Commissioning HVAC Systems: Lessons learned throughout the entire Cx process James D. Mascaro, PE, CCP December 17, 2007

Today’s Cx Discussion: Review of the Cx Process HVAC plan reviews Cx during Construction

What is Building Commissioning? ASHRAE Guideline 0-2005 Building Commissioning is a quality-oriented, systematic process for achieving, verifying and documenting that the performance of facility systems and assemblies meets Owner-defined objectives and criteria. This process begins at project inception during the pre-design phase and continues for the life of the facility through the Occupancy and Operations Phases.

Building Commissioning Improves... Comfort Air quality Occupant productivity Equipment life Maintainability – critical for O&M staff! Facility staff preparedness Energy performance

What Commissioning Achieves Energy Savings of 20 to 50 Percent Maintenance Savings of 15 to 35 Percent Reduction of Claims 2 to 10 Percent Reduction of Trouble Shooting Costs Source: Building Owners and Managers Association (BOMA) cost data for Office Buildings.

Commissioning…. Sets clear measurable goals for everyone Verifies goals are being met throughout the design and construction phases Establishes accountability Changes the way people perform Allows designers and contractors to measure success as well as deficiency

Commissioning also... Identifies issues & corrects deficiencies Design errors Improper installation Failed equipment Poorly tuned controls/improper sequences

The Commissioning Process New Construction

The Commissioning Process The Cx process involves steps that are integrated into every phase of the project: Pre-Design Design Construction Acceptance Warranty Commissioning is NOT just start-up / testing of systems at the end nor is it providing CM services.

The Commissioning Process Design Phase Document Basis of Design Refine Commissioning Scope Perform Design Review (sampling) Update Commissioning Plan Include Cx Requirements in Specifications Functional program space & equipment requirements Technical program system selection criteria, utility considerations scope selection early FPT = functional performance test detour review by CA is for functional issues, not coordination, different design approaches (except when design won’t work)

The Commissioning Process Construction Phase Update Commissioning Plan & Schedule Submittals and O&M Manuals (2 month) Review Control Sequences Write Checklists, Functional Test Procedures Document Construction Observation Static testing (pipe, duct, electrical grounding) Component checklists Document changes

Design Phase Cx Plan Reviews

Schematic Phase: Big Picture Coordinate with Sheet E-3 Verify sufficient clearance for maintenance Coordinate Notes (typ)

Design Phase Cx Issues: LOCATION?

Design Phase Cx Issues 8” HPWS/R lines?

Design Phase Cx Issues: Balancing Dampers? ACCESS? 750 Heat Pumps!

Balancing Damper Air takes path of least resistance Damper diverts air to where needed Eliminates noisy registers $2.50 each (6” residential round)

Design Phase Cx Issues: ACCESS ISSUES AFFECT Installation difficulties Increased risk for proving static testing Increased risk for system leaks Maintenance Replacement costs of compressors Disruption of End-User(s)

Review Details “Typ. Detail”? Compressor replacement Costs: Approx.: $1,500/unit “Typ. Detail”?

Mechanical Room – Plan View Design Phase: 95% Duct Transitions? Access Issues? Problem? Functional program space & equipment requirements Technical program system selection criteria, utility considerations scope selection early FPT = functional performance test detour review by CA is for functional issues, not coordination, different design approaches (except when design won’t work) Mechanical Room – Plan View

Review Sections Access Issues? Mechanical Room – Section Functional program space & equipment requirements Technical program system selection criteria, utility considerations scope selection early FPT = functional performance test detour review by CA is for functional issues, not coordination, different design approaches (except when design won’t work) Mechanical Room – Section

What’s Wrong Here? Drafting!!! Identification of piping? RA system Dampers? Filter Access?

Detail for Pump: No Strainer... Wrong! Correct Detail! ? Elevation of In-Line Pump Piping Detail

Why is Commissioning needed during Construction? Tina says, “Because the Contractor needs help!!!”

Commissioning Site Observation Report By: James D. Mascaro, PE, CCP September 15, 2006 NSU - Marie V. McDemmond Center for Applied Research MBP Project No.: J06093 Watch Rough-In Of Ductwork! 8’-6”

Watch out for issues like this… 90 Degree elbow @ end of system!!!

What’s Missing?

Protect the equipment from dust & dirt!

VAV Box: Great Job! 3 duct diameters straight inlet Duct sealed in plastic (notice tape) Inlets of VAV box sealed in plastic

Check Piping to Air Handling Units!

Think “outside the box” – what’s missing? Cx Services don’t just deal with “moving parts”. OPR!

Why is Commissioning Needed? Closing Comments….

No floor drain on drawings. Here’s Engineer’s Solution No floor drain on drawings? Here’s Engineer’s Solution! Don’t let this happen on your job!

¼” tubing on discharge of pump! Anything else wrong? Moisture to rooms!

Stay Tuned for the next Cx Webcast Discussion: What is Functional Performance Testing? And Life After “Substantial Completion”