☐ Flow switch operation verified

· ☐ Freeze protection tested

· ☐ Motor overloads / fan safeties verified

· ☐ E‑stop function verified & alarm annunciation to BAS

· Notes: ____________________________________________ G. Initial Startup (with Manufacturer’s Representative)

· ☐ Startup script followed (Section 4)

· ☐ Compressors/fans stage correctly

· ☐ Standby‑to‑full capacity < 2 minutes (record: ___ min)

· ☐ Power‑loss recovery to full capacity < 4 minutes (record: ___ min)

· Notes: ____________________________________________ H. Functional Performance (Design Criteria)

· ☐ Entering chilled water: 54°F (record trend range: –)

· ☐ Leaving chilled water: 44°F (record trend range: –)

· ☐ Flow: 350 GPM ± ___% (record: ___)

· ☐ Capacity ≥ 156.2 tons (method & result: ____________________)

· ☐ Energy Star requirements confirmed (submittals/testing attached)

· Notes: ____________________________________________ I. 72‑Hour Continuous Operation Test

· ☐ Run start: //__ : | Run end: //__ :

· ☐ Ambient range: – °F; Load profile: __________________

· ☐ No unresolved alarms/trips

· ☐ Stable temp differential and flow

· ☐ Trend logs captured and archived

· Notes: ____________________________________________ J. Closeout & Documentation

· ☐ As‑builts (mechanical/electrical/controls)

· ☐ O&M manuals; warranty registrations

· ☐ BAS trend exports; test data; commissioning report

· ☐ Training completed (topics: ops, maintenance, troubleshooting, BAS)

· ☐ 24/7 support contacts provided

· Manufacturer Startup Certification received: ☐ Yes (attach)

· Deficiency List Resolved: ☐ Yes (attach)

2) Formal Commissioning Plan

2.1 Purpose & Scope

Commission, test, and verify the new air‑cooled chiller system (≥156.2 ton) at USDA Building 89 to meet design intent, performance criteria, energy efficiency, reliability, and BAS integration—including environmental resilience for seacoast conditions and compliance with EPA Section 608.

2.2 Roles & Responsibilities

· USDA/Owner: Approvals, site access, AO coordination (Karla Agurto), acceptance.

· Contractor: Installation, pre‑functional checklists, tests, documentation, training.

· Manufacturer Rep: Startup oversight, certification, warranty activation.

· Commissioning Agent (Cx): Plan execution, test witnessing, reporting, deficiency tracking.

· BAS Vendor: Integration, point mapping, trending, cybersecurity compliance.

2.3 Submittals & Pre‑Reqs

· Manufacturer’s installation/startup procedures

· Electrical one‑lines, load calcs, breaker/OCPD data

· Mechanical piping drawings; pressure test reports

· BAS point list, network diagrams, protocol (e.g., BACnet), trend configuration

· EPA 608 refrigerant documentation

· Corrosion‑resistant materials verification (coatings, seacoast options)

2.4 Test Instrumentation (Accuracy)

· Clamp‑on ultrasonic flow meter (±1–2% of reading)

· Calibrated temp sensors (NIST‑traceable) for supply/return (±0.3–0.5°F)

· Differential pressure gauges/transducers (±1% FS)

· Power meter for kW/kWh (±1%)

· Data logger/BAS trending at ≤1‑min intervals for critical points

2.5 Pre‑Functional Checklists

Mechanical, Electrical, Controls/BAS, Safety/Environmental, per Section 1.

2.6 Functional Performance Tests (Acceptance Criteria)

· Hydronic: Achieve 350 GPM at ~4.97 psid; stable ΔT to 44°F leaving water under design conditions.

· Capacity/Energy: Demonstrate ≥156.2 tons minimum; Energy Star compliance per submittal and observed operating efficiency.

· Controls: Stable setpoint tracking; proper staging/lead‑lag; alarm thresholds; remote/local control function.

· Safety: Verified trips/alarms with correct annunciation and orderly shutdown.

· Reliability: Power‑loss recovery to full capacity < 4 minutes; standby‑to‑full capacity < 2 minutes.

· Integration: All BAS points verified and trended; commands/feedbacks match; cybersecurity conformance.

· Runtime: Uninterrupted ≥72 hours with no unresolved deficiencies.

2.7 Schedule & Sequencing

· Pre‑construction: surveys, permits, AO coordination.

· Decommission: refrigerant recovery per EPA; remove legacy wiring/piping.

· Install: set chiller; piping; electrical; controls; seacoast protections.

· Pre‑functional: closeout punch list before energization.

· Startup & FPT: witness by manufacturer rep and Cx agent.

· 72‑hour run: trend capture, mid‑run checks, post‑run review.

· Training & Turnover: deliver O&M, warranties, as‑builts, final report.

2.8 Data Management

· Configure BAS trends: 1‑min interval for supply/return temps, flow, DP, compressor stages, fan speeds, kW, alarms.

· Export to Owner: CSV/PDF with time stamps and instrument IDs.

· Archive on Owner’s network per USDA policy.

2.9 Deficiency Resolution

· Log all issues with root cause, corrective action, responsible party, target date, and retest verification.

· No final acceptance until all critical deficiencies closed.

2.10 Deliverables

· Completed checklists; FPT scripts with results

· BAS point‑to‑point verification table (signed)

· 72‑hour runtime trend package

· Manufacturer startup certification; warranty activation

· Training attendance and materials

· Final Commissioning Report

3) BAS Point‑to‑Point Verification Table (sample) Protocol: BACnet (or as provided), update rate ≤ 1 min for critical points.

Legend: AI=Analog Input, AO=Analog Output, BI=Binary Input, BO=Binary Output, AV/BV=Virtual

Add any site‑specific pumps/valves/VFD points (e.g., CHW pump run, DP setpoint, isolation valve command/feedback) to ensure end‑to‑end visibility.

4) Step‑by‑Step Startup Script (field use) Prerequisites: All pre‑functional checklists complete; BAS online; manufacturer’s rep onsite; safety briefing conducted; instruments calibrated.

Step 1 – Pre‑Start

1. Verify lockouts released and area secured; barriers removed.

2. Confirm hydronic system filled, vented, strainers cleaned.

3. Confirm electrical feeders energized; correct voltage and phase rotation.

4. Confirm BAS connected; point list loaded; trends configured.

Step 2 – Circulation & Flow 5. Start CHW pumps; verify flow = 350 GPM (adjust valves/VFD as needed).

6. Verify DP ≈ 4.97 psid across chiller; record baseline.

7. Confirm return temp ~54°F (or as actual load dictates).

Step 3 – Chiller Enable 8. Place chiller in Local then Remote/BAS as applicable.

9. Issue Enable from BAS (or local HMI); confirm run status and safeties proven.

10. Observe compressor/fan staging; validate stable control to 44°F supply target.

Step 4 – Functional Verifications 11. Simulate/verify alarms: low flow, high pressure, freeze protection; check BAS annunciation and orderly shutdown.

12. Verify command/feedback alignment for fans, stages, valves.

13. Confirm standby‑to‑full capacity < 2 minutes (document timing).

14. Simulate brief power loss; verify recovery to full capacity < 4 minutes (document timing).

Step 5 – Performance Checks 15. Record stabilized operating data: supply/return temps, flow, DP, kW, compressor stages, ambient.

16. Confirm capacity meets ≥156.2 tons (method: manufacturer test mode, load bank, or verified load conditions; document).

Step 6 – 72‑Hour Continuous Operation 17. Begin continuous run; maintain trending at ≤1‑min intervals for critical points.

18. Perform mid‑run checks at 12h/36h/60h; clear any alarms; record ambient/load.

19. Complete run; export trend data and summarize stability (ΔT, flow, trips).

Step 7 – Closeout 20. Reset to normal schedules; confirm BAS alarms cleared.

21. Complete checklists, attach instrument logs, and sign Manufacturer Startup Certification.

22. Deliver O&M manuals, warranties, as‑builts, commissioning report; conduct training (ops, maintenance, troubleshooting, BAS).

5) Acceptance Criteria (quick reference)

· Hydronic: 350 GPM at ~4.97 psid; 44°F leaving water at design load; stable ΔT.

· Capacity/Recovery: ≥156.2 tons; standby‑to‑full < 2 min; power‑loss recovery < 4 min.

· Controls/BAS: All points verified; commands/feedbacks match; critical points trended at ≤1‑min.

· Safety: All trips/alarms function and annunciate to BAS; orderly shutdown confirmed.

· Runtime: Continuous ≥72 hours; no unresolved deficiencies.

· Documentation: Startup certification, warranties, O&M, as‑builts, commissioning report delivered.

6) What I can do next for you

· Insert these sections into your Word file with Heading styles, fillable checkboxes, and signature blocks.

· Build a point list spreadsheet and trend export template (CSV/Excel).

· Create site‑specific forms for the Daikin ACCH‑160T (or approved equal) once you confirm BAS vendor/protocol and any pump/VFD controls.

Would you like me to:

1. Add these directly into your Word document,

2. Generate a separate commissioning package (.docx) with a table of contents, or

3. Provide editable Excel sheets for the BAS point list and 72‑hour trend log?