230593 FL Testing Adjusting and Balancing for HVAC.pdf

GSA Project #47PD0118C0011 Ice Storage Removal and Chiller Replacement

November 2022 – Amendment 1 Annex Building

Sensitive But Unclassified (SBU)

PROPERTY OF THE UNITED STATES GOVERNMENT FOR OFFICIAL USE ONLY

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SECTION 230593 - 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 Air Systems:

a. Exhaust fans.

2. Balancing Hydronic Piping Systems:

a. Variable-flow hydronic systems.

b. Primary-secondary hydronic systems.

3. Testing, Adjusting, and Balancing Equipment:

a. Motors.

b. Chillers.

4. Pipe leakage tests verification.

5. Duct leakage tests.

6. Testing, adjusting, and balancing of existing HVAC systems and equipment.

B. Refer to requirements in Section 019113 – “General Commissioning Requirements”.

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.

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

F. TAB Specialist: An entity engaged to perform TAB Work.

1.4 INFORMATIONAL SUBMITTALS

A. Qualification Data: Within 49 calendar days of Contractor's Notice to Proceed, submit documentation that the TAB contractor and this Project's TAB team members meet the qualifications specified in "Quality Assurance" Article.

B. Contract Documents Examination Report: Within 90 calendar days of Contractor's Notice to

Proceed, submit the Contract Documents review report as specified in Part 3. Provide statement of compliance with report consisting of a copy of this specification section with applicable paragraphs marked “C” for comply or “D” for deviation. For items marked “D”, provide explanation.

C. Strategies and Procedures Plan: Within 90 calendar days of Contractor's Construction Notice to

Proceed, submit TAB strategies and step-by-step procedures as specified in "Preparation" Article.

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

“Examination” Article. Provide statement of compliance with report consisting of a copy of this specification section with applicable paragraphs marked “C” for comply or “D” for deviation.

For items marked “D”, provide explanation.

E. Certified TAB reports.

F. Report forms specific to this project. Sample form are not acceptable.

G. All test equipment must have been calibrated according to NIST standards within the last 6 months of date to be used. Provide 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 (must be within last 12 months).

H. Provide preliminary pencil copies as the work is completed. Identify any issues discovered on these reports.

1.5 QUALITY ASSURANCE

A. TAB Contractor Qualifications: Engage a TAB entity certified by AABC NEBB or TABB.

1. TAB Field Supervisor: Employee of the TAB contractor and certified by AABC NEBB or TABB.

2. TAB Technician: Employee of the TAB contractor and who is certified by AABC NEBB or TABB as a TAB technician.

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B. TAB Conference: Meet with Government on approval of the TAB strategies and procedures plan to develop a mutual understanding of the details. Require the participation of the TAB field supervisor and technicians. Provide 14 days' advance notice of scheduled meeting time and location.

1. Agenda Items:

a. The Contract Documents examination report.

b. The TAB plan.

c. Coordination and cooperation of trades and subcontractors.

d. Coordination of documentation and communication flow.

C. Certify TAB field data reports and perform the following:

1. Review field data reports to validate accuracy of data and to prepare certified TAB reports.

2. Certify that the TAB team complied with the approved TAB plan and the procedures specified and referenced in this Specification.

D. TAB Report Forms: Use standard TAB contractor's forms approved by Government.

E. Instrumentation Type, Quantity, Accuracy, and Calibration: As described in ASHRAE 111, Section 5, "Instrumentation."

F. ASHRAE Compliance: Applicable requirements in ASHRAE 62.1, Section 7.2.2 - “Air

Balancing.”

G. ASHRAE/IESNA Compliance: Applicable requirements in ASHRAE/IESNA 90.1, Section 6.7.2.3 - "System Balancing."

1.6 PROJECT CONDITIONS

A. Government will occupy the site and existing building during entire TAB period. Cooperate with

Government during TAB operations to minimize conflicts with Governments’ operations.

1.7 COORDINATION

A. Notice: Provide fourteen days' advance notice for each test. Include scheduled test dates and times.

B. Perform TAB after pressure tests on water distribution systems have been satisfactorily completed.

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PART 2 - PRODUCTS (Not Applicable)

PART 3 - EXECUTION

3.1 SCOPE

A. Balance chilled water flows through primary chilled water pumps P-1.1, P-1.2, and P-1.3;

secondary chilled water pumps P-3.1, and P-3.2; fan coil loop secondary chilled water pumps P-

8.1, and P-8.2; existing chillers (free of glycol solution) and chillers CH-1, CH-2, CH-3, and CH-

4.

