Attachment_A_Appendix_1_Test_and_Balancing__0002.pdf

TESTING, ADJUSTING, AND BALANCING FOR HVAC

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. Section Includes:

1. Balancing Hydronic Piping Systems:

a. Constant-flow hydronic systems.

b. Variable-flow hydronic systems.

c. Primary-secondary hydronic systems.

2. Testing, Adjusting, and Balancing Equipment:

a. Heat exchangers.

b. Motors.

c. Chillers.

d. Cooling towers.

e. Condensing units.

f. Boilers.

g. Heat-transfer coils.

3. Testing, adjusting, and balancing existing systems and equipment.

4. Control system verification.

5. After testing, adjusting and balancing is complete the agency shall visit the job two additional times: once during the heating season, and once during the cooling season, to make adjustments to provide uniform temperatures throughout the building. Schedule the adjustments trips during the months of December through February, when the outdoor temperature is below 40°F, for the heating season, and June through August, when the outdoor temperature is above 85°F for the cooling season. Obtain a signed statement from the Owner acknowledging the trips and subsequent adjustments. Submit a statement to the Architect.

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1.3 DEFINITIONS

A. AABC: Associated Air Balance Council.

B. BAS: Building automation systems.

C. NEBB: National Environmental Balancing Bureau.

D. TAB: Testing, adjusting, and balancing.

E. TABB: Testing, Adjusting, and Balancing Bureau.

F. TAB Specialist: An independent entity meeting qualifications to perform TAB work.

G. TDH: Total dynamic head.

1.4 INFORMATIONAL SUBMITTALS

A. Qualification Data: Within 30 days of Contractor's Notice to Proceed, submit documentation that the TAB specialist and this Project's TAB team members meet the qualifications specified in "Quality Assurance" Article.

B. Contract Documents Examination Report: Within 30 days of Contractor's Notice to Proceed, submit the Contract Documents review report as specified in Part 3.

C. System Readiness Checklists: Within 30 days of Contractor's Notice to Proceed, submit system readiness checklists as specified in "Preparation" Article.

D. Examination Report: Submit a summary report of the examination review required in "Examination" Article.

E. Certified TAB reports.

F. Sample report forms.

G. Instrument calibration reports, to include the following:

1. Instrument type and make.

2. Serial number.

3. Application.

4. Dates of use.

5. Dates of calibration.

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1.5 QUALITY ASSURANCE

A. TAB Specialists Qualifications: Certified by NEBB.

1. TAB Field Supervisor: Employee of the TAB specialist and certified by NEBB.

2. TAB Technician: Employee of the TAB specialist and certified by NEBB as a

TAB technician.

3. Systems must be balanced for +/- 10% of quantities shown on contract document.

B. Instrumentation Type, Quantity, Accuracy, and Calibration: Comply with requirements in ASHRAE 111, Section 4, "Instrumentation."

C. ASHRAE/IES 90.1 Compliance: Applicable requirements in ASHRAE/IES 90.1, Section

6.7.2.3 - "System Balancing."

PART 2 - PRODUCTS (Not applicable)

PART 3 - EXECUTION

3.1 EXAMINATION

A. Examine the Contract Documents to become familiar with Project requirements and to discover conditions in systems designs that may preclude proper TAB of systems and equipment.

B. Examine installed systems for balancing devices, such as test ports, gage cocks, thermometer wells, flow-control devices, balancing valves and fittings, and manual volume dampers. Verify that locations of these balancing devices are applicable for intended purpose and are accessible.

C. Examine the approved submittals for HVAC systems and equipment.

D. Examine design data including HVAC system descriptions, statements of design assumptions for environmental conditions and systems output, and statements of philosophies and assumptions about HVAC system and equipment controls.

E. Examine equipment performance data including pump curves.

1. Relate performance data to Project conditions and requirements, including system effects that can create undesired or unpredicted conditions that cause reduced capacities in all or part of a system.

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F. Examine system and equipment installations and verify that field quality-control testing, cleaning, and adjusting specified in individual Sections have been performed.

