Developing a Commissioning Plan

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Developing a Commissioning Plan

• Associated Air Balance Council

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Summary of Presentation

• An example of a Commissioning Plan for a specific
  project
• The project the AABC Museum Project in the 2002
  CCA Certification Exam

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Project Description

• 2 storey, 60,000 ft2 museum. To provide
• Public exhibit spaces (incl. special exhibit
  space)
• Public assembly area
• Administration areas
• Artifact storage and workshop space
• Washrooms and other utility areas
• Close temperature and humidity control reqd.

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Project Description (contd)

• Heating hot water, serving air-side htg. coils
• Cooling chilled water, with ice storage,
  serving air-side cooling coils
• Main air handling systems VAV reheat
• Other systems
• Fan-coil units
• Process coolers
• Unit heaters

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Commissioning PlanTable of Contents

• Introduction
• Scope of Cx
• Design Review
• Cx Team
• Reference documents
• Resolution Tracking
• Cx Meetings
• Schedule

• Construction Checklist
• SVCs Pre-start Start
• Functional Perf. Tests
• TAB Verification
• Acceptance
• O M Training
• Documentation in Commissioning Report

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Section 1 - Introduction

• Executive summary
• emphasizes important points about the
  commissioning (Cx) process
• References the important sections in the plan
• States the purpose of the Cx Plan
• From the Cx Authoritys perspective
• Communicates to all Cx team members
• Forms the basis for all commissioning activity
• Designed to ensure that design intent is achieved

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Sec. 1 Introduction (contd)

• Includes summary of the Cx Authoritys approach
  to Commissioning
• How the Cx Authority fits into the Cx process
• Total team approach
• Authority plans, organizes and facilitates
• Length one or two pages

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Section 2 Scope of Commissioning

• A major section with 3 main components
• Part 1 Scope of Commissioning Work
• Part 2 HVAC equipment and systems to be
  commissioned
• Part 3 Commissioning Authoritys approach to
  the Commissioning Process

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Sec. 2, Part 1 Scope of Work

• Lists important Commissioning Authority
  activities by phase
• Construction ( 15 items),
• Acceptance (15 20 items), and
• Post-Acceptance ( 5 items)
• List of activities taken from AABC Guideline

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Sec. 2, Part 2 HVAC Systems

• Detailed list of
• HVAC systems to be commissioned, including
• major components of these systems
• Interfaces to other systems
• Includes all unitary equipment/systems to be
  commissioned

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Sec. 2, Part 2 List of HVAC Systems

• Air Systems
• AHUs 1 thru 3, including relief and exhaust fans
• VAV terminals 1 thru 47
• Fan-coil units, process cooling units,
  micro-climate cooling units, unit heaters
• Boiler/HW system, including pumps
• Chillers/ice storage/ChW system, including pumps
• DDC system

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Sec. 2, Part 3 Approach to Cx

• Description of HOW the Cx Authority will work
  with Cx Team members to achieve the goals of
  commissioning
• Detailed list of Cx Authority activities and
  interactions with team members explanation of
  how each activity or interaction contributes to
  commissioning success
• IMPORTANT! suggest this be 2 to 3 pages

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Commissioning Meeting Leadership As the HVAC
commissioning agent, The XXX Agency will schedule
and lead all commissioning meetings. These
meetings will keep the commissioning process on
track and will be a forum to resolve any
conflicts with schedule or construction issues.
Minutes will be written by The XXX Agency and
distributed to all commissioning team members.
All problems will be recorded on Resolution
Tracking Forms. These forms will be used to track
all issues through to their completion.
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HVAC Equipment Start-Up Start-up of major HVAC
systems will be witnessed by The XXX Agency. The
appropriate contractors and/or manufacturers
representatives will be required on site to
perform start-up. No system will be started until
the appropriate SVC pre-start checks have been
completed and reviewed. No system will be started
until the manufacturers pre-start checklists (if
applicable) have been completed. Start-up will be
performed according to the manufacturers
recommended procedures. The XXX Agency will visit
the site to review status of the installation in
conjunction with progress meetings prior to
starting HVAC equipment.
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Functional Performance Testing Functional
performance testing will encompass every mode of
control, and every specified sequence of control
action. Each major system will be tested. A
random sample of each subsystem (e.g. terminal
units) will be tested. Systems will be operated
by the contractor as directed by the XXX Agency
representative, and tests will be witnessed by
the XXX Agency representative and the Owners
maintenance staff. Both control actions and
physical responses will be verified. Witnessing
the FPTs will constitute part of the OM
training. No FPTs will be performed until the
system and related subsystems have been started,
the TAB work has been completed, and the control
contractors pre-commissioning work is complete.
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Section 3 Design Review

• Explains purpose of Cx Authoritys design review
  to bring constructive comments to the
  designers attention
• Goal provide input at design so potential
  installation or operations problems can be
  corrected BEFORE construction
• Design review comments listed in this section
  with suggested action for each
• A powerful benefit brought by the Cx Authority

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Section 3 Examples of Design Review Comments

• The micro-climate ducts (pipe) cross at column
  3.3 and C.9. Clarify if they connect or not.
• Mismatch between airflows on VAV schedule and the
  sum of the supply diffusers lists 25 different
  VAV boxes to which this applies
• No motorized dampers shown for minimum or
  economizer outside air intake
• HW piping shows circuit-setters on pump inlet,
  should be on outlet side to avoid cavitation

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Section 4 Commissioning Team

• Lists commissioning teams members, including
  contact information
• From AABC Guideline
• Where identity not known designated team
  member when known

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Section 5 Reference Documents

• Project drawings
• Lists drawing numbers for each discipline
• Project specifications
• Submittal data
• Applicable codes and regulations
• Applicable standards
• Lists to be as specific as possible

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Section 6 Resolution Tracking Forms

• Purpose and use of RTFs explained
• Track ALL issues that are identified
• Use a numbering system to facilitate referencing
• Assign responsibility for each
• Issues discussed as needed in Cx meetings
• Each issue kept open until resolved
• Sample blank form should be in Cx Plan

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Section 7 Commissioning Meetings

• Critical part of communications among Cx team
• Lists kick-off meeting
• Lists attendees and purpose of commissioning
• Regular on-site commissioning meetings
• Attendance
• Starting at least 1 month before start-up
• Start-up period weekly or bi-weekly as needed
• Minutes will cover all items discussed

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Section 7 Commissioning Meetings (contd)

• Typical commissioning meeting agenda
• Review schedule RE commissioning activities
• Identify priority work
• Address unresolved issues from old RTFs
• Identify and address new issues new RTFs
• Assign ACTION responsibilities
• During FPTs daily planning review for that
  days tests PLUS weekly general meetings

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Section 8 - Schedule

• Tabular form lists activities, pre-requisites,
  and start/finish weeks or days (or elapsed time).
• As construction proceeds, insert specific dates
• Bar graph form line for each activity, start
  and finish dates in terms of weeks (or days)
  after construction start.
• As const. proceeds, insert specific dates
• Use of graphing software facilitates revisions

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Section 9 Construction Checklist

• Cx Authority monitors construction progress
• Construction checklists cover
• General observations
• Air handling systems
• Hydronic systems hot and chilled water/ice
• Unitary Equipment fan-coils, process micro
  cooling unit, and unit heaters
• Electrical and controls, incl. VFDs
• Operational checks

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HVAC SYSTEMS COMMISSIONING AIR HANDLING SYSTEM
CHECKLIST  
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Section 10 SVCs and Start-up Checklists

• Major section approx. 50 pages
• Pre-start Start-up instructions for contractor
• Schedule of all reqd. pre-start work all
  trades
• Pre-start checks done by contractor, verified
  by Commissioning Agent before start-up
• Regular status reviews at commissioning meetings
• SVC checklist for EVERY piece of equipment listed
  in Section 2, Part 2

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SVC Checklist Format

• Basic format taken from AABC Commissioning
  Guideline
• Most checklists all items on one page
• Complex equipment e.g. air handling unit
• 1 page for overall unit incl. casing, plenums,
  filters also references extra pages
• Extra pages for SFs, RFs, htg clg coils,
  condensing units
• Multiple equipment e.g. VAV terminals
• List of checks, then table of several units on
  each page
• EXAMPLES in following SVC presentation

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Section 11 Functional Performance Testing

• Major section approx. 75 pages
• Consists of
• Table of contents for section, listing all
  systems equipment included
• FPT package for every system (or type of
  equipment)

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FPT Package

• For each system (or type of equipment)
• Pre-requisites before FPT can start
• System description
• List of components
• List of modes of operation and control
• Sequence of operations all modes
• FPT checklist form details test procedure,
  including specific control system functions
• EXAMPLES in following FPT presentation

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Section 12 TAB Verification

• Short description of process
• TAB Agency repeats reported measurements
• As selected by Cx Auth., who verifies results
• Lists the types of measurement to be verified
• E.g. airflows at AHUs, in main and branch
  ducts, terminal units, and at diffusers
• E.g. water flows in hot water and chilled
  water, at boilers/chillers, cooling towers, in
  branch piping.
• Indicates of measurements to be verified

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Section 13 - Acceptance

• Description of what constitutes acceptance
• Substantial completion
• Completed FPTs demonstrate that everything
  functions as per spec.
• Cx Authority recommends acceptance to designer
  and owner
• Final completion
• After project passes 12 month warranty inspection
• