230810 mechanical testing requirements.pdf

F5W61608 USPFO Warehouse Ohio Army National Guard Rev. 0 Defense Supply Center Columbus, Ohio 30 January 2009 Bid Final

MECHANICAL TESTING REQUIREMENTS 230810 - 1

SECTION 230810 – MECHANICAL TESTING REQUIREMENTS

PART 1 - GENERAL

1.1 INCLUDED SYSTEMS AND EQUIPMENT

A. The following is a list of the equipment and system test requirements included in this section:

1. Air handler systems (AHUs, Blower Coils, FCUs, Condensing Units, etc.)

2. Building Automation System

3. Exhaust fans (General, Vehicle, Fume, etc.)

4. Terminal units

5. Test and balance (TAB) work

1.2 DESCRIPTION

A. This section specifies the functional testing requirements for Division 23 systems and equipment. From these requirements, the Commissioning Authority (CxA) shall develop step-by-step procedures to be executed by the Subs or the Commissioning Authority. The general functional testing process, requirements and test method definitions are described in Section 019113. The test requirements for each piece of equipment or system contain the following:

1. The contractors responsible to execute the tests, under the direction of the CxA.

2. A list of the integral components being tested.

3. Prefunctional checklists associated with the components.

4. Functions and modes to be tested.

5. Required conditions of the test for each mode.

6. Special procedures.

7. Required methods of testing.

8. Required monitoring.

9. Acceptance criteria.

10. Sampling strategies allowed.

1.3 PREREQUISITES

A. The following applicable generic prerequisite checklist items are required to be listed on each written functional test form and be completed and checked off by CxA prior to functional testing.

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1. All related equipment has been started up and start-up reports and prefunctional checklists submitted and approved ready for functional testing.

2. All control system functions for this and all interlocking systems are programmed and operable per contract documents, including final setpoints and schedules with debugging, loop tuning and sensor calibrations completed.

Controls Contractor Signature or Verbal Date

3. Piping system flushing complete and required report approved.

4. Water treatment system complete and operational.

5. Test and balance (TAB) complete and approved for the hydronic system.

6. All A/E punchlist items for this equipment corrected.

7. These functional test procedures reviewed and approved by installing contractor.

8. Safeties and operating ranges reviewed by the CxA.

9. False loading equipment, system and procedures ready.

10. Sufficient clearance around equipment for servicing.

11. Record of all values for pre-test setpoints changed to accommodate testing has been made and a check box provided to verify return to original values (control parameters, limits, delays, lockouts, schedules, etc.).

12. Other miscellaneous checks of the prefunctional checklist and start-up reports completed successfully.

1.4 MONITORING

A. Monitoring is a method of testing as a stand-alone method or to augment manual testing.

B. All points listed in the required monitoring section of the test requirements which are control system monitored points shall be trended by the controls contractor. Other points shall be monitored by the CxA using dataloggers. At the option of the CxA, some control system monitoring may be replaced with datalogger monitoring. At the CxA’s request, the controls contractor shall trend up to 20% more points than listed herein at no extra charge.

C. Hard copies of monitored data must be in columnar format with time down the left column and at least 5 columns of point values on the same page.

D. Graphical output is desirable, and will be required for all output, if the system can produce it.

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PART 2 - PRODUCTS (NOT APPLICABLE)

PART 3 - EXECUTION

3.1 AIR HANDLING UNITS (AHU)

A. Parties Responsible to Execute Functional Test

1. Controls contractor: operate the controls to activate the equipment as needed.

2. CxA: to witness, direct and document testing.

B. Integral Components or Related Equipment Being Tested

1. AHU and components (AHUs, FCUs, and Condensing Units, etc)

C. Prerequisites: The applicable prerequisite checklist items listed in the beginning of Section 230810 shall be listed on each functional test form and checked off prior to functional testing. The commissioning agent will also spot-check misc. items and calibrations on the prefunctional checklists previously completed by the installer, before the beginning of functional testing.

D. Functions / Modes Required To Be Tested, Test Methods and Seasonal Test Requirements

1. The following testing requirements are an addition to and do not replace any testing requirements elsewhere in this Division.