G. Examine test reports specified in individual system and equipment Sections.

H. Examine HVAC equipment and verify that bearings are greased, belts are aligned and tight, filters are clean, and equipment with functioning controls is ready for operation.

I. Examine strainers. Verify that startup screens have been replaced by permanent screens with indicated perforations.

J. Examine control valves for proper installation for their intended function of throttling, diverting, or mixing fluid flows.

K. Examine heat-transfer coils for correct piping connections and for clean and straight fins.

L. Examine system pumps to ensure absence of entrained air in the suction piping.

M. Examine operating safety interlocks and controls on HVAC equipment.

N. Report deficiencies discovered before and during performance of TAB procedures.

Observe and record system reactions to changes in conditions. Record default set points if different from indicated values.

3.2 PREPARATION

A. Prepare a TAB plan that includes the following:

1. Equipment and systems to be tested.

2. Strategies and step-by-step procedures for balancing the systems.

3. Instrumentation to be used.

4. Sample forms with specific identification for all equipment.

B. Perform system-readiness checks of HVAC systems and equipment to verify system readiness for TAB work. Include, at a minimum, the following:

1. Hydronics:

a. Verify leakage and pressure tests on water distribution systems have been satisfactorily completed.

b. Piping is complete with terminals installed.

c. Water treatment is complete.

d. Systems are flushed, filled, and air purged.

e. Strainers are pulled and cleaned.

f. Control valves are functioning per the sequence of operation.

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g. Shutoff and balance valves have been verified to be 100 percent open.

h. Pumps are started and proper rotation is verified.

i. Pump gage connections are installed directly at pump inlet and outlet flanges or in discharge and suction pipe prior to valves or strainers.

j. Suitable access to balancing devices and equipment is provided.

3.3 GENERAL PROCEDURES FOR TESTING AND BALANCING

A. Perform testing and balancing procedures on each system according to the procedures contained in NEBB's "Procedural Standards for Testing, Adjusting, and Balancing of Environmental Systems" and in this Section.

B. Cut insulation, ducts, pipes, and equipment cabinets for installation of test probes to the minimum extent necessary for TAB procedures.

1. Install and join new insulation that matches removed materials. Restore insulation, coverings, vapor barrier, and finish according to Section 230713 "Duct Insulation," Section 230716 "HVAC Equipment Insulation," and Section 230719 "HVAC Piping Insulation."

C. Mark equipment and balancing devices, including damper-control positions, valve position indicators, fan-speed-control levers, and similar controls and devices, with paint or other suitable, permanent identification material to show final settings.

3.4 GENERAL PROCEDURES FOR HYDRONIC SYSTEMS

A. Prepare test reports for pumps, coils, and heat exchangers. Obtain approved submittals and manufacturer-recommended testing procedures. Crosscheck the summation of required coil and heat exchanger flow rates with pump design flow rate.

B. Prepare schematic diagrams of systems' "as-built" piping layouts.

C. In addition to requirements in "Preparation" Article, prepare hydronic systems for testing and balancing as follows:

1. Check liquid level in expansion tank.

2. Check highest vent for adequate pressure.

3. Check flow-control valves for proper position.

4. Locate start-stop and disconnect switches, electrical interlocks, and motor starters.

5. Verify that motor starters are equipped with properly sized thermal protection.

6. Check that air has been purged from the system.

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3.5 PROCEDURES FOR CONSTANT-FLOW HYDRONIC SYSTEMS

A. Adjust pumps to deliver total design gpm.

1. Measure total water flow.

a. Position valves for full flow through coils.

b. Measure flow by main flow meter, if installed.

c. If main flow meter is not installed, determine flow by pump TDH or exchanger pressure drop.

2. Measure pump TDH as follows:

a. Measure discharge pressure directly at the pump outlet flange or in discharge pipe prior to any valves.

b. Measure inlet pressure directly at the pump inlet flange or in suction pipe prior to any valves or strainers.

c. Convert pressure to head and correct for differences in gage heights.

d. Verify pump impeller size by measuring the TDH with the discharge valve closed. Note the point on manufacturer's pump curve at zero flow and verify that the pump has the intended impeller size.

e. With valves open, read pump TDH. Adjust pump discharge valve until design water flow is achieved.

