230800 Commissioning of HVAC Systems.doc

A&E

NATIONAL INSTITUTES OF HEALTH (NIH)

HAMILTON, MONTANA

SECTION 23 08 00 - COMMISSIONING OF HVAC SYSTEMS

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

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

B. The OPR and BOD documentation are included by reference for information only.

1.2 SUMMARY

A. This section includes commissioning process requirements for HVAC&R systems, assemblies, and equipment.

B. Related Sections:

1. Division 01 Section 91 13 "General Commissioning Requirements" for general commissioning process requirements.

2. Division 01 section 019113 General Commissioning Requirements

3. All Division 23 sections

4. Division 01 section 017823 Operation and Maintenance Data

1.3 DESCRIPTION

A. Refer to Division 01 Section 91 13 “General Commissioning Requirements” for the description of commissioning.

1.4 DEFINITIONS

A. Refer to Division 01 Section 91 13 “General Commissioning Requirements” for definitions.

1.5 SUBMITTALS

A. Refer to Division 01 Section “Submittals” for specific requirements.

B. In addition, the GC or subcontractors are to provide the following:

1. Certificates of readiness

2. Certificates of completion of installation, prestart, and startup activities.

3. O&M manuals

4. Test reports

a. Duct leakage testing

b. Piping pressure testing

c. Hydronic flush and fill glycol percentage and other chemistry reports

d. Equipment startup reports (self-performed or by vendors/manufacturers)

e. Testing, Adjusting and Balancing Reports C. Control Drawings Submittal

1. The control drawings shall have a key to all abbreviations.

2. The control drawings shall contain graphic schematic depictions of the systems and each component.

3. The schematics will include the system and component layout of any equipment that the control system monitors, enables or controls, even if the equipment is primarily controlled by packaged or integral controls.

4. Provide a completed point to point verification table with testing notes.

1.6 QUALITY ASSURANCE

A. Test Equipment Calibration Requirements: Contractors will comply with test manufacturer’s calibration procedures and intervals.

1.7 COORDINATION

A. Refer to Division 01 Section “General Commissioning Requirements” for requirements pertaining to coordination during the commissioning process.

PART 2 - PRODUCTS

2.1 TEST EQUIPMENT

A. All standard testing equipment required to perform startup, initial checkout and functional performance testing shall be provided by the Contractor for the equipment being tested. For example, the mechanical contractor of Division 23 shall ultimately be responsible for all standard testing equipment for the HVAC&R system and controls system in Division 23, except for equipment specific to and used by TAB in their commissioning responsibilities.

B. Special equipment, tools and instruments (specific to a piece of equipment and only available from vendor) required for testing shall be included in the base bid price to the Owner and left on site, except for stand-alone data logging equipment that may be used by the CxA.

C. Proprietary test equipment and software required by any equipment manufacturer for programming and/or start-up, whether specified or not, shall be provided by the manufacturer of the equipment. Manufacturer shall provide the test equipment, demonstrate its use, and assist in the commissioning process as needed. Proprietary test equipment (and software) shall become the property of the Owner upon completion of the commissioning process.

D. Data logging equipment and software required to test equipment will be provided by the CxA, but shall not become the property of the Owner.

E. All testing equipment shall be of sufficient quality and accuracy to test and/or measure system performance with the tolerances specified in the Specifications. If not otherwise noted, the following minimum requirements apply: Temperature sensors and digital thermometers shall have a certified calibration within the past year to an accuracy of 0.5(F and a resolution of + or - 0.1(F. Pressure sensors shall have an accuracy of + or - 2.0% of the value range being measured (not full range of meter).

PART 3 - EXECUTION

3.1 GENERAL DOCUMENTATION REQUIREMENTS

A. With assistance from the installing contractors, the CxA will prepare Pre-Functional Checklists for all commissioned components, equipment, and systems. The installing contractors will complete the forms to confirm readiness for scheduled equipment startups, Testing, Adjusting and Balancing, and subsequent Functional Performance Testing.