B. Balance condenser water pumps flows through condenser water pumps P-2.1, P-2.2, and P-2.3.

C. Balance airflows through exhaust fan EF-1.

3.2 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 systems for installed 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 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.

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, and equipment with functioning controls is ready for operation.

I. Examine strainers. Verify that startup screens are 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 existing system pumps to ensure absence of entrained air in the suction piping.

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

M. 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.

3.3 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. Forms with specific identification for all equipment.

B. Complete system-readiness checks and prepare reports. Verify the following:

1. Airside:

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

b. Duct systems are complete with terminals installed.

c. Volume, smoke, and fire dampers are open and functional.

d. Fans are operating, free of vibration, and rotating in correct direction.

e. Variable-frequency controllers' startup is complete and safeties are verified.

f. Ceilings are installed.

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

2. Hydronics:

a. Permanent electrical-power wiring is complete.

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

c. Hydronic systems are complete, filled, clean, and free of air.

d. Strainers are pulled and cleaned.

e. Automatic temperature-control systems are functioning per the sequence of operations.

f. Isolating and balancing valves are open and control valves are operational.

g. Pumps are started and proper rotation is verified.

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

i. Variable-frequency controllers’ startup is complete and safeties are verified.

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

3.4 GENERAL PROCEDURES FOR TESTING AND BALANCING

A. Perform testing and balancing procedures on each system according to the procedures contained in AABC's "National Standards for Total System Balance", NEBB's "Procedural Standards for

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Testing, Adjusting, and Balancing of Environmental Systems" or SMACNA's "HVAC Systems -

Testing, Adjusting, and Balancing" and in this Section.

B. Cut insulation, 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 230719 "HVAC and Plumbing

Piping Insulation."

C. At least fourteen days before Functional Testing, mark equipment and balancing devices, including valve position indicators, and similar controls and devices, with paint or other suitable, permanent identification material to show final settings.

D. Calibration:

1. Provide technician and certified equipment to support the controls contractor in their calibration of all controls system meters and sensors. Take readings at various ranges during this process to be led by the controls contractor.

E. Take and report testing and balancing measurements in inch-pound (IP) units.

F. Submit TAB report preliminary copies to CxA so that system conditions can be reviewed before beginning functional testing.

3.5 GENERAL PROCEDURES FOR BALANCING AIR SYSTEMS

A. Prepare test reports for both fans and outlets. Obtain manufacturer's outlet factors and recommended testing procedures. Cross-check the summation of required outlet volumes with required fan volumes.

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

C. Determine the best locations in main and branch ducts for accurate duct-airflow measurements.

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

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

F. Check dampers for proper position to achieve desired airflow path.

G. Check for airflow blockages.

H. Verify that air duct system is sealed as specified in Section 233113 "Metal Ducts."

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3.6 GENERAL PROCEDURES FOR HYDRONIC SYSTEMS

A. Prepare test reports with pertinent design data, and number in sequence starting at pump to end of system. Check the sum of branch-circuit flows against the approved pump flow rate. Correct variations that exceed plus or minus 5 percent.

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

C. Prepare hydronic systems for testing and balancing according to the following, in addition to the general preparation procedures specified above:

1. Open all manual valves for maximum flow.

2. Check pump-motor load. If motor is overloaded, throttle main flow-balancing device so motor nameplate rating is not exceeded.

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

4. Verify with electrical contractor that motor starters are equipped with properly sized thermal protection.

3.7 PROCEDURES FOR VARIABLE-FLOW HYDRONIC SYSTEMS

A. Balance systems with automatic two- way control valves by setting systems at maximum flow through coils, and proceed as specified above for hydronic systems.

B. Measure total water flow.

1. Position valves for full flow.

2. Measure flow by flow meter, if installed.

3. If flow meter is not installed, determine flow by coil pressure drop.

C. 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.

D. 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. Perform temperature tests after flows have been balanced.

E. Prior to verifying final system conditions, determine the system differential-pressure set point.

F. Mark final settings and verify that all memory stops have been set.

G. Verify final system conditions as follows:

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

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2. Mark final settings.