3. Monitor motor performance during procedures and do not operate motor in an overloaded condition.

B. Adjust flow-measuring devices installed in mains and branches to design water flows.

1. Measure flow in main and branch pipes.

2. Adjust main and branch balance valves for design flow.

3. Re-measure each main and branch after all have been adjusted.

C. Adjust flow-measuring devices installed at terminals for each space to design water flows.

1. Measure flow at terminals.

2. Adjust each terminal to design flow.

3. Re-measure each terminal after it is adjusted.

4. Position control valves to bypass the coil, and adjust the bypass valve to maintain design flow.

5. Perform temperature tests after flows have been balanced.

D. For systems with pressure-independent valves at terminals:

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1. Measure differential pressure and verify that it is within manufacturer's specified range.

2. Perform temperature tests after flows have been verified.

E. For systems without pressure-independent valves or flow-measuring devices at terminals:

1. Measure and balance coils by either coil pressure drop or temperature method.

2. If balanced by coil pressure drop, perform temperature tests after flows have been verified.

F. Verify final system conditions as follows:

1. Re-measure and confirm that total water flow is within design.

2. Re-measure final pumps' operating data, TDH, volts, amps, and static profile.

3. Mark final settings.

G. Verify that memory stops have been set.

3.6 PROCEDURES FOR MOTORS

A. Motors 1/2 HP and Larger: Test at final balanced conditions and record the following data:

1. Manufacturer's name, model number, and serial number.

2. Motor horsepower rating.

3. Motor rpm.

4. Phase and hertz.

5. Nameplate and measured voltage, each phase.

6. Nameplate and measured amperage, each phase.

7. Starter size and thermal-protection-element rating.

8. Service factor and frame size.

B. Motors Driven by Variable-Frequency Controllers: Test manual bypass of controller to prove proper operation.

3.7 PROCEDURES FOR CHILLERS

A. Balance water flow through each evaporator and condenser to within specified tolerances of indicated flow with all pumps operating. With only one chiller operating in a multiple chiller installation, do not exceed the flow for the maximum tube velocity recommended by the chiller manufacturer. Measure and record the following data with each chiller operating at design conditions:

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1. Evaporator-water entering and leaving temperatures, pressure drop, and water flow.

2. For water-cooled chillers, condenser-water entering and leaving temperatures, pressure drop, and water flow.

3. Evaporator and condenser refrigerant temperatures and pressures, using instruments furnished by chiller manufacturer.

4. Power factor if factory-installed instrumentation is furnished for measuring kilowatts.

5. Kilowatt input if factory-installed instrumentation is furnished for measuring kilowatts.

6. Capacity: Calculate in tons of cooling.

7. For air-cooled chillers, verify condenser-fan rotation and record fan and motor data including number of fans and entering- and leaving-air temperatures.

3.8 PROCEDURES FOR COOLING TOWERS

A. Balance total condenser-water flows to towers. Measure and record the following data:

1. Condenser-water flow to each cell of the cooling tower.

2. Entering- and leaving-water temperatures.

3. Wet- and dry-bulb temperatures of entering air.

4. Wet- and dry-bulb temperatures of leaving air.

5. Condenser-water flow rate recirculating through the cooling tower.

6. Cooling-tower spray pump discharge pressure.

7. Condenser-water flow through bypass.

8. Fan and motor operating data.

3.9 PROCEDURES FOR BOILERS

A. Hydronic Boilers:

1. Measure and record entering- and leaving-water temperatures.

2. Measure and record water flow.

3. Record relief valve pressure setting.

3.10 SOUND TESTS

A. After the systems are balanced and construction is Substantially Complete, measure and record sound levels at 5 locations as designated by the Architect.

B. Instrumentation:

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1. The sound-testing meter shall be a portable, general-purpose testing meter consisting of a microphone, processing unit, and readout.

2. The sound-testing meter shall be capable of showing fluctuations at minimum and maximum levels, and measuring the equivalent continuous sound pressure level

(LEQ).

3. The sound-testing meter must be capable of using 1/3 octave band filters to measure mid-frequencies from 31.5 Hz to 8000 Hz.

4. The accuracy of the sound-testing meter shall be plus or minus one decibel.

C. Test Procedures:

1. Perform test at quietest background noise period. Note cause of unpreventable sound that affects test outcome.

2. Equipment should be operating at design values.

3. Calibrate the sound-testing meter prior to taking measurements.

4. Use a microphone suitable for the type of noise levels measured that is compatible with meter. Provide a windshield for outside or in-duct measurements.

5. Take readings no closer than 36 inches from a wall or from the operating equipment and approximately 60 inches from the floor, with the meter held or mounted on a tripod.

6. For outdoor measurements, move sound-testing meter slowly and scan area that has the most exposure to noise source being tested. Use A-weighted scale for this type of reading.

D. Reporting:

1. Report shall record the following:

a. Location.

b. System tested.

c. dBA reading.

d. Sound pressure level in each octave band with equipment on and off.

2. Plot sound pressure levels on NC worksheet with equipment on and off.

3.11 CONTROLS VERIFICATION

A. In conjunction with system balancing, perform the following:

1. Verify temperature control system is operating within the design limitations.

2. Confirm that the sequences of operation are in compliance with Contract

Documents.

3. Verify that controllers are calibrated and function as intended.

4. Verify that controller set points are as indicated.

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5. Verify the operation of lockout or interlock systems.

6. Verify the operation of valve and damper actuators.

7. Verify that controlled devices are properly installed and connected to correct controller.

8. Verify that controlled devices travel freely and are in position indicated by controller: open, closed, or modulating.

9. Verify location and installation of sensors to ensure that they sense only intended temperature, humidity, or pressure.

B. Reporting: Include a summary of verifications performed, remaining deficiencies, and variations from indicated conditions.

3.12 PROCEDURES FOR TESTING, ADJUSTING, AND BALANCING EXISTING SYSTEMS

A. Perform a preconstruction inspection of existing equipment that is to remain and be reused.

1. Measure and record the operating speed, airflow, and static pressure of each fan.

2. Measure motor voltage and amperage. Compare the values to motor nameplate information.

3. Check the refrigerant charge.

4. Check the condition of filters.

5. Check the condition of coils.

6. Check the operation of the drain pan and condensate-drain trap.

7. Check bearings and other lubricated parts for proper lubrication.

8. Report on the operating condition of the equipment and the results of the measurements taken. Report deficiencies.

B. Before performing testing and balancing of existing systems, inspect existing equipment that is to remain and be reused to verify that existing equipment has been cleaned and refurbished. Verify the following:

1. New filters are installed.

2. Coils are clean and fins combed.

3. Drain pans are clean.

4. Fans are clean.

5. Bearings and other parts are properly lubricated.

6. Deficiencies noted in the preconstruction report are corrected.

C. Perform testing and balancing of existing systems to the extent that existing systems are affected by the renovation work.

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1. Compare the indicated airflow of the renovated work to the measured fan airflows, and determine the new fan speed and the face velocity of filters and coils.

2. Verify that the indicated airflows of the renovated work result in filter and coil face velocities and fan speeds that are within the acceptable limits defined by equipment manufacturer.

3. If calculations increase or decrease the airflow rates and water flow rates by more than 5 percent, make equipment adjustments to achieve the calculated rates. If increase or decrease is 5 percent or less, equipment adjustments are not required.

4. Balance each air outlet.

3.13 TOLERANCES

A. Set HVAC system's airflow rates and water flow rates within the following tolerances:

1. Supply, Return, and Exhaust Fans and Equipment with Fans: Plus or minus 10 percent.

2. Heating-Water Flow Rate: Plus or minus 10 percent.

3. Cooling-Water Flow Rate: Plus or minus 10 percent.

B. Maintaining pressure relationships as designed shall have priority over the tolerances specified above.

3.14 FINAL REPORT

A. General: Prepare a certified written report; tabulate and divide the report into separate sections for tested systems and balanced systems.

1. Include a certification sheet at the front of the report's binder, signed and sealed by the certified testing and balancing engineer.