B. Red-lined Drawings:

1. The contractor will verify all equipment, systems, instrumentation, wiring and components are shown correctly on red-lined drawings.

2. Preliminary red-lined drawings must be made available to the Commissioning Team for use prior to the start of Functional Performance Testing.

3. Changes, as a result of Functional Testing, must be incorporated into the final as-built drawings, which will be created from the red-lined drawings.

4. The contracted party, as defined in the Contract Documents will create the as-built drawings.

C. Operation and Maintenance Data:

1. Contractor will provide a copy of O&M literature within 45 days of each submittal acceptance for use during the commissioning process for all commissioned equipment and systems.

2. The CxA will review the O&M literature once for conformance to project requirements.

3. The CxA will receive a copy of the final approved O&M literature once corrections have been made by the Contractor.

D. Demonstration and Training:

1. Contractor will provide demonstration and training as required by the specifications.

2. A complete training plan and schedule must be submitted by the contractor to the CxA four weeks (4) prior to any training.

3. A training agenda for each training session must be submitted to the CxA one (1) week prior the training session.

4. The CxA shall be notified at least 72 hours in advance of scheduled tests so that testing may be observed by the CxA and Owner's representative. A copy of the test record shall be provided to the CxA, Owner, and Architect.

5. The Contractor shall engage a Factory-authorized service representative to train Owner's maintenance personnel to adjust, operate, and maintain specific equipment.

6. The Contractor shall train Owner's maintenance personnel on procedures and schedules for starting and stopping, trouble shooting, servicing, and maintaining equipment.

7. The Contractor and CxA shall Review data in O&M Manuals.

E. Systems manual or Operations and Maintenance (O&M) manual requirements:

1. The Systems or O&M Manual is intended to be a usable information resource containing all of the information related to the systems, assemblies, and Commissioning Process in one place with indexes and cross references.

2. The GC shall include final approved versions of the following information for the Systems / O&M Manual:

a. As-Built System Schematics

b. Verified Record Drawings

c. Test Results (not otherwise included in Cx Record)

d. Periodic Maintenance Information for computer maintenance management system

e. Recommendations for recalibration frequency of sensors and actuators

f. A list of contractors, subcontractors, suppliers, architects, and engineers involved in the project along with their contact information

g. Training Records, Information on training provided, attendees list, and any on-going training

3. This information shall be organized and arranged by building system, such as fire alarm, chilled water, heating hot water, etc.

4. Information should be provided in an electronic version to the extent possible. Legible, scanned images are acceptable for non-electronic documentation to facilitate this deliverable.

3.2 CONTRACTOR'S RESPONSIBILITIES

A. Mechanical, Controls and TAB Contractors. The commissioning responsibilities applicable to each of the mechanical, controls and TAB contractors of Division 23 are as follows (all references apply to commissioned equipment only):

B. Perform commissioning tests at the direction of the CxA.

C. Attend construction phase controls coordination meetings.

D. Attend testing, adjusting, and balancing review and coordination meetings.

E. Participate in HVAC&R systems, assemblies, equipment, and component maintenance orientation and inspection as directed by the CxA.

F. Provide information requested by the CxA for final commissioning documentation.

G. Include requirements for submittal data, operation and maintenance data, and training in each purchase order or sub-contract written.

H. Update schedule as required throughout the construction period.

I. During the startup and initial checkout process, execute the related portions of the prefunctional checklists for all commissioned equipment.

J. Assist the CxA in all verification and functional performance tests.

K. Provide measuring instruments and logging devices to record test data, and provide data acquisition equipment to record data for the complete range of testing for the required test period.

L. Gather operation and maintenance literature on all equipment, and assemble in binders as required by the specifications. Submit to CxA (45) days after submittal acceptance.

M. Coordinate with the CxA to provide (48) hour advance notice so that the witnessing of equipment and system start-up and testing can begin.

