01805 Commissioning of Mech Systems_Rev1_changes w-Bar.pdf

USDA R&D FACILITY – ALBANY, CA JACOBS No. 25KT8810 TASK ORDER No. 53-3K15-1-0616 RECOVERY-MAJOR RENOVATIONS, PHASES 3-6

Jacobs ISSUED FOR FINAL SUBMITTAL February 19,2010 USDA, Recovery-Major Renovations, Phases 3-6 Page 1 of 63 Rev. 1 Section 01805, Commissioning of Mechanical Systems

SECTION 01805

COMMISSIONING OF MECHANICAL SYSTEMS

PART 1 GENERAL

1.1 SUMMARY

A. Use this specification in the commissioning phase of this project in accordance with ASHRAE Guideline 1 - 1996 "The HVAC Commissioning Process". Copies of the guideline may be purchased from the American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc., 1791 Tullie Circle, NE, Atlanta, GA 30329; phone

(404) 636-8400.

B. This Section also includes Recommissioning. Recommissioning is for systems that were previously commissioned but may have been affected by the current project work, as well as for systems that have been commissioned but were installed in previous phases of work at the project site.

C. The Government will retain a Commissioning Agent for all commissioning/ recommissioning activities related to this project.

1.2 SUBMITTALS

A. Commissioning Data: Provide a list of team members representing the Contractor in the pre-commissioning checks and functional performance testing, at least 2 weeks prior to the start of pre-commissioning checks.

B. Schedules: Provide schedule for pre-commissioning checks and functional performance tests, at least 2 weeks prior to the start of pre-commissioning checks.

C. Test Reports: Provide completed pre-commissioning checklists and functional performance tests checklists organized by system and by sub-system and submitted as one package. Include the results of failed tests along with a description of the corrective action taken.

1.3 SEQUENCING AND SCHEDULING

A. Commence pre-commissioning of HVAC equipment when installation of each piece of equipment is completed. O&M Data submission listed to substantial completion in Section 01730, Operation and Maintenance Data.

B. Perform Testing, Adjusting and Balancing upon completion of related HVAC Sections, after testing of individual pieces of equipment is successfully completed and test and inspection reports have been submitted.

C. The complete HVAC systems shall be examined in occupied and unoccupied modes.

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1.4 RECOMMISSIONING

A. Recommissioning sequence is indicated on Drawing G004, Sequence of Construction, Sequence 2 Activities, item 4.

B. The Contractor shall schedule all recommissioning activities with the Government and

WRRC / lab users prior to starting any work.

C. The Contractor shall schedule the following recommissioning activities:

1. Perform a walk-through of the systems to be recommissioned with the Government and Government’s Commissioning Agent to identify deficiencies in systems.

2. Provide a written report of such deficiencies a minimum of 8 weeks prior to start of recommissioning activities.

3. If a system or part of a system is not operating as designed (including controls), a schedule shall be developed by the Government/Government’s Commissioning Agent to ensure that corrections of deficiencies are implemented within a minimum of three weeks prior to the scheduled start of recommissioning activities.

4. The Government shall provide the following prior to starting the recommissioning process:

a. Drawings relevant to the systems. Refer to drawing “Issued for Commissioning Purposes – reference only”.

b. Test and balance (TAB) reports.

c. Control system documentation (i.e., sequence of operations).

d. Current maintenance logs and/or schedules.

E. The following mechanical systems shall be recommissioned:

1. Evaporative Cooler EC1-1 (Phases 1 thru 3)

2. Chiller CH1-1 (Phases 1 thru 3)

3. Air Handling Unit AHU1-2 (Phase 1)

4. Air Handling Unit AHU2-1 (Phase 2)

5. Exhaust Fans EF2-1, EF2-2, EF2-4, EF2-5, EF2-6 (Phase 2)

6. Exhaust Fan EF1-4 (Phase 1)

7. Exhaust Fan EF1-5 (Phase 1)

8. Chilled Water Pump CHWP1-1 and CHWP1-2 (Phases 1 thru 3)

9. Condenser Water Pump CWP1-1 and CWP1-2 (Phases 1 thru 4)

10. Hot Water Pump HWP1-1 and HWP1-2 (Phases 1 thru 4)

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11. Fume Hoods – 2 countertop style (Phase 2). An independent fume hood company is required to do hood recertification.

12. Bio-safety hood – 1 walk-in style (Phase 2). An independent fume hood company is required to do walk-in hood recertification.

13. Heat Exhaust HE1-1 (Phases 1 thru 4)

14. Fire/Smoke Dampers – 10 FSDs will be required to be checked for full operation

(Phases 1 thru 4)

F. After each phase (suffix) of work that is completed, a total recommissioning of the entire mechanical system will be required that was affected by the project work. The equipment that may be affected is listed above, as well as the equipment located on the design documents (plans and schedules).

1.5 COMMISSIONING

A. Commissioning sequence is indicated on Drawings G004 and G005, Sequence of Construction.

B. The Contractor shall schedule all commissioning activities with the Government and

WRRC / lab users prior to starting any work.

C. The Contractor shall perform a walk-through of the systems to be commissioned with the Government/Government’s Commissioning Agent to complete the pre-commissioning checklist (Appendix A).

PART 2 PRODUCTS

Not used.

PART 3 EXECUTION

3.1 COMMISSIONING TEAM AND CHECKLISTS

A. Designate team members to participate in the pre-commissioning checks and the functional performance testing specified. Government will be represented the Contracting Officer. The team members shall include:

1. Contractor's Chief Quality Control Representative

2. Mechanical Representative

3. Contractor's Electrical Representative

4. Contractor's Testing, Adjusting, and Balancing Representative

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5. Contractor's BAS (Building Automation System) Specialist Representative and LCS (Laboratory Control System) Specialist Representative, if applicable

6. Government (WRRC) Representative

7. USDA Quality Assurance Representative

B. Indicate acceptance each pre-commissioning checklist item by initials and date, unless an

"N/A" is shown indicating that participation by the individual is not required. Acceptance by each commissioning team member of each functional performance test checklist shall be indicated by signature and date.

3.2 TEST

A. Perform the pre-commissioning checks and functional performance tests in a manner, which essentially duplicates the checking, testing, and inspection methods established in the related Sections. Where checking, testing, and inspection methods are not specified in other Sections, information methods shall be provided. Perform testing and verification specified in Section 15910, Direct Digital Control Systems during the Commissioning phase. Provide all materials, services, and labor required for performing the pre-commissioning checks and functional performance tests. Abort a pre-commissioning check or functional performance test if any system deficiency prevents the successful completion of the test, or if any commissioning team member whose participation is specified is not present. The Contractor shall reimburse the Government for all costs associated with effort lost due to tests that are aborted. Costs shall include salary, travel costs and per diem (where applicable) for commissioning team members.

3.3 PRE-COMMISSIONING CHECKS

A. Perform pre-commissioning checks for items indicated on the checklists in Appendix A.

Deficiencies discovered during these checks shall be corrected and retested in accordance with the applicable Contract Requirements.

3.4 FUNCTIONAL PERFORMANCE TESTS

A. Perform functional performance tests for the items indicated on the checklists in Appendix B. Begin functional performance tests only after all pre-commissioning checks have been successfully completed.

B. Test shall prove all modes of the sequences of operation, and verify all other relevant

Contract Requirements. Test shall begin with equipment or components and progress through sub-systems to complete systems. Upon failure of any functional performance-test checklist item, the Contractor shall correct all deficiencies in accordance with the applicable Contract Requirements. Repeat checklist without errors.

END OF SECTION 01805

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APPENDIX A

PRE-COMMISSIONING CHECKLISTS

• Piping:

o Heating Hot Water Piping System o Heating Hot Water VAV Units / Reheat Coils o Condenser Water System o Waste and Vent Piping System o Domestic Hot Water System o Domestic Cold Water System o Compressed Air System o Chilled Water System o Steam Piping System o Nitrogen Piping System

• Air Side Systems (air handling units, fan coil units, heat pumps)

• Building Automation System (air handling units, fan coil units, heat pumps, air-cooled chiller, fluid cooler, evaporative cooler)

• HVAC System o Lab Airflow Control System o Humidifier o Exhaust Fans o Heating Systems: Heating Hot Water Heating Coils o Fluid Cooler o Evaporative Cooler o Chillers o Pumps

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Precommissioning Checklist: PIPING

HEATING HOT WATER PIPING SYSTEM

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

Piping complete N/A N/A N/A

As-built shop drawings submitted N/A N/A N/A

Piping flushed and cleaned N/A N/A N/A

Strainers cleaned N/A N/A N/A

Valves installed as required N/A N/A N/A

Piping insulated as required N/A N/A N/A

Thermometers & gauges installed as required N/A N/A N/A

Verify operation of valves N/A N/A N/A

Flexible connectors installed as specified N/A N/A N/A

Verify that piping has been labeled and vales identified as specified

N/A N/A

System pressure tested ( hrs) N/A

Water makeup station installed N/A

Fill pressure set ( PSI) N/A

Safety refill valve setting ( PSI) N/A

Safety relief valve capacity ( PSI) N/A

Backflow preventer installed on CW makeup N/A

Expansion tank online & sized to pumps N/A

Air vent installed (high points in system) manual type N/A

Automatic air vents installed at equipment & coils N/A

Shutoff valves provided to equipment & coils N/A

Chemical pot feeder installed

Balance valves located at coils & equipment N/A

Pumps ready to start – checklist complete

Boilers ready to start – checklist complete

Pipe supports to include seismic complete

Manufacturer’s rep onsite for installation acceptance

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CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

CHEMICAL CLEANING & TREATMENT

Cleaning carried out by qualified personnel N/A

Valves positioned for full circulation

City water circulated ( hrs)

System drained – strainers cleaned N/A

Cleaning solution circulated ( hrs) N/A

Cleaning solution drained – strainers cleaned N/A

2nd City circulation (stable pH and TDH) N/A

Corrosion inhibitor added per manufacturer’s instructions

N/A

System valves cycled during flushing

All low points blown down during flushing N/A

Chemical cleaning report attached N/A

Final PH =

Final TDH =

TESTING, ADJUSTING & BALANCING (TAB)

Hydrostatic test complete N/A N/A

TAB operation complete

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HEATING HOT WATER VARIABLE AIR VOLUME (VAV) UNITS / REHEAT COILS,

AIR-COOLED CHILLER, FLUID COOLER, EVAPORATIVE COOLER

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep Piping complete N/A N/A N/A

As-built shop drawings submitted N/A N/A N/A

Piping flushed and cleaned N/A N/A N/A

Strainers cleaned N/A N/A N/A

Valves installed as required N/A N/A N/A

Piping insulated as required N/A N/A N/A

Thermometers & gauges installed as required N/A N/A N/A

Verify operation of valves N/A N/A N/A

Flexible connectors installed as specified N/A N/A N/A

Verify that piping has been labeled and vales identified as specified

N/A N/A

Air vent installed (high points at coil) manual type N/A N/A

Pete’s Plugs /gauge cock installed N/A N/A

Shut-off valves provided to coils N/A N/A

Drain with shut-off valve and hose connection installed N/A N/A

Balance valves located at coils (circuit setter) N/A N/A

Control valves cycled N/A N/A

Temperature control modulating valve installed N/A N/A

Pipe supports to include seismic complete (as required) N/A N/A

Strainer with drain valve installed N/A N/A

CHEMICAL CLEANING & TREATMENT

Cleaning carried out by qualified personnel N/A N/A

Valves positioned for full circulation N/A N/A

Coil drained – strainers cleaned N/A N/A

Cleaning solution circulated ( hrs) N/A N/A

Cleaning solution drained – strainers cleaned N/A N/A

All low points blown down during flushing N/A N/A

TESTING, ADJUSTING & BALANCING (TAB)

TAB operation complete N/A

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CONDENSER WATER SYSTEM

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep Piping complete N/A N/A N/A

As-built shop drawings submitted N/A N/A N/A

Piping flushed and cleaned N/A N/A N/A

Strainers cleaned N/A N/A N/A

Valves installed as required N/A N/A N/A

Piping insulated as required N/A N/A N/A

Thermometers & gauges installed as required N/A N/A N/A

Verify operation of valves N/A N/A N/A

Air vents installed as specified N/A N/A N/A

Flexible connectors installed as specified N/A N/A N/A

Verify that piping has been labeled and vales identified as specified

N/A N/A

Mountings checked – pump & motor

Alignment by millwright or installer

Seismic restraints installed

Wire fan guard installed

Piping & valves completed and tested

Pumps & fans rotate freely

Pumps, fans & motors lubricated

Electrical interlocks/starters installed

Electrical connection completed

Disconnect switch installed

Overload heaters size __________

Access hatches & ladders on place

Water side stream sand filter installer

Ultraviolet side stream water treatment

Full installed & equal water distribution noted

STARTUP INSPECTION

Pump & fan rotation correct

Electrical interlocks verified

Status indicators verified (local / remotes)

Level control tested

Vibration & noise level acceptable

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Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep Motor amps-rated ____ actual _____

Startup manuf. Rep (checklist attached)

Controls adjusted

Log provided

* This checklist is suitable to prepare most types of cooling towers for startup. Include cooling tower institute test data for ATF.105 when completed for report.

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WASTE AND VENT PIPING SYSTEM

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep Piping complete N/A N/A N/A

As-built shop drawings submitted N/A N/A N/A

Piping flushed and cleaned N/A N/A N/A

Piping flushed and cleaned N/A N/A N/A

All cleanouts tight N/A N/A N/A

Hangers installed as required N/A N/A N/A

Piping sloped as required N/A N/A N/A

Verify operation of valves N/A N/A N/A

Vents through roof installed as specified N/A N/A N/A

No hub stainless connectors installed as specified N/A N/A N/A

Verify that piping has been labeled and vales identified as specified

N/A N/A

TESTING, ADJUSTING & BALANCING (TAB)

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DOMESTIC HOT WATER SYSTEM

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

Piping complete N/A N/A N/A

As-built shop drawings submitted N/A N/A N/A

Piping flushed and cleaned N/A N/A N/A

Strainers cleaned N/A N/A N/A

Valves installed as required N/A N/A N/A

Piping insulated as required N/A N/A N/A

Thermometers and gauges installed as required N/A N/A N/A

Verify operation of valves N/A N/A N/A

Air vents installed as specified N/A N/A N/A

Flexible connectors installed as specified N/A N/A N/A

Verify that piping has been labeled and vales identified as specified

N/A N/A

Verify circulation pump is operation

Verify hot water heater is operational

TESTING, ADJUSTING & BALANCING (TAB)

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DOMESTIC COLD WATER SYSTEM

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

Piping complete N/A N/A N/A

As-built shop drawings submitted N/A N/A N/A

Piping flushed and cleaned N/A N/A N/A

Strainers cleaned N/A N/A N/A

Valves installed as required N/A N/A N/A

Piping insulated as required N/A N/A N/A

Thermometers and gauges installed as required N/A N/A N/A

Verify operation of valves N/A N/A N/A

Air vents installed as specified N/A N/A N/A

Flexible connectors installed as specified N/A N/A N/A

Verify that piping has been labeled and vales identified as specified

N/A N/A

TESTING, ADJUSTING & BALANCING (TAB)

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COMPRESSED AIR SYSTEM

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

Piping complete N/A N/A N/A

As-built shop drawings submitted N/A N/A N/A

Piping flushed and cleaned N/A N/A N/A

Strainers cleaned N/A N/A N/A

Valves installed as required N/A N/A N/A

Piping supported as required N/A N/A N/A

Gauges installed as required N/A N/A N/A

Verify operation of valves N/A N/A N/A

Air outlet stations w/quik-disconnects installed as specified

N/A N/A N/A

Flexible connectors installed as specified N/A N/A N/A

Verify that piping has been labeled and valves identified as specified

N/A N/A

Verify that compressor, air dryer, receiver, and filter are operational

Verify pressure relief valves installed and set at proper psi setting.

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CHILLED WATER SYSTEM

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Controls Rep

Contracting Officer

Rep

Piping complete N/A N/A N/A

As-built shop drawings submitted N/A N/A N/A

Piping flushed and cleaned N/A N/A N/A

Strainers cleaned N/A N/A N/A

Valves installed as required N/A N/A N/A

Piping insulated as required N/A N/A N/A

Thermometers and gauges installed as required N/A N/A N/A

Verify operation of valves N/A N/A N/A

Flexible connectors installed as specified N/A N/A N/A

Verify that piping has been labeled and valves identified as specified

N/A N/A

System pressure tested ( hrs)

Water make-up station installed

Fill pressure set ( PSI) N/A

Safety relief valve setting ( PSI) N/A

Safety relief valve capacity ( PSI) N/A

Back flow preventer installed on CW make-up N/A

Air separator provided prior to pumps N/A

Expansion tank on-line & sized to pumps N/A

Air vent installed (high points in system) manual type N/A

Automatic air vents installed at equipment & coils N/A

Pumps ready to start- checklist complete

Balance valves located at coils & equipment N/A

Shut off valves provided to equipment & coils N/A

Chiller controls activated

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Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Controls Rep

Contracting Officer

Balance valves located at coils & equipment N/A

Controls system complete (end to end)

Pipe insulation installed complete N/A N/A N/A

Pumps ready to start- checklist complete

Pipe supports to include seismic complete N/A N/A N/A

Chemical Cleaning & Treatment N/A N/A

Cleaning carried out by Qualified personnel N/A N/A N/A

Valves positioned for full circulation N/A

City water circulated ( hrs) N/A

System drained-strainers cleaned N/A

Cleaning solution circulated ( hrs) N/A

Cleaning solution drained-strainers cleaned N/A

2nd City circulation (stable PH & TDH) N/A

Corrosion inhibitor added per manuf. Instruc N/A

Final PH = N/A

Final TDH = N/A

Chemical concentration = PPM N/A

TESTING, ADJUSTING, AND BALANCING (TAB)

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STEAM PIPING SYSTEM

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Controls Rep

Contracting Officer

Air vents installed as specified N/A N/A N/A

Verify that piping has been labeled and valves identified as specified

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NITROGEN PIPING SYSTEM

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Controls Rep

Contracting Officer

Piping supported as required N/A N/A N/A

Nitrogen outlet stations w/quik-disconnects installed as specified

N/A N/A N/A

Flexible tubing at tanks to change over manifold installed as specified

Verify that tanks are racked and supported to meet code

Verify pressure relief valves installed and set at proper psi setting

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Precommissioning Checklist: AIR SIDE SYSTEMS

AIR HANDLING UNITS, FAN COIL UNITS, AND HEAT PUMPS

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

Vibration isolation devices installed N/A N/A N/A

Inspection and access doors are operable and sealed N/A N/A

Casing undamaged N/A N/A N/A

Insulation undamaged N/A N/A N/A

Condensate drainage is unobstructed (visually verify drainage by pouring a cup of water into drain pan)

N/A N/A N/A

Fan belt adjusted N/A N/A N/A

Manufacturer’s required maintenance clearance provided

N/A N/A N/A

ELECTRICAL

Power available to unit disconnect N/A N/A

Power available to unit control panel N/A

Proper motor rotation verified N/A N/A

Verify that power disconnect is located within sight of unit it controls

N/A

PIPING

Chilled water piping properly connected N/A N/A N/A

Chilled water piping pressure tested N/A N/A N/A

Hot water piping properly connected N/A N/A N/A

Steam and condensate piping properly connected N/A N/A N/A

Hot water piping pressure tested N/A N/A N/A

Steam and condensate piping pressure tested N/A N/A N/A

Air vents installed on water coils as specified N/A N/A N/A

Any damage to coil fins has been repaired N/A N/A N/A

CONTROL

Control valves/actuators properly installed N/A N/A

Dampers/actuators properly installed N/A N/A

Vibration isolation device installed N/A N/A

Dampers/actuators operable N/A N/A

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Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

Verify proper location, installation and calibration of duct static pressure sensors

N/A N/A

Variable speed drive operable N/A

Air handler controls system operational N/A N/A

TESTING, ADJUSTING AND BALANCING (TAB)

Construction filters removed and replaced N/A

TAB report submitted N/A N/A

TAB results within +10% / -0% of L/S shown on drawings

TAB results for outside air intake within +10% / -0% of both the minimum and maximum L/S shown on

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Precommissioning Checklist: BUILDING AUTOMATION SYSTEM

HVAC SYSTEM - AIR HANDLING UNITS, FAN COIL UNITS, AND HEAT PUMPS. PUMPS,

AIR-COOLED CHILLER, FLUID COOLERS, EVAPORATIVE COOLER

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

As-built shop drawings submitted N/A N/A

Layout of control panel matches drawings N/A N/A

Framed instructions mounted in or near control panel N/A N/A

Components properly labeled (on inside and outside of panel)

N/A N/A

Control components piped and/or wired to each labeled terminal strip

N/A N/A

EMCS connection made to each labeled terminal strip as shown

N/A N/A

Control wiring and tubing labeled at all terminations, splices, and junctions

N/A N/A

Shielded wiring used on electronic sensors N/A N/A

Air dryer installed as specified N/A N/A

Water drain installed as specified N/A N/A

MAIN POWER AND CONTROL AIR

110 volt AC power available to panel N/A

138 kPa gauge (20 psig) compressed air available to panel

N/A N/A

TESTING, COMMISSIONING & BALANCING

Testing, commissioning, and balancing report submitted

N/A

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Precommissioning Checklist: HVAC SYSTEMS

LAB AIR FLOW CONTROL

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

As-built shop drawings submitted N/A N/A

Layout of control panel matches drawings N/A N/A

Framed instructions mounted in or near control panel N/A N/A

Components properly labeled (on inside and outside of panel)

N/A N/A

Control components piped and/or wired to each labeled terminal strip

N/A N/A

EMCS connection made to each labeled terminal strip as shown

N/A N/A

Control wiring and tubing labeled at all terminations, splices, and junctions

N/A N/A

Shielded wiring used on electronic sensors N/A N/A

Air dryer installed as specified N/A N/A

Water drain installed as specified N/A N/A

MAIN POWER AND CONTROL AIR

110 volt AC power available to panel N/A

138 kPa gauge (20 psig) compressed air available to panel

N/A N/A

TESTING, COMMISSIONING & BALANCING

Testing, commissioning, and balancing report

N/A

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Precommissioning Checklist: HVAC SYSTEM