Function / Mode Test Method

Manual, Monitoring, Either or Both3

Required Seasonal

Test1

General

1. Test each sequence in the sequence of operations, and other significant modes and sequences not mentioned; including startup, shutdown, unnoccupied & manual modes and power failure. Test functionality of this piece of equipment or system in all control strategies or interlocks with which it is associated.

Manual

In addition to, or as part of (1) above, the following modes or tests are required:

2. Mixed & supply air, & reset temperature control functions. Both

3. Economizer functions. Both Cooling

4. SF, RF and exhaust fan interlocks. Either

5. No CCV flow when there is HCV flow. Both

6. Duct static pressure (SP) control. Both

7. Damper interlocks and correct modulation in all modes, including smoke and fire dampers.

Manual

8. Verification of minimum OSA control through varying VAV box positions. Either 2

9. Heating and cooling coils freeze protection. Manual 2

10. Night low limit, morning warmup cycle. Either

11. Verify TAB reported SF cfm with control system reading. Manual 2

12. All alarms (low limits, high static, etc.). Manual

13. Heating and cooling coil capacity test, optional. Manual Design

14. Verify schedules and setpoints to be reasonable and appropriate

1Cooling season, Heating season or Both. “Design” means within 5°of season design (ASHRAE 2 1/2%), or 95% of loading design. A blank cell denotes no special seasonal test is required and that test can be executed during any

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season, if condition simulation is appropriate.

2Seasonal test not required if seasonal conditions can be adequately simulated.

3Refer to Special Procedures

E. Acceptance Criteria (referenced by function or mode ID)

1-14. For the conditions, sequences and modes tested, the AHU, integral components and related equipment respond to varying loads and changing conditions and parameters appropriately as expected, as specified and according to acceptable operating practice.

2. AHU with supporting systems shall be able to maintain the SA temperature within 1.0F either side of the deadband of the current setpoint without excessive hunting.

6. AHU and controls shall control the duct static pressure so that it does not drift more than an amount equal to 10% of the setpoint value either side of the deadband without excessive hunting.

F. Sampling Strategy for Identical Units

1. All identical AHU’s over 15 tons shall not have any sampling--test all units.

However, 25% of the units may have monitoring be the verification method for modes listed with Monitoring or Both as testing methods, with no less than three units being fully tested per the above requirements.

2. All identical AHU’s equal to or less than 15 tons shall be sampled:

Randomly test at least 50% of each group of identical equipment (the 1st sample) per the above tests. In no case test less than three units in each group. If 20% of the units in the first sample fail the functional performance tests, test another the remaining 50%, fully at the contractor’s expense. This sampling applies to the testing subsections. That is, if calibration is off on more than 10% of the tested piece of equipment, then another sample shall have calibrations checked, but not all other tests need to be done on the second sample.

3. All units not included in the sampling testing and monitoring shall be fully monitored for the monitoring modes listed above in the monitoring section.

END OF REQUIREMENTS FOR AHU TEST

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3.2 BUILDING AUTOMATION SYSTEM (BAS)

A. Parties Responsible to Execute Functional Test

1. Controls contractor: operate the controls to activate the equipment.

2. CxA: to witness, direct and document testing.

B. Integral Components or Related Equipment Being Tested

1. Building Automation System

2. All prefunctional checklists of controlled equipment

C. Prerequisites: The applicable prerequisite checklist items listed in the beginning of Section 230810 shall be listed on each functional test form and checked off prior to functional testing. The commissioning agent will also spot-check misc. items and calibrations on the prefunctional checklists previously completed by the installer, before the beginning of functional testing.

D. A significant part of the BAS functional testing requirements is the successful completion of the functional tests of equipment the BAS controls or interlocks with.

Uncompleted equipment functional tests or outstanding deficiencies in those tests lend the required BAS functional testing incomplete.

E. Integral or stand-alone controls are functionally tested with the equipment they are attached to, including any interlocks with other equipment or systems and thus are not covered under the BAS testing requirements, except for any integrated functions or interlocks listed below.

F. In addition to the controlled equipment testing, the following tests are required for the BAS, where features have been specified.

1. The following testing requirements are in addition to and do not replace any testing requirements elsewhere in the specifications.

Function / Mode

Test Method Manual (demonstration), Monitoring, Either or Both

MISC. FUNCTIONS

1. All specified functions and features are set up, debugged and fully operable Verbal discussion of features

2. Power failure and battery backup and power-up restart functions Demonstration

3. Specified trending and graphing features demonstration See equipment trends

4. Global commands features Demonstration

5. Security and access codes Demonstration

6. Occupant over-rides (manual, telephone, key, keypad, etc.) Demonstration

7. O&M schedules and alarms Demonstration

8. Scheduling features fully functional and setup, including holidays Observation in terminal screens or printouts

9. Date and time setting in central computer and verify field panels read the same time Demonstration

10. Included features not specified to be setup are installed (list) Demonstration

11. Occupancy sensors and controls Demonstration

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Function / Mode

Test Method Manual (demonstration), Monitoring, Either or Both

12. Demonstrate functionality of field panels using local operator keypads and local ports (plug-ins) using portable computer/keypad

Demonstration of 100% of panels and 10% of ports

13. All graphic screens and value readouts completed Demonstration

14. Setpoint changing features and functions Done during equipment testing

15. Communications to remote sites Demonstration

16. Final as-builts or redlines (per spec) control drawings, final points list, program code, setpoints, schedules, warranties, etc. per specs, submitted for O&Ms.

Observation

17. Verify that points that are monitored only, having no control function, are checked for proper reporting to BAS.

Observation

INTEGRATED TESTS

18. Fire alarm interlocks and response Demonstration

19. Optimum start-stop functions Monitoring

20. All control strategies and sequences not tested during controlled equipment testing Either

21. Other integrated tests specified in the contract documents

G. Special Procedures: (other equipment to test with, etc.; reference to function ID).

None.

H. Acceptance Criteria: For the conditions, sequences and modes tested, the BAS, integral components and related equipment respond to changing conditions and parameters appropriately as expected, as specified and according to acceptable operating practice.

I. Sampling Strategy for Identical Units

1. Sample 10% of the field panels for procedure 9, and 10% of the local ports for procedure 12. If 10% fail, test another 10%. If 10% of those fail, test all remaining units at the contractor’s expense.

END OF REQUIREMENTS FOR BAS TEST

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3.3 EXHAUST FANS

A. The testing requirements apply to the following fans: restroom, mechanical room, vehicle exhaust, fume exhaust, etc. fans.

1. Parties Responsible to Execute Functional Test

a. Controls contractor: operate the controls to activate the equipment, if BAS controlled.

b. CxA: to witness, direct and document testing.

2. Integral Components or Related Equipment Being Tested

a. Exhaust fans (General, Vehicle, Fume, etc)

3. Prerequisites: The applicable prerequisite checklist items listed in the beginning of Section 230810 shall be listed on each functional test form and checked off prior to functional testing. The commissioning agent will also spot-check misc. items and calibrations on the prefunctional checklists previously completed by the installer, before the beginning of functional testing.

4. Functions / Modes Required To Be Tested, Test Methods and Seasonal Test Requirements

a. The following testing requirements are in addition to and do not replace any testing requirements elsewhere in this Division.

Function / Mode Test Method

Manual, Monitoring, Either or Both1

Required Seasonal

Test

General

1. Test each sequence in the sequence of operations, and other significant modes and sequences not mentioned; including startup, shutdown, unnoccupied & manual modes and power failure. Test functionality of this piece of equipment or system in all control strategies or interlocks that it is associated with.

Manual

In addition to, or as part of (1) above, the following modes or tests are required:

2. Verify schedules and setpoints to be reasonable and appropriate

3. Function at fire alarm (off, depressurization, etc.) Manual

5. Speed controls Either

6. Check TAB report record of sound power level tests and space pressures and compare to specifications Review

7. Sensor calibration checks on any controlling temperature or pressure sensor Manual 1Refer to Special Procedures

5. Special Procedures (other equipment to test with, etc.; reference to function ID) None

6. Acceptance Criteria (referenced by function or mode ID) 1-6. For the conditions, sequences and modes tested, the fans, integral components and related equipment respond to changing conditions and

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parameters appropriately as expected, as specified and according to acceptable operating practice.

7. Sampling Strategy for Identical Units of the same type and function, but different in size, are considered identical for sampling purposes.

a. Randomly test at least 10% of each group of identical equipment (the 1st sample). In no case test less than three units in each group. If 10% of the units in the first sample fail the functional performance tests, test another 10% of the group (the 2nd sample). If 10% of the units in the 2nd sample fail, test all remaining units in the whole group, fully at the contractor’s expense. This sampling applies to the testing subsections. That is, if calibration is off on more than 10% of the tested piece of equipment, then another sample shall have calibrations checked, but not all other tests need to be done on the second sample.

END OF REQUIREMENTS FOR EXHAUST FAN TEST

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3.4 TEST AND BALANCE WORK (TAB)

A. Parties Responsible to Execute Functional Test

1. TAB contractor: perform checks using test instruments.

2. Controls contractor: operate the controls to activate the equipment.

3. CxA: to witness, direct and document testing.

B. Integral Components or Related Equipment Being Tested

1. TAB air-side

C. Prerequisites: The applicable prerequisite checklist items listed in the beginning of Section 230810 shall be listed on each functional test form and checked off prior to functional testing. The commissioning agent will also spot-check misc. items and calibrations on the prefunctional checklists previously completed by the installer, before the beginning of functional testing.

D. Purpose: The purpose of this test is to spot check the TAB work to verify that it was done in accordance with the contract documents and acceptable practice and that the TAB report is accurate.

E. The following tests and checks will be conducted. The following testing requirements are in addition to and do not replace any testing requirements elsewhere in this Division.

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Test or Check Test Method Required Seasonal Test3

1. A random sample of up to 10% the TAB report data shall be selected for verification (air velocity, air or water flow rate, pressure differential, electrical or sound measurement, etc.). The original TAB contractor will execute the checks, witnessed by the commissioning authority. The TAB contractor will use the same test instruments as used in the original TAB work.

A failure1 of more than 10% of the selected items of a given system2 shall result in the failure of acceptance of the system TAB report and the TAB contractor shall be responsible to rebalance the system, provide a new system TAB report and repeat random verifications of the new TAB report.

The random testing will include the verification of minimum outdoor air intake flows at minimum, maximum and intermediate total airflow rates for 100% of the air handlers. Other selected data to be verified will be made known upon day of testing.

Demonstration

2. Verify that final settings of all valves, splitters, dampers and other adjustment devices have been permanently marked by the TAB Contractor.

Demonstration

3. Verification that the air system is being controlled to the lowest possible static pressure while still meeting design loads, less diversity. This shall include a review of TAB methods, control setpoints established by TAB and a physical verification of at least one leg from fan to diffuser having all balancing dampers wide open and that during full cooling of all TUs taking off downstream of the static pressure sensor, the TU on the critical leg has its damper 90% or more open.

Demonstration

4. Verification that the water system is being controlled to the lowest possible pressure while still meeting design loads, less diversity. This shall include a review of TAB methods, control setpoints established by TAB and a physical verification of at least one leg from the pump to the coil having all balancing valves wide open and that during full cooling the cooling coil valve of that leg is 90% or more open.

Demonstration

1Failure of an item is defined as follows:

For air flow of supply and return: a deviation of more than 10% of instrument reading For minimum outside air flow: 20% of instrument reading (30% for reading at intermediate supply flow for inlet vane or VFD OSA compensation system using linear proportional control) For temperatures: a deviation of more than 1°F For air and water pressures: a deviation of more than 10% of full scale of test instrument reading For sound pressures: a deviation of more than 3 decibels. (Variations in background noise must be considered)

2Examples of a “system” are: the air distribution system served by one air handler or the hydronic chilled water supply system served by a chiller or the condenser water system. Systems can be defined smaller if inaccuracies in TAB work within the smaller defined system will have little or no impact on connected systems.

3Cooling season, Heating season or Both. “Design” means within 5°of season design (ASHRAE 2 1/2%), or 95% of loading design. A blank cell denotes no special seasonal test is required and that test can be executed during any season, if condition simulation is appropriate.

F. Special Procedures (other equipment to test with, etc.; reference to function ID) None

G. Required Monitoring None

H. Acceptance Criteria (referenced by function or mode ID) Provided in footnote to test table above.

I. Sampling Strategy for Identical Units Described in test table above.

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END OF REQUIREMENTS FOR TAB TEST

END OF SECTION 230810