15910 Add 2.doc

Interior Renovations at U.S. Courthouse

GSA Number: GS-03P-98-CDC-0019

Pittsburgh, Pennsylvania

SECTION 15910

COMMISSIONING OF HVAC

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.

1.2 Description

A. Commissioning is a systematic process of ensuring that all building systems perform interactively according to the design intent and the governments operational needs. This is achieved by beginning in the construction phase, acceptance and the warranty period with actual verification of performance. The commissioning process shall encompass and coordinate the traditionally separate functions of system documentation, equipment startup, control system calibration, testing and balancing, performance testing and training.

B. This project contains phased construction, with in the phased construction periods each system completed and delivered for substantial use shall be fully commissioned before acceptance by the CO. Upon completion of the final phase of construction C. Commissioning during the construction phase is intended to achieve the following specific objectives according to the Contract Documents:

1. Verify that applicable equipment and systems are installed according to the contract documents, the manufacturer’s recommendations and to industry accepted minimum standards and that they receive adequate operational checkout by installing Contractors/Sub-Contractors.

2. Verify and document proper performance of equipment and systems.

3. Verify that O&M documentation left on site is complete.

4. Verify that the Government’s operating personnel are trained.

D. The commissioning process does not take away from or reduce the responsibility of the system designers or installing Contractors/Sub-Contractors to provide a finished and fully functioning product.

E. Approximately 10 months after Final Acceptance the Commissioning Team shall complete a Warranty Walk to review any issues noted by the Building Manager and Construction Manager. The TAB (test and Balance) contractor shall perform sample air and water balance readings relating to warranty issues as directed by the Construction Manager.

1.3 Definitions

1. Acceptance Phase - phase of construction after startup and initial checkout when functional performance tests, O&M documentation review and training occur.

2. Approval - acceptance that a piece of equipment or system has been properly installed and is functioning in the tested modes according to the Contract Documents.

3. Architect / Engineer (A/E) - the prime consultant and sub-consultants who comprise the design team, generally the HVAC mechanical designer/engineer and the electrical designer/engineer.

4. Commissioning Authority (CxA) - an agent, not otherwise responsible for the design or the construction. The CxA directs and coordinates the day-to-day commissioning activities. The CxA does not take an oversight role like the Construction Manager. The CxA is part of the commissioning team and shall report directly to the Construction Manager.

5. Construction Checklist (CC) - a list of items to inspect and elementary component tests to conduct to verify proper installation of equipment, provided by the CxA to the General contractor. Construction and startup checklists are primarily static inspections and procedures to prepare the equipment or system for initial operation (e.g., belt tension, oil levels OK, labels affixed, gages in place, sensors calibrated, etc.). However, some construction and startup checklist items entail simple testing of the function of a component, a piece of equipment or system (such as measuring the voltage imbalance on a three phase pump motor of a chiller system). Construction and startup checklists augment and are combined with the manufacturer’s startup checklist.

6. Construction Manager (CM) - the contracting and managing authority for the owner over the construction of the project.

7. Contracting Officer’s Technical Representative (COTR) – the governments point of contact for this construction project.

8. Contracting Officer (CO)- The governments individual having final approval of installation and all contract issues.

9. Contract Documents - the documents binding on parties involved in the construction of this project (drawings, specifications, change orders, amendments, contracts, etc.).

10. Contractors/Sub-Contractors – Construction Contractors and their Sub-Contractors who are awarded a contract for the construction or some aspect of the construction of the project in accordance with the contract documents.

11. Control System - the central building direct digital control system.

12. Deferred Functional Tests - FTs that are performed later, after substantial completion, due to partial occupancy, equipment, seasonal requirements, design or other site conditions that disallow the test from being performed.

13. Deficiency - a condition in the installation or function of a component, piece of equipment or system that is not in compliance with the Contract Documents (that is, does not perform properly or is not complying with the sequence of operations).

14. Factory Testing - testing of equipment on-site or at the factory, by factory personnel with an Construction Managers representative present.

15. Functional Performance Test (FT) - test of the dynamic function and operation of equipment and systems using manual (direct observation) or monitoring methods. Functional testing is the dynamic testing of systems (rather than just components) under full operation. Systems are tested under various modes, such as during low cooling or heating loads, high loads, component failures, unoccupied, varying outside air temperatures, fire alarm, power failure, etc. The systems are run through all the control system’s sequences of operation and components are verified to be responding as the sequences state. Traditional air or water test and balancing (TAB) is not functional testing, in the commissioning sense of the word. TAB’s primary work is setting up the system flows and pressures as specified, while functional testing is verifying that which has already been set up. The commissioning authority develops the functional test procedures in a sequential written form, coordinates, oversees and documents the actual testing, which is usually performed by the installing Contractors/Sub-Contractors or vendor. FTs are performed after construction checklists and startup are complete.

16. General Contractors (GC) - the prime Contractor awarded this project. General contractor shall coordinate, communicate and direct the entire process of construction in terms of scope, quality, time and cost within the authority and responsibility limits of the contract documents. Generally refers to all the GC’s Sub-Contractors as well. Also referred to as the Contractors in some contexts.

17. Indirect Indicators - indicators of a response or condition, such as a reading from a control system screen reporting a damper to be 100% closed.

18. Manual Test - using hand-held instruments, immediate control system readouts or direct observation to verify performance (contrasted to analyzing monitored data taken over time to make the “observation”).

19. Monitoring - the recording of parameters (flow, current, status, pressure, etc.) of equipment operation using dataloggers or the trending capabilities of control systems.

20. Non-Compliance - see Deficiency.

21. Non-Conformance - see Deficiency.

22. Over-written Value - writing over a sensor value in the control system to see the response of a system (e.g., changing the outside air temperature value from 50(F to 75(F to verify economizer operation). See also “Simulated Signal.”

23. Sampling - functionally testing only a fraction of the total number of identical or near identical pieces of equipment. Refer to Part 3.6, F for details.

24. Seasonal Performance Tests - FT that are deferred until the system(s) shall experience conditions closer to their design conditions.

25. Simulated Condition - condition that is created for the purpose of testing the response of a system (e.g., applying a hair dryer to a space sensor to see the response in a VAV box).

26. Simulated Signal - disconnecting a sensor and using a signal generator to send an amperage, resistance or pressure to the transducer and DDC system to simulate a sensor value.

27. Specifications - the construction specifications of the Contract Documents.

28. Startup - the initial starting or activating of dynamic equipment, including executing startup checklists.

29. Subs - the subcontractors to the General Contractor who provide and install building components and systems.

30. TAB Contractor – the sub-contractor to the General Contractor responsible for adjustments of all equipment and systems installed as part of this project. This contractor shall provide adjustment as needed to attain the performance requirements indicated in the documents, prior to review by CxA.

31. Test Procedures - the step-by-step process that must be executed to fulfill the test requirements. The CxA develops the test procedures.

32. Test Requirements - requirements specifying what modes and functions, etc. shall be tested. The test requirements are not the detailed test procedures. The test requirements are specified in the Contract Documents.

33. Trending - monitoring using the building control system.

34. Vendor - supplier of equipment.

35. Warranty Period - warranty period for entire project, including equipment components. Warranty begins at Substantial Completion and extends for at least one year, unless specifically noted otherwise in the Contract Documents and accepted submittals. Equipment that does not initially pass seasonal or deferred functional testing shall have the warranty start date adjusted to date of passing test completion.

1.4 Coordination

A. Commissioning Team. The members of the commissioning team consist of the Commissioning Authority (CxA), the Construction Manager, the General Contractor , the design Architects/Engineers (A/E), the Mechanical Contractors/Sub-Contractors (MC), the Testing, Adjusting and Balancing Contractor (TAB), the Controls Contractor (ATC), including all government representatives (COTR), fire protection representatives, and electrical sub-contractors, and any other installing subcontractors or suppliers of equipment.

B. Management. The Construction Manager hires the CxA directly. The CxA directs and coordinates the commissioning activities and is part of the commissioning team. The CxA is responsible to the CM and shall provide recommendations to the CM and COTR.

C. Scheduling. The CxA shall work with the General Contractor according to established protocols to schedule the commissioning activities. The CxA shall provide sufficient notice to the General Contractor for scheduling commissioning activities. The General Contractor shall integrate all commissioning activities into the Construction schedule. All parties shall address scheduling problems and make necessary notifications in a timely manner in order to expedite the commissioning process.

D. The (CO) Contracting Officer will have the authority to grant final acceptance of each system commissioned.

E. The General Contractor shall provide the initial schedule of primary commissioning events at the commissioning “Scoping” meeting. As construction progresses more detailed schedules are developed by the CxA. The Commissioning Plan also provides a format for detailed schedules.

1.5 Commissioning Process

A. Commissioning Process. The following narrative provides a brief overview of the typical commissioning tasks during construction and the general order in which they occur.

1. Commissioning during construction begins with a scope meeting conducted by the CxA where the commissioning process is reviewed with the commissioning team members.

2. Additional “Scoping” meetings shall be required monthly throughout construction, scheduled by the CxA with necessary parties attending, to plan, scope, coordinate, schedule future activities and resolve problems.

3. Equipment documentation is submitted to the CxA during normal submittals, including detailed startup procedures.

4. The CxA works with the Contractors/Sub-Contractors in developing startup plans and startup documentation formats, including providing the Contractors/Sub-Contractors with construction and startup checklists to be completed, during the startup process. General contractor to provide completed “Certificates of Proper Installation” forms for all equipment prior to testing and start-up.