HUMIDIFIER

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Controls Rep

Contracting Officer

As-built shop drawings submitted N/A N/A

Layout of control panel matches drawings N/A

Framed instructions mounted in or near control panel N/A N/A

Components properly labeled (on inside and outside of panel) N/A N/A

Control components piped and/or wired to each labeled terminal strip N/A N/A

EMCS connection made to each labeled terminal strip as shown N/A

Control wiring and tubing labeled at all terminations, splices, and junctions N/A

Shielded wiring used on electronic sensors N/A

Drain cooler installed as specified N/A

MAIN POWER AND CONTROL AIR

110 volt AC power available to panel N/A

138 kPa gauge (20 psig) 20 psig compressed air available to panel N/A

TESTING, COMMISSIONING AND BALANCING

Testing, commissioning and balancing report

USDA, Recovery-Major Renovations, Phases 3-6 Page 33 of 63 Rev. 1

USDA, Recovery-Major Renovations, Phases 3-6 Page 34 of 63 Rev. 1

EXHAUST FANS

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Controls Rep

Contracting Officer

Rep

Mounting checked (shipping bolts removed) N/A N/A

Vibration isolators installed N/A N/A

Seismic restraints installed N/A

Equipment guards installed N/A

Pulleys aligned & belt tension correct N/A

Plenums clear & free of loose material N/A

Fans rotate freely N/A

Fans motors & linkages lubricated N/A N/A

Smoke & fire dampers (or combination) if req’d.

Balance dampers positioned & locked N/A

Backdraft dampers free to operate N/A

Weather proofing required N/A N/A

Electrical connections complete N/A

Explosion proofing if required N/A

Disconnect switch installed N/A

Overload heaters in place (sized correctly) N/A

Building & fan room clean for start-up N/A

Ductwork flexible connectors installed N/A N/A

Material used applicable to type of exhaust stream N/A N/A

Exhaust stream air treatment N/A N/A

USDA, Recovery-Major Renovations, Phases 3-6 Page 35 of 63 Rev. 1

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Controls Rep

Contracting Officer

Rep

START-UP INSPECTION

Fan rotation correct

Electrical interlocks verified

Fan status indicators verified (Local/Remote)

Local Air leakage acceptable N/A N/A

Vibration & noise level acceptable

Motor Amps – Rated_____Actual____

Motor Volts – Rated _____Actual____

ELECTRICAL

Power available to fan disconnect N/A N/A

Proper motor rotation verified

Verify that power disconnect is located within sight of the unit it controls

CONTROLS

Control interlocks properly installed N/A

Control interlocks operable

Dampers/actuators properly installed N/A

Dampers/actuators operable

Verify proper location and installation of thermostat

TESTING, ADJUSTING, AND BALANCING (TAB)

TAB results +10%/-0% to L/s cfm shown on drawings

TAB report submitted

USDA, Recovery-Major Renovations, Phases 3-6 Page 36 of 63 Rev. 1

HEATING HOT WATER HEATING COILS

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Controls Rep

Contracting Officer

Piping complete N/A N/A

As-built shop drawings submitted N/A N/A

Valves installed as required N/A N/A

Thermometers and gauges installed as required N/A N/A

Verify operation of valves N/A

Air vents installed as specified N/A N/A N/A

USDA, Recovery-Major Renovations, Phases 3-6 Page 37 of 63 Rev. 1

USDA, Recovery-Major Renovations, Phases 3-6 Page 38 of 63 Rev. 1

FLUID COOLER

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep Fluid cooler in place N/A

Fluid cooler piped N/A N/A

Fluid cooler fan drive adjusted N/A

Fluid cooler makeup water supply piped N/A N/A

Verify makeup control valve shutoff N/A N/A

Fan lubricated and blade pitch adjusted N/A N/A

Manufacturer's required maintenance/operational clearance provided

N/A N/A

ELECTRICAL

Power available to cooler disconnect N/A

Power available to electric sump heater N/A

Control system interlocks functional N/A

Motor and fan rotation checked N/A

Verify that power disconnect is located within sight of the unit it controls

N/A

PIPING

Fluid cooler basin is clean and filled N/A N/A N/A

Condenser water treatment functional for both closed loop and open recirculation water loop

N/A N/A N/A

Water balance with design flow verified N/A N/A

Water distribution headers balanced N/A N/A

CONTROL

Control valves/actuators properly installed N/A N/A

Dampers/actuators properly installed N/A N/A

Dampers/actuators operable N/A N/A

Verify proper location, installation and calibration of leaving water temperature sensor

USDA, Recovery-Major Renovations, Phases 3-6 Page 39 of 63 Rev. 1

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

Variable speed drive operable N/A

Fluid cooler controls system operational N/A N/A

TESTING, ADJUSTING, AND BALANCING (TAB)

Construction strainers removed and replaced N/A

TAB report submitted N/A N/A

USDA, Recovery-Major Renovations, Phases 3-6 Page 40 of 63 Rev. 1

EVAPORATIVE COOLER

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep Evaporative cooler in place N/A

Evaporative cooler drain piping installed and routed to drain

N/A N/A

Evaporative cooler fan belts adjusted N/A N/A

Evaporative cooler makeup water supply piped N/A N/A

Verify makeup control valve shutoff N/A N/A

Fan lubricated and blade pitch adjusted N/A N/A

Manufacturer's required maintenance/operational clearance provided

N/A N/A N/A

Fan spring isolators have been adjusted N/A N/A N/A

Flexible connection has been installed between fan section and discharge of cabinet