2. Include a list of instruments used for procedures, along with proof of calibration.

3. Certify validity and accuracy of field data.

B. Final Report Contents: In addition to certified field-report data, include the following:

1. Pump Curves

2. Manufacturers' test data.

3. Field test reports prepared by system and equipment installers.

4. Other information relative to equipment performance; do not include Shop

Drawings and Product Data.

C. General Report Data: In addition to form titles and entries, include the following data:

1. Title page.

2. Name and address of the TAB specialist.

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3. Project name.

4. Project location.

5. Architect's name and address.

6. Engineer's name and address.

7. Contractor's name and address.

8. Report date.

9. Signature of TAB supervisor who certifies the report.

10. Table of Contents with the total number of pages defined for each section of the report. Number each page in the report.

11. Summary of contents including the following:

a. Indicated versus final performance.

b. Notable characteristics of systems.

c. Description of system operation sequence if it varies from the

Contract Documents.

12. Nomenclature sheets for each item of equipment.

13. Data for terminal units, including manufacturer's name, type, size, and fittings.

14. Notes to explain why certain final data in the body of reports vary from indicated values.

D. System Diagrams: Include schematic layouts of air and hydronic distribution systems.

Present each system with single-line diagram and include the following:

1. Water flow rates.

2. Pipe and valve sizes and locations.

3. Balancing stations.

4. Position of balancing devices.

E. Pump Test Reports: Calculate impeller size by plotting the shutoff head on pump curves and include the following:

1. Unit Data:

a. Unit identification.

b. Location.

c. Service.

d. Make and size.

e. Model number and serial number.

f. Water flow rate in gpm.

g. Water pressure differential in feet of head or psig.

h. Required net positive suction head in feet of head or psig.

i. Pump rpm.

j. Impeller diameter in inches.

k. Motor make and frame size.

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l. Motor horsepower and rpm.

m. Voltage at each connection.

n. Amperage for each phase.

o. Full-load amperage and service factor.

p. Seal type.

2. Test Data (Indicated and Actual Values):

a. Static head in feet of head or psig.

b. Pump shutoff pressure in feet of head or psig.

c. Actual impeller size in inches

d. Full-open flow rate in gpm .

e. Full-open pressure in feet of head or psig.

f. Final discharge pressure in feet of head or psig

g. Final suction pressure in feet of head or psig .

h. Final total pressure in feet of head or psig.

i. Final water flow rate in gpm.

j. Voltage at each connection.

k. Amperage for each phase.

F. Instrument Calibration Reports:

1. Report Data:

a. Instrument type and make.

b. Serial number.

c. Application.

d. Dates of use.

e. Dates of calibration.

3.15 VERIFICATION OF TAB REPORT

A. The TAB specialist's test and balance engineer shall conduct the inspection in the presence of commissioning authority.

B. Architect and Owner shall randomly select measurements, documented in the final report, to be rechecked. Rechecking shall be limited to either 10 percent of the total measurements recorded or the extent of measurements that can be accomplished in a normal 8-hour business day.

C. If rechecks yield measurements that differ from the measurements documented in the final report by more than the tolerances allowed, the measurements shall be noted as

"FAILED."

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D. If the number of "FAILED" measurements is greater than 10 percent of the total measurements checked during the final inspection, the testing and balancing shall be considered incomplete and shall be rejected.

E. If TAB work fails, proceed as follows:

1. TAB specialists shall recheck all measurements and make adjustments. Revise the final report and balancing device settings to include all changes; resubmit the final report and request a second final inspection.

2. If the second final inspection also fails, Owner may contract the services of another TAB specialist to complete TAB work according to the Contract Documents and deduct the cost of the services from the original TAB specialist's final payment.

3. If the second verification also fails, Owner may contact AABC Headquarters regarding the AABC National Performance Guaranty.

F. Prepare test and inspection reports.

3.16 ADDITIONAL TESTS

A. Within 90 days of completing TAB, perform additional TAB to verify that balanced conditions are being maintained throughout and to correct unusual conditions.

B. Seasonal Periods: If initial TAB procedures were not performed during near-peak summer and winter conditions, perform additional TAB during near-peak summer and winter conditions.