5. In general, the checkout and performance verification proceeds from simple to complex; from component level to equipment to systems and intersystem levels with construction and startup checklists being completed before functional testing.

6. Construct a typical terminal air unit with inlet and supply air outlets and supply and return piping and valves and control devices.

7. The Contractors/Sub-Contractors, under their own direction, execute and document the construction and startup checklists. The CxA documents that the checklists were completed according to the contract documents. This may include the CxA witnessing startup of selected equipment. The CxA shall be notified 48 hours in advance of starting up equipment. Where applicable, manufacturers representative executes and documents startup of equipment.

8. The CxA develops specific equipment and system functional performance test procedures. The Contractors/Sub-Contractors review the procedures.

9. The procedures are executed by the Contractors/Sub-Contractors, under the direction of, and documented by the CxA.

10. Items of non-compliance in material, installation or setup are corrected at the Contractors/Sub-Contractors’ expense and the system retested in accordance with paragraphs 3.5 of this section.

11. The CxA reviews the O&M documentation for completeness.

12. Commissioning is completed before Substantial Completion is achieved.

13. The CxA reviews, pre-approves and coordinates the training provided by the Contractors/Sub-Contractors and verifies that is was completed. The CxA shall attend two training sessions.

14. Deferred testing is conducted, as specified or required.

1.6 Responsibilities

A. The responsibilities of various parties in the commissioning process are provided in this section. The responsibilities of the mechanical contractor, TAB (test and balance) and ATC (automatic temperature control) Contractors are in Division 15. The responsibilities of the contractors are noted in their specification documents. Their responsibilities are listed here to clarify the commissioning process.

B. All Parties

1. Attend commissioning scoping meeting and additional meetings, as scheduled.

C. Mechanical and Electrical Designers/Engineers (A/E)

1. Perform normal submittal review, construction observation, as-built drawing preparation, records, etc., as contracted.

2. Provide any design narrative and sequences documentation requested by the CxA. The designers shall assist (along with the contractors) in clarifying the operation and control of commissioned equipment in areas where the specifications, control drawings or equipment documentation is not sufficient for writing detailed testing procedures.

3. Attend commissioning scoping meetings and other selected commissioning team meetings, as requested.

4. Participate in the resolution of system deficiencies identified during commissioning, according to the contract documents.

5. Review and approve the O&M manuals.

6. Participate in the resolution of non-compliance, non-conformance and design deficiencies identified during commissioning including warranty-period commissioning.

D. Commissioning Authority (CxA)

1. The CxA is not responsible for design concept, design criteria, compliance with codes, design or general construction scheduling, cost estimating, or construction management. The CxA may assist with problem-solving non-conformance or deficiencies, but ultimately that responsibility resides with the General Contractor and the A/E. The primary role of the CxA is to develop and coordinate the execution of a testing plan, observe and document performance—that systems are functioning in accordance with the Contract Documents. The Contractors/Sub-Contractors shall provide all tools or the use of tools to start, checkout and functionally test equipment and systems.

2. Coordinates and directs the commissioning activities in a logical, sequential and efficient manner using consistent protocols and forms, centralized documentation, clear and regular communications and consultations with all necessary parties, frequently updated timelines and schedules and technical expertise.

3. Coordinate the commissioning work and, with the General Contractor, ensure that commissioning activities are being scheduled into the master schedule.

4. Plan and conduct a commissioning scoping meeting and other commissioning meetings.

5. Request and review additional information required to perform commissioning tasks, including O&M materials, contractor startup and checkout procedures.

6. Before startup, gather and review the current control sequences and interlocks and work with Contractors/Sub-Contractors and design engineers until sufficient clarity has been obtained, in writing, to be able to write detailed testing procedures.

7. Concurrent with the A/E reviews, the CxA shall review normal Contractors/Sub-Contractors submittals related to the commissioned equipment for conformance to the Contract Documents as it relates to the commissioning process, to the functional performance of the equipment and adequacy for developing test procedures. The CxA shall notify the General Contractor or A/E as requested, of items missing or areas that are not in conformance with Contract Documents and which require resubmission.

8. Write and distribute construction startup checklists.

9. Review factory startup plan and develop a startup plan and initial systems checkout plan with Contractors/Sub-Contractors.

10. Perform site visits, as necessary, to observe component and system installations. Attends selected progress meetings and job-site meetings to obtain information on construction progress. Review construction meeting minutes for revisions/substitutions relating to the commissioning process. Assist in resolving any discrepancies.

11. Witness all or part of the HVAC piping test and flushing procedure, sufficient to be confident that proper procedures were followed. Include the testing report and cleaning procedures documentation in O&M manuals. Notify CM representative of any deficiencies in results or procedures.

12. Witness all or part of any ductwork testing and cleaning procedures, sufficient to be confident that proper procedures were followed. Include the testing report and cleaning procedures documentation in O&M manuals. Notify Construction Manager of any deficiencies in results or procedures.