N/A N/A N/A

Confirm wet section is stainless steel Grade 304 N/A N/A N/A

ELECTRICAL

Power available to cooler disconnect N/A

Control system interlocks functional N/A

Motor and fan rotation checked N/A

Verify that power disconnect is located within sight of the unit it controls

N/A

PIPING

Evaporative cooler basin is clean and filled N/A N/A N/A

Water balance with design flow verified N/A N/A

Water distribution headers balanced N/A N/A

CONTROL

Control valves/actuators properly installed N/A N/A

Dampers/actuators properly installed N/A N/A

Dampers/actuators operable N/A N/A

Verify proper location, installation and calibration of thermostat

USDA, Recovery-Major Renovations, Phases 3-6 Page 41 of 63 Rev. 1

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep

Two variable speed drive operable N/A

TESTING, ADJUSTING, AND BALANCING (TAB)

TAB report submitted N/A N/A

USDA, Recovery-Major Renovations, Phases 3-6 Page 42 of 63 Rev. 1

CHILLER

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep Chilled water connections properly piped

N/A N/A

Condenser water connections properly piped (if water cooled)

Chilled water pipe leak tested

High efficiency purge unit installed and operating as specified

Refrigerant leak detector installed N/A Oxygen sensor installed and tested N/A Mechanical room ventilation installed as specified N/A Manufacturer's required maintenance clearance provided N/A N/A N/A Field assembled couplings aligned to meet manufacturer's prescribed tolerances

Vibration isolation & seismic restraints installed N/A Installation complete Equipment & piping insulation installed N/A Equipment & piping identification N/A Shut off valves for isolation installed N/A Electrical connections/voltage checked Safety controls complete & operational Sensor & gauge location noted N/A Chiller controls complete & operational Local valving & piping correct N/A Electrical interlocks completed Chilled water temp. set point = _____deg. F N/A Overload protection heater size:_____ Chemical treatment completed N/A Emergency shower/eyewash in area N/A Refrigerant monitoring system installed Chiller room ventilation system is operational N/A

CHILLER STARTUP INSPECTION

Startup by manufacture’s representative Startup by manufacture’s representative Startup by manufacture’s representative Safety cutout- temperature Safety cutout – pressure Electrical interlocks tested Pressure & temperature gauges checked N/A Water temperature maintained N/A Pump interlocks tested Motor Amps – Rated_____Actual_____ Motor Volts – Rated _____Actual_____

USDA, Recovery-Major Renovations, Phases 3-6 Page 43 of 63 Rev. 1

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep Manufacturer’s start-up sheets attached

* This checklist is suitable to prepare most types of chillers for start-up. Start-up technician should follow manufacturer’s equipment specific checklist & submit copy for report

ELECTRICAL

Power available to unit starter X Power available to unit control panel X

X

CONTROLS

Factory startup and checkout complete X X Chiller safety/protection devices tested X Chilled water flow switch installed X X Chilled water flow switch tested X X Chilled water pump interlock installed X Chilled water pump interlock tested X Condenser water flow switch installed X Condenser water flow switch tested X Condenser water pump interlock installed X Condenser water pump interlock test X

USDA, Recovery-Major Renovations, Phases 3-6 Page 44 of 63 Rev. 1

PUMPS/WATER SYSTEM

CHECKLIST ITEM

INSTALLATION

Quality Control

Rep

Mechanical Rep

Electrical Rep

TAB

Rep

Control s Rep

Contracting Officer

Rep Pumps grouted in place N/A N/A N/A Pump vibration isolation devices functional N/A N/A N/A Pump/motor coupling alignment verified N/A N/A N/A Piping system installed N/A N/A N/A Piping system pressure tested N/A N/A N/A Pump not leaking N/A N/A N/A Mounting checked – pump & motor Alignment by millwright or installer Seismic restraints installed N/A Piping supported & seismically restrained N/A Equipment Guards installed N/A Pump rotate freely N/A Pump & Motor lubricated N/A Local valve set for normal operation N/A Pressure gauges in supply & return piping N/A Disconnect switch installed Overloads heaters installed (size correctly) Pipe & Equipment insulation provided N/A Shut off valves for insulation installed N/A Vibration isolation installed N/A Flexible connectors installed N/A Drain leg provided N/A Balancing valve installed N/A

START-UP INSPECTION

Pump rotation correct Electrical interlocks verified Pump status indicators verified (Local/Remote) Check valve operation tested System static pressure N/A Vibration & noise level acceptable N/A Motor Amps – Rated _______Actual_______ Motor Volts – Rated _______Acutal________

ELECTRICAL

Power available to pump disconnect Pump rotation verified Control system interlocks functional

Pressure/temperature gauges installed X X Piping system cleaned, incl strainers and suction diffuser X X X Chemical water treatment complete X X X Water balance complete X X Water balance with design maximum flow X X TAB report submitted X X

USDA, Recovery-Major Renovations, Phases 3-6 Page 45 of 63 Rev. 1

USDA, Recovery-Major Renovations, Phases 3-6 Page 46 of 63 Rev. 1

APPENDIX B

FUNCTIONAL PERFORMANCE TESTS CHECKLIST

• Variable Air Volume ( air handling units, fan coil units, heat pumps)

• Exhaust Fans

• Building Automation System

• Humidifier

• Pumps

• Chillers

• Fluid Cooler

• Evaporative Cooler

USDA, Recovery-Major Renovations, Phases 3-6 Page 47 of 63 Rev. 1

USDA, Recovery-Major Renovations, Phases 3-6 Page 48 of 63 Rev. 1

Functional Performance Test Checklist

VARIABLE AIR VOLUME AIR HANDLING UNIT, FAN COIL UNITS, HEAT PUMPS

TAG NO. ________

Ensure that a slight negative pressure exists on in-board side of the outside air dampers throughout the operation of the dampers. Modulate OA, RA, and EA dampers from fully open to fully closed positions.

1. Functional Performance Test: Verify operation of air handling unit as specified and including the following:

a. The following shall be verified when the [supply fan operating] [supply and return fans operating] mode is initiated:

1) All dampers in normal position [and fan inlet valves modulate to maintain the required static pressure]:

2) All valves in normal position:

3) System safeties allow start if safety conditions are met:

4) VAV fan controller shall “soft-start” fan:

5) VFD operation ______________________ Built-in safety __________________________

b. Occupied mode of operation – economizer de-energized:

1) Outside air damper at minimum position:

2) Return air damper open:

3) Relief air damper (at minimum position] [closed]:

4) Chilled water control valve modulating to maintain leaving air temperature set point:

c. Occupied mode of operation – economizer energized:

1) Outside air damper modulated to maintain mixed air temperature set point:

2) Relief air damper modulates with outside air damper according to sequence of operation:

3) Chilled water control valve modulating to maintain leaving air temperature setpoint:

4) Hot water control valve modulating to maintain leaving air temperature setpoint:

d. Unoccupied mode of operation:

1) All dampers in normal position: Open Closes

2) Verify low limit space temperature is maintained as specified in sequence of operation: Night time setback setpoints:

e. The following shall be verified when the [supply fan off] [supply and return fans off] mode is initiated:

1) All dampers in normal position: Open Closes

2) All valves in normal position: Open Closes

3) Fan de-energizes:

USDA, Recovery-Major Renovations, Phases 3-6 Page 49 of 63 Rev. 1 Section 01805, Commissioning of Mechanical Systems

f. Verify the chilled water coil control valve operation by setting all VAV’s to maximum and minimum cooling:

VFD Hz Design

Max Cooling Min Cooling

Supply air volume ( cfm) Supply air temperature ( º F)

g. Verify safety shutdown initiated by smoke detectors:

h. Verify safety shutdown initiated by low temperature protection thermostat:

Set PT Outside air damper closes

i. Freeze stet works:

HHW Valves Open Closes CHW Valves Open Closes

j. Location of room thermostat:

Duct Room No.

2. Smoke Fire Dampers (SFD)

SFD’s interlocked with AHU? Yes No Do SFD’s open/close correctly? Yes No SFD’s shutdown AHU motor? Yes No Other equipment? Yes No

3. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications:

Signature and Date

Contractor's Chief Quality Control Representative Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's Testing, Adjusting and Balancing Representative Contractor's BAS Representative Contracting Officer's Representative

USDA, Recovery-Major Renovations, Phases 3-6 Page 50 of 63 Rev. 1

EXHAUST FANS

1. Functional Performance Test: Verify operation of exhaust fans as specified and including the following:

a. The following shall be verified when the supply fan operating mode is initiated:

• All dampers in normal position and fan VSD modulates to maintain the required building pressure relationships

• All volume dampers balanced for occupied air flow:

• System safeties allow start if safety conditions are met:

• VFD fan controller shall "soft-start" fan:

• VFD Operational:

• Built-in Safeties:

b. Occupied mode of operation:

• Fan VFD controller receiving signal from duct static pressure sensor and modulating fan to maintain building pressure differential setpoints:

b. Unoccupied mode of operation:

• All dampers in normal position:

• Verify low limit space temperature is maintained as specified in sequence of operation:

c. The following shall be verified when the occupied and unoccupied mode is initiated:

• All dampers in normal position, equipment on:

Design Max Cooling Min Cooling VFD Hz Exhaust air volume ( cfm)

e. Verify safety shutdown initiated by smoke detectors:

f. Verify building pressure requirements satisfied:

2. Smoke/Fire Dampers:

a. Smoke fire dampers (SFD) interlocked with what equipment?

AHU#

Exhaust Fan#

USDA, Recovery-Major Renovations, Phases 3-6 Page 51 of 63 Rev. 1 Section 01805, Commissioning of Mechanical Systems

b. SFD Shutdown

AHU#

Exhaust Fan#

c. Do the SFDs open/close correctly? Yes No

d. Building/room pressure requirements:

3. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the Specifications:

Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's Testing, Adjusting and Balancing Representative

USDA, Recovery-Major Renovations, Phases 3-6 Page 52 of 63 Rev. 1

BUILDING AUTOMATION SYSTEMS

For HVAC System:

Contracting Officer will select BAS control systems to undergo functional performance testing. The number of systems will not exceed 10 percent.

1. Functional Performance Test: Verify operation of BAS controls by performing the following tests:

a. Verify that controller is maintaining the setpoint by manually measuring the controlled variable with a thermometer, sling psychrometer, inclined manometer, etc.

b. Verify sensor/controller combination by manually measuring the controlled medium. Take readings from control panel display and compare readings taken manually. Record all readings.

Sensor:

Manual measurement:

Panel reading value:

c. Verify system stability by changing the controller setpoint as follows:

1) Air temperature: 10º F

2) Water temperature: 10º F

3) Static pressure: 10 percent of setpoint

4) Relative humidity: percent (RH)

Observe control system for 10 minutes after change in setpoint. Instability or excessive hunting is unacceptable.

d. Verify interlock with other BAS controls.

e. Verify interlock with fire alarm control panel.

f. Verify interlock with EMCS.

g. Change controller setpoint 10 percent with EMCS and verify correct response.

2. Verify that operation of control system conforms to that specified in the sequence of operation.

3. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications:

Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's Testing, Adjusting and Balancing Representative

USDA, Recovery-Major Renovations, Phases 3-6 Page 53 of 63 Rev. 1

USDA, Recovery-Major Renovations, Phases 3-6 Page 54 of 63 Rev. 1

HUMIDIFIER

TAG NO. _________

Prior to performing this checklist, ensure that all controls, piping, electrical connections, dispersion tube have been installed properly.