H. Verify that memory stops have been set.

3.8 PROCEDURES FOR PRIMARY-SECONDARY HYDRONIC SYSTEMS

A. Balance the primary circuit flow first.

B. Balance the secondary circuits after the primary circuits are complete.

C. 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.

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

D. 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.

E. 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.

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

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

2. Perform temperature tests after flows have been verified.

G. 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.

H. 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.

I. Verify that memory stops have been set.

3.9 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. Efficiency rating.

6. Nameplate and measured voltage, each phase.

7. Nameplate and measured amperage, each phase.

8. Starter thermal-protection-element rating.

9. Service factor and frame size.

B. Motors Driven by Variable-Frequency Controllers: Test for proper operation at speeds varying from minimum to maximum. Test the manual bypass of the controller to prove proper operation.

Record observations including name of controller manufacturer, model number, serial number, and nameplate data.

3.10 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:

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

2. Condenser-water entering and leaving temperatures, pressure drop, and water flow.

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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. Efficiency: Calculate operating efficiency for comparison to submitted equipment..

3.11 DUCT LEAKAGE TESTS

A. Witness the duct pressure testing performed by Installer.

B. Verify that proper test methods are used and that leakage rates are within specified tolerances.

C. Report deficiencies observed.

3.12 PROCEDURES FOR TESTING, ADJUSTING, AND BALANCING EXISTING SYSTEMS

A. Perform a preconstruction inspection of existing condenser water pumps that are to remain and be reused; chilled water pumps and chillers to be remain during phase 1 and once glycol free solution ins removed.

1. Measure and record the operating speed, and static head of each pump.

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

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

4. Measure and record flows, temperatures, and pressures of each piece of equipment in the glycol solution loop that are to remain in operation after phase 1 (refer to M-002 and Phase

1, Step 5 on MD401). Compare the values to BAS trend data and nameplate information, where information is available.

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

3.13 TOLERANCES

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

1. Condenser-Water Flow Rate: Plus or minus 10 percent.

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

3. Exhaust Air Flow Rate: Plus or minus 10 percent.

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.

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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 contractor.

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

D. Fan Test Reports:

1. Fan Data:

a. System identification.

b. Location.

c. Make and type.

d. Model number and size.

e. Manufacturer's serial number.

f. Arrangement and class.

g. Sheave make, size in inches, and bore.

h. Center-to-center dimensions of sheave and amount of adjustments in inches.

2. Motor Data:

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a. Motor make, and frame type and size.

b. Horsepower and rpm.

c. Volts, phase, and hertz.

d. Full-load amperage and service factor.

e. Sheave make, size in inches, and bore.

f. Center-to-center dimensions of sheave, and amount of adjustments in inches.

g. Number, make, and size of belts.

3. Test Data (Indicated and Actual Values):

a. Total airflow rate in cfm.

b. Total system static pressure in inches wg.

c. Fan rpm.

d. Discharge static pressure in inches wg.

e. Suction static pressure in inches wg.

E. Rectangular Duct Traverse Reports: Include a diagram with a grid representing the duct cross-section and record the following:

1. Report Data:

a. System and air-handling-unit number.

b. Location and zone.

c. Traverse air temperature in deg F.

d. Duct static pressure in inches wg.

e. Duct size in inches.

f. Duct area in sq. ft..

g. Indicated airflow rate in cfm.

h. Indicated velocity in fpm.

i. Actual airflow rate in cfm.

j. Actual average velocity in fpm.

k. Barometric pressure in psig.

F. 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.

l. Motor horsepower and rpm.

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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.

G. Instrument Calibration Reports:

1. Report Data:

a. Instrument type and make.

b. Serial number.

c. Application.

d. Dates of use.

e. Dates of calibration (must be within last 12 months).

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. Commissioning authority shall randomly select measurements, documented in the final report, to be rechecked. Rechecking shall be limited to either 10 percent of each type of equipment or 3 pieces of each type of equipment, whichever is greater. 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."

C. 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.

D. 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.

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2. If the second final inspection also fails, Government 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.

E. Prepare test and inspection reports.

3.16 COMMISSIONING

A. The commissioning process applies to all portions of this specification section. Commissioning is a formal process to thoroughly document the installation and verify the operation of building systems. Refer to 019113 “General Commissioning Requirements”.

END OF SECTION 230593