13. Review and approve construction and startup checklists completion in conjunction with selected site observation and spot checking.

14. Review TAB execution plan.

15. Oversee sufficient startup and initial testing of the control system and verify it is ready to be used for TAB, before TAB is executed.

16. Review air and water systems balancing by spot testing, by reviewing completed reports and by selected site observation.

17. After TAB is complete and with necessary assistance and review from installing contractors, write the functional performance test procedures for equipment and systems. This may include direct digital control system trending, stand-alone datalogger monitoring or manual functional testing.

18. Analyze up to 3 functional performance trend logs and monitoring data to verify performance.

19. Maintain a master deficiency and resolution log and a separate testing record. Provide the CM with written progress reports and test results with recommended actions.

20. Oversee and coordinate the training of the Owner’s operating personnel attending sessions.

21. Compile and maintain a commissioning record.

22. Review of the final O&M manuals.

23. Provide a final commissioning report (as described in this section).

E. Construction Manager (CM)

1. Manage the contract of the CxA and of the General Contractor.

2. Arrange the opportunity for facility operating and maintenance personnel to attend various field commissioning activities and field training.

3. Identify any possible warranty items, document and contact the Contractors for follow-up.

4. Ensure that any seasonal or deferred testing and any deficiency issues are identified.

F. General Contractor (General Contractor)

1. Facilitate the coordination of the commissioning work by the CxA. The General Contractor and CxA ensure that commissioning activities are being scheduled into the master schedule.

2. Furnish a copy of all construction documents, addenda, change orders and approved submittals and shop drawings related to commissioned equipment to the CxA.

3. In each purchase order or subcontract written, include requirements for submittal data, O&M data, commissioning tasks and training.

4. Ensure that all Contractors/Sub-Contractors execute their commissioning responsibilities according to the Contract Documents and schedule.

5. Perform the normal review of Contractors/Sub-Contractors submittals.

6. A representative shall attend a commissioning scope meeting and other necessary meetings scheduled by the CxA to facilitate the Commissioning process.

7. When necessary, observe and witness construction, construction and startup checklists, startup, and functional testing of selected equipment.

8. Review commissioning progress and deficiency reports.

9. Coordinate the resolution of non-compliance and design deficiencies identified in all phases of commissioning.

10. Coordinate the training of owner personnel.

11. Prepare O&M manuals, according to the Contract Documents, including clarifying and updating the original sequences of operation to as-built conditions.

G. Contractors/Sub-Contractors

1. Coordinate the commissioning work with the CxA.

2. Execute their commissioning responsibilities according to the Contact Documents and schedule.

3. Attend the commissioning scope meeting(s) and other necessary meetings scheduled by the CxA to facilitate the Cmx process.

4. When necessary, observe and witness construction, construction and startup checklists, startup, and functional testing of selected equipment.

5. Review commissioning progress and deficiency reports.

6. Resolve the non-compliance and design deficiencies identified in all phases of commissioning.

7. Coordinate the training of Owner personnel for the systems provided under this contract.

8. Prepare O&M manuals, according to the Contract Documents, including clarifying and updating the original sequences of operation to as-built conditions.

H. Equipment Suppliers

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

2. Assist in equipment testing per agreements with Contractors/Sub-Contractors.

3. Include all special tools and instruments (only available from vendor, specific to a piece of equipment) required for testing equipment according to these Contract Documents in the base bid price to the Contractors/Sub-Contractors.

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

5. Review test procedures for equipment started up by factory representatives.

1.7 Systems to be Commissioned

A. The following systems shall be commissioned in this project.

· Automatic temperature control system. Includes general operational checkout in conjunction with specific commissioned equipment and the sequences of operation.

· HVAC Air Systems

· Air handling units, both new and renovated

· Return air fans

· Air terminal units

· HVAC Instrumentation and Control Systems

· Automatic temperature control system. Includes general operational checkout in conjunction with specific commissioned equipment and the sequences of operation.

· HVAC Exhaust Systems/ Power Ventilators

· Humidifiers

PART 2 - PRODUCTS

2.1 Test Equipment

A. All standard testing equipment required to perform startup and initial checkout and required functional performance testing shall be provided by the Contractors/Sub-Contractors for the equipment being tested.

B. Special equipment, tools and instruments (only available from vendor, specific to a piece of equipment) required for testing equipment, shall be included in the Contractors/Sub-Contractors bid price.

C. All testing equipment shall be of sufficient quality and accuracy to test and/or measure system performance. All equipment shall be calibrated within the last year, and according to the manufacturer’s recommended intervals, and when dropped or damaged. Calibration tags shall be affixed or certificates readily available.

D. Refer to Para. 3.4, for details regarding equipment that may be required to simulate required test conditions.

PART 3 – EXECUTION

3.1 Meetings

A. Orientation Meeting. Within 45 days of commencement of construction, the CxA shall schedule, plan and conduct a commissioning orientation meeting with the entire commissioning team in attendance. The CxA shall provide agenda and distribute meeting minutes to all parties.