1. Adjust humidistat to “call” setting. Does it call for steam?

2. Check function of field installed airflow switch. Does it work?

3. Check function of field installed duct high limit (RH) stat Setpoint

4. Test cycling the drain/flush system. (Check pin locations 20, 40 80 minutes). Drain cycling set at ______

5. Steam inlet pressure is.

6. PRV station set at 15 psi

7. All valves in correct position.

a. Steam line open to control valve.

b. Drain line open to drain cooler.

8. Automatic steam valve installed and operational.

9. Steam traps installed and operational on.

a. Steam supply.

b. Dispersion tube.

c. Before control valve.

10. Traps / P traps installed on humidifier drain line to drain cooler.

11. Traps / P traps installed on humidifier steam dispersion tube line to drain cooler.

12. All condensate piping sloped properly.

13. Water (valve) line installed and operational.

14. Room humidistat is reading back to BMS system properly.

15. Room humidistat is set at 35 to 50 %.

16. Drain cooler installed and operating properly

a. Any blow-by steam thru traps?

b. Water valve working properly (opening/closing).

USDA, Recovery-Major Renovations, Phases 3-6 Page 55 of 63 Rev. 1 Section 01805, Commissioning of Mechanical Systems

17. Certification: We the undersigned have witnessed the above functional performance tests and certify that the

Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's Testing, Adjusting and Balancing Representative

USDA, Recovery-Major Renovations, Phases 3-6 Page 56 of 63 Rev. 1

PUMPS

Prior to performing this checklist, ensure that for closed loop systems, system is pressurized and the make-up water system is operational or, for open loop systems, that the sumps are filled to the proper level.

1. Activate pump start using control system commands (all possible combination, on/auto, etc).

ON AUTO OFF

a. Verify pressure drop across strainer:

Strainer inlet pressure psig Strainer outlet pressure psig

b. Verify pump inlet/outlet pressure reading, compare to Testing, Adjusting, and Balancing (TAB) Report, pump design conditions, and pump manufacturer's performance.

DESIGN TAB ACTUAL

Pump inlet pressure (psig) Pump outlet pressure (psig)

c. Operate pump at shutoff and at 100 percent of designed flow when all components are in full flow when all components are in full flow. Plot test readings on pump curve and compare results against readings taken from flow measuring devices

SHUTOFF 100 PERCENT

Pump inlet pressure (psig) Pump outlet pressure Pump flow rate (gpm)

d. Operate pump at shutoff and at minimum flow or when all components are in full by-pass. Plot test readings on pump curve and compare results against readings taken from flow measuring devices.

SHUTOFF 100 PERCENT

Pump inlet pressure (psig) Pump outlet pressure Pump flow rate (gpm)

2. Verify motor amperage each phase and voltage phase to phase and phase to ground for both the full flow and the minimum flow conditions.

a. Full Flow:

Phase 3 Phase 4 Phase 5 Phase 6 RERA Amperage Voltage Voltage Voltage to ground

USDA, Recovery-Major Renovations, Phases 3-6 Page 57 of 63 Rev. 1

b. Minimum Flow:

Phase 3 Phase 4 Phase 5 Phase 6 RERA Amperage Voltage Voltage Voltage to ground

3. Unusual vibration, nose, etc.

4. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications.

Signature and Date

Contractor's Chief Quality Control Representative Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's Testing, Adjusting and Balancing Representative

USDA, Recovery-Major Renovations, Phases 3-6 Page 58 of 63 Rev. 1

CHILLERS

1. Functional Performance Test: Demonstrate operation of chilled water system as specified and including the following: Start building air handler to provide load for chiller. Activate controls system chiller start sequence as indicated:

a. Time of day startup program initiates chiller start:

b. Start condenser water pump and establish condenser water flow. Verify chiller condenser water proof-of-flow switch operation:

c. Start chilled water pump and establish chilled water flow. Verify chiller chilled water proof-of-flow switch operation:

d. Verify control system energizes chiller start sequence:

e. Verify chiller senses chilled water temperature above set point and control system activates chiller start:

f. Verify functioning of "soft start" sequence:

g. Shut off air handling equipment to remove load on chilled water system. Verify chiller shutdown sequence is initiated and accomplished after load is removed:

h. Restart air-handling equipment 1-minute after chiller shutdown. Verify condenser water pump, cooling tower, and chiller restart sequence:

2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the

Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's Testing, Adjusting and Balancing Representative

USDA, Recovery-Major Renovations, Phases 3-6 Page 59 of 63 Rev. 1

USDA, Recovery-Major Renovations, Phases 3-6 Page 60 of 63 Rev. 1

FLUID COOLER

1. Functional Performance Test: Demonstrate operation of the fluid cooler as specified and the following:

a. Activate fluid cooler fan start using control system command. This should first start condenser water pump, establish flow, delay fan start, as specified, to equalize flow in distribution basin and sump.

Verify fan start after timed delay:

b. After fluid cooler startup, control system should modulate variable speed fan motor to maintain condenser water set point. Verify function temperature controls under varying loads:

c. Verify makeup water float valve is functioning:

d. Activate chemical treatment feed valve, verify makeup of chemical treatment system, pump, and controls:

f. Entering water temperature: [ ] degrees F Leaving water temperature: [ ] degrees F Air volume measured: [ ] cfm Air volume calculated: [ ] cfm Entering wet bulb temperature: [ ] degrees F Measured water flow [ ] gpm

2. Certification: We the undersigned have witnessed the above functional performance tests and certify that the item tested has met the performance requirements in this section of the specifications.

Signature and Date

Contractor's Chief Quality Control Representative Contractor's Mechanical Representative Contractor's Electrical Representative Contractor's Testing, Adjusting and Balancing Representative

USDA,…