N. Notify the CxA a minimum of (2) weeks in advance of the time for start of the testing and balancing work. Attend the initial testing and balancing meeting for review of the official testing and balancing procedures.

O. Participate in, and schedule vendors and contractors to participate in the training sessions.

P. Provide written notification to the CM/GC and CxA Authority that the following work has been completed in accordance with the contract documents, and that the equipment, systems, and sub-system are operating as required.

1. HVAC&R equipment including all fans, air handling units, ductwork, dampers, terminals, and all other equipment furnished under this Division.

Q. Provide training of the Owner’s operating staff using expert qualified personnel, as specified.

R. Test, Adjust and Balance Contractor

1. Attend initial commissioning coordination meeting scheduled by the Commissioning Authority.

2. Submit the site specific testing and balancing plan to the CxA and AE for review and acceptance.

3. Attend the testing and balancing review meeting scheduled by the CxA. Be prepared to discuss the procedures that shall be followed in testing, adjusting, and balancing the HVAC&R system.

4. At the completion of the testing and balancing work, and the submittal of the final testing and balancing report, notify the HVAC&R contractor and the CM/GC.

5. At the completion of testing and balancing work, and the submittal of the final testing and balancing report, notify the HVAC&R Contractor and the CM/GC.

6. Participate in verification of the testing and balancing report, which will consist of repeating measurements contained in the testing and balancing reports. Assist in diagnostic purposes when directed.

S. Equipment Suppliers

1. Provide all requested submittal data, including detailed start-up procedures and specific responsibilities of the Owner, to keep warranties in force.

2. Assist in equipment testing per agreements with contractors.

3. Provide information requested by CxA regarding equipment sequence of operation and testing procedures.

4. The equipment supplier shall document the performance of his equipment.

T. Refer to Division 01 Section “General Commissioning Requirements” for additional contractor responsibilities.

3.3 OWNER’S RESPONSIBILITIES

A. Refer to Division 01 Section “General Commissioning Requirements” for Owner’s Responsibilities.

3.4 DESIGN PROFESSIONAL'S RESPONSIBILITIES

A. Refer to Division 01 Section “General Commissioning Requirements” for Design Professional’s Responsibilities.

3.5 CxA’s RESPONSIBILITIES

A. Refer to Division 01 Section “General Commissioning Requirements” for CxA’s Responsibilities.

3.6 TESTING PREPARATION

A. Certify in writing to the CxA that HVAC&R systems, subsystems, and equipment have been installed, calibrated, and started and are operating according to the Contract Documents.

B. Certify in writing to the CxA that HVAC&R instrumentation and control systems have been completed and calibrated, that they are operating according to the Contract Documents, and that pretest set points have been recorded.

C. Certify in writing that testing, adjusting, and balancing procedures have been completed and that testing, adjusting, and balancing reports have been submitted, discrepancies corrected, and corrective work approved.

D. Place systems, subsystems, and equipment into operating mode to be tested (e.g., normal shutdown, normal auto position, normal manual position, unoccupied cycle, emergency power, and alarm conditions).

E. Inspect and verify the position of each device and interlock identified on checklists.

F. Check safety cutouts, alarms, and interlocks with smoke control and life-safety systems during each mode of operation.

G. Testing Instrumentation: Install measuring instruments and logging devices to record test data as directed by the CxA.

3.7 TESTING, ADJUSTING AND BALANCING VERIFICATION

A. Notify the CxA at least ten (10) days in advance of testing and balancing Work, and provide access for the CxA to witness testing and balancing Work.

B. Provide technicians, instrumentation, and tools to verify testing and balancing of HVAC&R systems at the direction of the CxA.

1. The CxA will notify testing and balancing subcontractor ten (10) days in advance of the date of field verification. Notice will not include data points to be verified.

2. The testing and balancing subcontractor shall use the same instruments (by model and serial number) that were used when original data were collected.

3. Remedy the deficiency and notify the CxA so verification of failed portions can be performed.

3.8 GENERAL TESTING REQUIREMENTS

A. Provide technicians, instrumentation, and tools to perform commissioning test at the direction of the CxA.

B. Scope of HVAC&R testing shall include entire HVAC&R installation, from central equipment for heat generation and refrigeration through distribution systems to each conditioned space. Testing shall include measuring capacities and effectiveness of operational and control functions.

C. Test all operating modes, interlocks, control responses, and responses to abnormal or emergency conditions, and verify proper response of building automation system controllers and sensors.

D. The CxA along with the HVAC&R contractor, testing and balancing Subcontractor, and HVAC&R Instrumentation and Control Subcontractor shall prepare detailed testing plans, procedures, and checklists for HVAC&R systems, subsystems, and equipment.

E. Tests will be performed using design conditions whenever possible.

F. The CxA may direct that set points be altered when simulating conditions is not practical.

G. The CxA may direct that sensor values be altered with a signal generator when design or simulating conditions and altering set points are not practical.

H. If tests cannot be completed because of a deficiency outside the scope of the HVAC&R system, document the deficiency and report it to the Owner. After deficiencies are resolved, reschedule tests.

I. If the testing plan indicates specific seasonal testing, complete appropriate initial performance tests and documentation and schedule seasonal tests.

3.9 HVAC&R SYSTEMS, SUBSYSTEMS, AND EQUIPMENT TESTING PROCEDURES

A. Equipment Testing and Acceptance Procedures: Testing requirements are specified in individual Division 23 sections. Provide submittals, test data, inspector record, and certifications to the CxA.

B. HVAC&R Instrumentation and Control System Testing: Field testing documents will be developed by the CxA.

C. Pipe system cleaning, flushing, hydrostatic tests, and chemical treatment: Test requirements are specified in Division 23 piping Sections. HVAC&R Contractor shall prepare a pipe system cleaning, flushing, and hydrostatic testing plan. Provide cleaning, flushing, testing, and treating plan and final reports to the CxA. Documentation of testing and treatment shall be submitted to the CxA. Sign off by GC is acceptable for testing.

D. Refrigeration System Testing: Provide technicians, instrumentation, tools, and equipment to test performance of chillers, cooling towers, refrigerant compressors and condensers, heat pumps, and other refrigeration systems.

E. HVAC&R Distribution System Testing: Provide technicians, instrumentation, tools, and equipment to test performance of air, steam, and hydronic distribution systems; special exhaust; and other distribution systems, including HVAC&R terminal equipment and unitary equipment.

F. The work included in the commissioning process involves a complete and thorough evaluation of the operation and performance of all components, systems and sub-systems. The following equipment and systems shall be evaluated:

1. HVAC Systems and Sub-systems

2. VFD’s

3. Building Automation Systems

4. Test and Balance (witness a sample of work by and review reports by TAB)

5. See also the complete list of Systems to Be Commissioned in 019113

3.10 DEFICIENCIES/NON-CONFORMANCE, COST OF RETESTING, FAILURE DUE TO MANUFACTURER DEFECT

A. Refer to Division 01 Section “General Commissioning Requirements” for requirements pertaining to deficiencies/non-conformance, cost of retesting, or failure due to manufacturer defect.

3.11 APPROVAL

A. Refer to Division 01 Section “General Commissioning Requirements” for approval procedures.

3.12 DEFERRED TESTING

A. Refer to Division 01 Section “General Commissioning Requirements” for requirements pertaining to deferred testing.

3.13 OPERATION AND MAINTENANCE MANUALS

A. The Operation and Maintenance Manuals shall conform to Contract Documents requirements as stated in Division 01.

B. Refer to Division 01 Section “General Commissioning Requirements” for the AE and CxA roles in the Operation and Maintenance Manual contribution, review and approval process.

C. An updated as-built version of the control drawings and sequences of operation shall be included in the final controls O&M manual submittal.

3.14 TRAINING OF OWNER PERSONNEL

A. Refer to Division 01 Section “General Commissioning Requirements” for requirements pertaining to training.

B. Mechanical Contractor. The mechanical contractor shall have the following training responsibilities:

1. Provide the CxA with a training plan two weeks before the planned training.

2. Provide designated Owner personnel with comprehensive orientation and training in the understanding of the systems and the operation and maintenance of each piece of HVAC equipment including, but not limited to, all HVAC equipment (ex. pumps, heat exchangers, chillers, heat rejection equipment, air conditioning units, air handling units, fans, terminal units, controls and water treatment systems, etc.)

3. Training shall normally start with classroom sessions followed by hands-on training on each piece of equipment, which shall illustrate the various modes of operation, including startup, shutdown, fire/smoke alarm, power failure, etc.

4. During any demonstration, should the system fail to perform in accordance with the requirements of the O&M manual or sequence of operations, the system will be repaired or adjusted as necessary and the demonstration repeated.

5. The appropriate trade or manufacturer's representative shall provide the instructions on each major piece of equipment. This person may be the start-up technician for the piece of equipment, the installing contractor or manufacturer’s representative. Practical building operating expertise as well as in-depth knowledge of all modes of operation of the specific piece of equipment are required. More than one party may be required to execute the training.

6. The controls contractor shall attend sessions other than the controls training, as requested, to discuss the interaction of the controls system as it relates to the equipment being discussed.

7. The training sessions shall follow the outline in the Table of Contents of the operation and maintenance manual and illustrate whenever possible the use of the O&M manuals for reference.

8. Training shall include:

a. Use of the printed installation, operation and maintenance instruction material included in the O&M manuals.

b. A review of the written O&M instructions emphasizing safe and proper operating requirements, preventative maintenance, special tools needed and spare parts inventory suggestions. The training shall include start-up, operation in all modes possible, shut-down, seasonal changeover and any emergency procedures.

c. Discussion of warranties and guarantees.

d. Common troubleshooting problems and solutions.

e. Explanatory information included in the O&M manuals.

f. Discussion of any peculiarities of equipment installation or operation.

9. Hands-on training shall include start-up, operation in all modes possible, including manual, shut-down and any emergency procedures and preventative maintenance for all pieces of equipment.

10. The mechanical contractor shall fully explain and demonstrate the operation, function and overrides of any local packaged controls, not controlled by the central control system.

11. Training shall occur after functional testing is complete, unless approved otherwise by the Owner.

C. Controls Contractor. The controls contractor shall have the following training responsibilities:

1. Provide the CxA and AE with a training plan four weeks before the planned training.

2. The controls contractor shall provide designated Owner personnel training on the control system in this facility. The intent is to clearly and completely instruct the Owner on all the capabilities of the control system.

3. Training manuals. The standard operating manual for the system and any special training manuals will be provided for each trainee, with three extra copies left for the O&M manuals. In addition, copies of the system technical manual will be demonstrated during training and three copies submitted with the O&M manuals. Manuals shall include detailed description of the subject matter for each session. The manuals will cover all control sequences and have a definitions section that fully describes all relevant words used in the manuals and in all software displays. Manuals will be approved by the CxA and AE. Copies of audiovisuals shall be delivered to the Owner.

4. The trainings will be tailored to the needs and skill-level of the trainees.

5. The trainers will be knowledgeable on the system and its use in buildings. For the on-site sessions, the most qualified trainer(s) will be used. The Owner shall approve the instructor prior to scheduling the training.

6. During any demonstration, should the system fail to perform in accordance with the requirements of the O&M manual or sequence of operations, the system will be repaired or adjusted as necessary and the demonstration repeated.

7. The controls contractor shall attend sessions other than the controls training, as requested, to discuss the interaction of the controls system as it relates to the equipment being discussed.

8. Training shall be accomplished as specified in Section 230900

END OF SECTION 23 08 00

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