B. Miscellaneous Meetings. Other meetings shall be planned and conducted by the CxA as construction progresses. These meetings shall cover coordination, deficiency resolution and planning issues with particular Contractors/Sub-Contractors. The CxA shall organize these meetings and shall minimize unnecessary time being spent by Contractors/Sub-Contractors. These meetings may be held monthly, until the final 3 months of construction when they may be held as frequently as one per week.

3.2 Reporting

A. The CxA shall provide regular reports to the COTR, General Contractor and CM, with increasing frequency as construction and commissioning progresses, and at the completion of each completed phase of work related to completed installation of a system or piece of equipment.

B. The CxA shall regularly communicate with all members of the commissioning team, keeping them apprised of commissioning progress and scheduling changes through memos, progress reports, etc.

C. Testing or review approvals and non-conformance and deficiency reports are made regularly with the review and testing as described in later sections.

D. A final summary report by the CxA shall be provided to the COTR and the CM, focusing on evaluating commissioning process. All acquired documentation, logs, minutes, reports, deficiency lists, communications, findings, unresolved issues, etc., shall be compiled in appendices and provided with the summary report. Construction and startup checklists, functional tests and monitoring reports shall not be part of the final report, but shall be stored as the Commissioning Record in the O&M manuals.

3.3 Start-Up Checklists and Initial Checkout

A. The following procedures apply to all equipment to be commissioned, according to para. 1.7, Systems to be Commissioned. Some systems that are not composed of actual dynamic machinery may have very simplified CC’s and startup.

B. Startup and Initial Checkout Plan. The CxA shall assist the commissioning team members responsible for startup of any equipment in developing detailed startup plans for all equipment. The primary role of the CxA in this process is to ensure that there is written documentation that each of the manufacturer-recommended procedures have been completed. Parties responsible for construction and startup checklists, and startup are identified in the commissioning orientation meeting and in the checklist forms.

1. The CxA provides these checklists and tests to the Contractors/Sub-Contractors. The Contractors/Sub-Contractors determines which trade is responsible for executing and documenting the tests.

2. The Contractor/Sub-Contractor responsible for the purchase of the equipment develops the full startup plan by combining (or adding to) the CxA’s checklists with the manufacturer’s detailed startup and checkout procedures from the O&M manual and the normally used field checkout sheets. The plan shall include checklists and procedures with specific boxes or lines for recording and documenting the checking and inspections of each procedure and a summary statement with a signature block at the end of the plan. Where required, the equipment shall be started up by factory representatives. The CxA shall be notified a minimum 48 hours prior to equipment startup.

3. The Contractor/Sub-Contractor submits the full startup plan to the CxA for review.

4. The CxA reviews the procedures and the format for documenting them, noting any procedures that need to be added.

C. Sensor and Actuator Calibration

1. All field-installed temperature, relative humidity, CO, CO2 and pressure sensors and gages, and all actuators (dampers and valves) on all equipment shall be calibrated using the methods described below. Alternate methods may be used, if approved by the CxA beforehand. All test instruments shall have performed a certified calibration within the previous 12 months. Sensors installed in the unit at the factory with calibration certification provided, need not be field calibrated.

2. All procedures used shall be fully documented on the construction and startup checklists or other suitable forms, clearly referencing the procedures followed and written documentation of initial, intermediate and final results.

3. Sensor Calibration Methods

a. All Sensors. Verify that all sensor locations are appropriate and away from causes of erratic operation. For sensor pairs that are used to determine a temperature or pressure difference, make sure they are reading within 0.2°F of each other for temperature and within a tolerance equal to 2% of the reading, of each other, for pressure. Tolerances for critical applications may be tighter.

b. Sensors Without Transmitters--Standard Application. Make a reading with a calibrated test instrument within 6 inches of the site sensor. Verify that the sensor reading (via the permanent meter, gage or direct digital control system (DDCS)) is within the tolerances in the table below of the instrument-measured value. If not, install offset in DDCS, calibrate or replace sensor.

c. Sensors With Transmitters--Standard Application. Disconnect sensor. Connect a signal generator in place of sensor. Connect ammeter in series between transmitter and DDCS control panel. Using manufacturer’s resistance-temperature data, simulate minimum desired temperature. Adjust transmitter potentiometer zero until the ammeter reads 4 mA. Repeat for the maximum temperature matching 20 mA to the potentiometer span or maximum and verify at the DDCS. Record all values and recalibrate controller as necessary to conform to specified control ramps, reset schedules, proportional relationship, reset relationship and P/I reaction. Reconnect sensor. Make a reading with a calibrated test instrument within 6 inches of the site sensor. Verify that the sensor reading (via the permanent thermostat, gage or DDCS) is within the tolerances in the table below of the instrument-measured value. If not, replace sensor and repeat. For pressure sensors, perform a similar process with a suitable signal generator.

d. Critical Applications. For critical applications (process, manufacturing, etc.) more rigorous calibration techniques may be required for selected sensors. Describe any such methods used on an attached sheet.

4. Tolerances, Standard Applications

Sensor Required Tolerance (+/-)

Sensor Required Tolerance (+/-)

Cooling coil, chilled water temps

0.4F

Flow rates, water Relative humidity 4% of design 4% of design

5. Valve and Damper Stroke Setup and Check

a. DDCS Readout. For all valve and damper actuator positions checked, verify the actual position against the DDCS readout.

b. Set pumps or fans to normal operating mode. Command valve or damper closed, visually verify that valve or damper is closed and adjust output zero signal as required. Command valve or damper open, verify position is full open and adjust output signal as required. Command valve or damper to a few intermediate positions. If actual valve or damper position doesn’t reasonably correspond, replace actuator or adjust.

c. Closure for heating coil valves (NO): Set heating setpoint 20°F above room temperature. Observe valve open. Remove control power from the valve and verify that the valve stem and actuator position do not change. Restore to normal. Set heating setpoint to 20°F below room temperature. Observe the valve close. Restore to normal.

d. Closure for cooling coil valves (NC): Set cooling setpoint 20°F above room temperature. Observe the valve close. Remove control power from the valve and verify that the valve stem and actuator position do not change. Restore to normal. Set cooling setpoint to 20°F below room temperature. Observe valve open. Restore to normal.

D. Execution of Construction and Startup Checklists, and Startup

1. The Contractors/Sub-Contractors and vendors schedule startup and checkout with the General Contractor, CM and CxA. The performance of the construction and startup checklists, startup and checkout are directed and executed by the Contractors/Sub-Contractors or vendor. When checking off construction and startup checklists, signatures may be required of other Contractors/Sub-Contractors for verification of completion of their work.

2. The CxA shall observe, at minimum, the procedures for each piece of primary equipment. In no case shall the number of units witnessed be less than the contractual agreement on any one building.

3. For lower-level components of equipment, (e.g., VAV boxes, sensors, controllers), the CxA shall observe a sampling of the construction, and startup, and startup procedures.

4. The Contractors/Sub-Contractors and vendors shall execute startup and provide the CxA with a signed and dated copy of the completed startup, and construction and startup tests and checklists.

5. Only individuals that have direct knowledge and witnessed that a line item task on the construction and startup checklist was actually performed shall initial or check that item off. It is not acceptable for supervisors to fill out these forms.

E. Deficiencies, Non-Conformance and Approval in Checklists and Startup

1. The Contractors/Sub-Contractors shall clearly list any outstanding items of the initial startup and construction and startup procedures that were not completed successfully, and any completed corrections, at the bottom of the procedures form or on an attached sheet. The procedures form and any outstanding deficiencies are provided to the CxA within two days of test completion.

2. The CxA reviews the report and submits either a non-compliance report or an approval form to the Contractor/Sub-Contractor or General Contractor. The CxA shall work with the Contractors/Sub-Contractors and vendors to correct and retest deficiencies or uncompleted items. The CxA shall involve the General Contractor and others as necessary. The installing Contractors/Sub-Contractors or vendors shall correct all areas that are deficient or incomplete in the checklists and tests in a timely manner, and shall notify the CxA as soon as outstanding items have been corrected and resubmit an updated startup report and a Statement of Correction on the original non-compliance report. When satisfactorily completed, the CxA recommends approval of the execution of the checklists and start up of each system.

3. Items left incomplete, which later cause deficiencies or delays during functional testing will result in incidental damages to the responsible party. Refer to Para. 3.5 sub-item B.4 herein for details.

3.4 Functional Performance Testing

A. This sub-section applies to all commissioning functional testing for all divisions.

B. The general list of equipment to be commissioned is found in Para. 1.7.

C. Objectives and Scope. The objective of functional performance testing is to demonstrate that each system is operating according to the Contract Documents. During the testing process, areas of deficient performance are identified and corrected, improving the operation and functioning of the systems.

In general, each system should be operated through all modes of operation (seasonal, occupied, unoccupied, warm-up, cool-down, part- and full-load) where there is a specified system response. Verifying each step in the sequences of operation is required. Proper responses to such modes and conditions as power failure, freeze condition, low oil pressure, no flow, equipment failure, etc. shall also be tested.

D. Development of Test Procedures. Before test procedures are written, the CxA shall obtain all requested documentation and a current list of change orders affecting equipment or systems, including an updated points list, program code, control sequences and parameters. The CxA shall develop specific test procedures and forms to verify and document proper operation of each piece of equipment and system. Each Contractors/Sub-Contractors or vendor responsible to execute a test shall provide limited assistance to the CxA in developing the procedures review. Prior to execution, the CxA shall provide a copy of the test procedures to the Contractors/Sub-Contractors who shall review the tests for feasibility, safety, equipment and warranty protection. When requested, the CxA will submit the tests to the A/E for review.

The purpose of any given specific test is to verify and document compliance with the stated criteria of acceptance given on the test form.

The test procedure forms developed by the CxA shall include (but not be limited to) the following information:

1. System and equipment or component name(s)

2. Equipment location and ID number

3. Unique test ID number, and reference to unique construction and startup checklist and startup documentation ID numbers for the piece of equipment

4. Date

5. Project name

6. Participating parties

7. A copy of the specific sequence of operations or other specified parameters being verified

8. Required pre-test field measurements

9. Instructions for setting up the test

10. Special cautions, alarm limits, etc.

11. Specific step-by-step procedures to execute the test, in a clear, sequential and repeatable format

12. Acceptance criteria of proper performance with a check box to allow for clearly marking whether or not proper performance of each part of the test was achieved

13. A section for comments

14. Signatures and date block for the CxA

E. Test Methods

1. Functional performance testing and verification may be achieved by manual testing (persons manipulate the equipment and observe performance) or by monitoring the performance and analyzing the results using the control system’s trend log capabilities or by stand-alone dataloggers. The CxA may substitute specified methods or require an additional method to be executed, other than what was specified. The CxA shall determine which method is most appropriate for tests that do not have a method specified.

2. Simulated Conditions. Simulating conditions (not by an overwritten value) shall be allowed, though timing the testing to experience actual conditions is encouraged wherever practical.

3. Overwritten Values. Overwriting sensor values to simulate a condition, such as overwriting the outside air temperature reading in a control system to be something other than it really is, shall be allowed, but shall be used with caution and avoided when possible.

4. Simulated Signals. Using a signal generator which creates a simulated signal to test and calibrate transducers and DDC constants is generally recommended over using the sensor to act as the signal generator via simulated conditions or overwritten values.

5. Altering Setpoints. Rather than overwriting sensor values, and when simulating conditions is difficult, altering setpoints to test a sequence is acceptable.

6. Indirect Indicators. Relying on indirect indicators for responses or performance shall be allowed only after visually and directly verifying and documenting, over the range of the tested parameters, that the indirect readings through the control system represent actual conditions and responses. These verifications shall be completed during construction and startup testing.

7. Setup. Each function and test shall be performed under conditions that simulate actual conditions as close as is practically possible. The Contractor/Sub-Contractor executing the test shall provide all necessary materials, system modifications, etc. to produce the necessary flows, pressures, temperatures, etc. necessary to execute the test according to the specified conditions. At completion of the test, the Contractors/Sub-Contractors shall return all affected building equipment and systems, due to these temporary modifications, to their pre-test condition.

8. Sampling. Multiple identical pieces of non-life-safety or otherwise non-critical equipment may be functionally tested using a sampling strategy. Significant application differences and significant sequence of operation differences in otherwise identical equipment invalidates their common identity. A small size or capacity difference, alone, does not constitute a difference. It is noted that no sampling by Contractors/Sub-Contractors is allowed in construction and startup checklist execution.

F. Coordination and Scheduling. The Contractors/Sub-Contractors shall provide sufficient notice to the CxA regarding their completion schedule for the construction and startup checklists and startup of all equipment and systems. The CxA shall schedule functional tests through the General Contractor and affected Contractors/Sub-Contractors. The CxA shall direct, witness and document the functional testing of all equipment and systems. The Contractors/Sub-Contractors shall execute the tests.

In general, functional testing is conducted after construction and startup testing has been satisfactorily completed. The air balancing and water balancing is completed and debugged before functional testing of air-related or water-related equipment or systems. Testing proceeds from components to subsystems to systems. When the proper performance of all interacting individual systems has been achieved, the interface or coordinated responses between systems is checked.

G. Test Equipment. Refer to Part 2 for test equipment requirements.

H. Problem Solving. The CxA may recommend solutions to problems found, however the burden of responsibility to solve, correct and retest problems is with the General Contractor, Contractors/Sub-Contractors and A/E.

3.5 Documentation, Non-Conformance and Approval of Tests

A. Documentation. The CxA shall witness and document the results of all functional performance tests using the specific procedural forms developed for that purpose. Prior to testing, these forms are provided to the General Contractor for review and approval and to the Contractors/Sub-Contractors for review. The CxA shall include the filled out forms in the O&M manuals.

B. Non-Conformance

1. The CxA shall record the results of the functional test on the procedure or test form. All deficiencies or non-conformance issues shall be noted and reported to the General Contractor on a standard non-compliance form.

2. Corrections of minor deficiencies identified may be made during the tests at the discretion of the CxA. In such cases the deficiency and resolution shall be documented on the procedure form.

3. As tests progress and a deficiency is identified, the CxA discusses the issue with the executing Contractors/Sub-Contractors.

a. When there is no dispute on the deficiency and the Contractors/Sub-Contractors accepts responsibility to correct it:

1) The CxA documents the deficiency and the Contractors/Sub-Contractors response and intentions and they go on to another test or sequence. After the day’s work, the CxA submits the non-compliance reports to the General Contractor for signature, if required. A copy is provided to the Contractors/Sub-Contractors and CxA. The Contractors/Sub-Contractors corrects the deficiency, signs the statement of correction at the bottom of the non-compliance form certifying that the equipment is ready to be retested and sends it back to the CxA.

2) The CxA reschedules the test and the test is repeated. See sub-item 4.

b. If there is a dispute about a deficiency, regarding whether it is a deficiency or who is responsible:

1) The deficiency shall be documented on the non-compliance form with the Contractors/Sub-Contractors’ response and a copy given to the General Contractor and to the Contractors/Sub-Contractors’ representative assumed to be responsible.

2) Resolutions are made at the lowest management level possible. Other parties are brought into the discussions as needed. Final interpretive authority is with the A/E. Final acceptance authority is with the CM’s representative.

3) The CxA documents the resolution process. The CxA will test equipment once and provide one re-test, additional cost associated with further required re-testing of the same equipment shall be borne by the responsible Contractors/Sub-Contractors.

4) Once the interpretation and resolution have been decided, the appropriate party corrects the deficiency, signs the statement of correction on the non-compliance form and provides it to the CxA. The CxA reschedules the test and the test is repeated until satisfactory performance is achieved.

4. Cost of Retesting

a. The cost for the Contractors/Sub-Contractors to retest a construction or functional test, if they are responsible for the deficiency, shall be theirs. If they are not responsible, any cost recovery for retesting costs shall be negotiated with the General Contractor.

b. For a deficiency identified, not related to any construction and startup checklist or startup fault, the following shall apply: The CxA and General Contractor shall direct the retesting of the equipment once at no “charge” to the Owner for their time. However, the CxA’s and General Contractor’s time for a second retest shall be charged to the Contractor/Sub-Contractor, who may choose to recover costs from the responsible Sub-Contractor/vendor.

c. The time for the CxA and General Contractor to direct any retesting required because a specific construction checklist or construction test item, reported to have been successfully completed, but determined during functional testing to be faulty, shall be in the form of incidental damages to the General Contractor, who may choose to recover costs from the party responsible for executing the faulty construction and startup test.

d. Refer to the sampling section of Para. 3.4 for requirements for testing and retesting identical equipment.

5. The Contractors/Sub-Contractors shall respond in writing to the CxA and CM at least as often as commissioning meetings are being scheduled concerning the status of each apparent outstanding discrepancy identified during commissioning. Discussion shall cover explanations of any disagreements and proposals for their resolution.

6. The CxA retains the original non-conformance forms until the end of the project.

7. The prime Contractors/Sub-Contractors shall not consider any required retesting by any Contractors/Sub-Contractors a justified reason for a claim of delay or for a time extension.

C. Failure Due to Manufacturer Defect. If 10%, or three, whichever is greater, of identical pieces (size alone does not constitute a difference) of equipment fail to perform to the Contract Documents (mechanically or substantively) due to manufacturing defect, not allowing it to meet its submitted performance spec, all identical units may be considered unacceptable by the CM. In such case, the Contractors/Sub-Contractors shall provide the CM with the following:

1. Within one week of notification from the General Contractor or CM, the Contractors/Sub-Contractors or manufacturer’s representative shall examine all other identical units making a record of the findings. The findings shall be provided to the General Contractor or CM within two weeks of the original notice.

2. Within two weeks of the original notification, the Contractors/Sub-Contractors or manufacturer shall provide a signed and dated, written explanation of the problem, cause of failures, etc. and all proposed solutions which shall include full equipment submittals. The proposed solutions shall not significantly exceed the specification requirements of the original installation.

3. The CM shall determine whether a replacement of all identical units or a repair is acceptable.

4. Two examples of the proposed solution shall be installed by the Contractors/Sub-Contractors and the General Contractor shall be allowed to test the installations for up to one week, upon which the CM shall decide whether to accept the solution.

5. Upon acceptance, the Contractors/Sub-Contractors and/or manufacturer shall replace or repair all identical items, at their expense and extend the warranty accordingly, if the original equipment warranty had begun. The replacement/repair work shall proceed with reasonable speed beginning within one week from when parts can be obtained.

D. Approval. The CxA notes each satisfactorily demonstrated function on the test form. Formal approval of the functional test is made later after review by the CxA. The CxA recommends acceptance of each test to the CM using a standard form. The CxA gives final approval on each test using the same form, providing a signed copy to the Contractors/Sub-Contractors.

3.6 Operation and Maintenance Manuals

A.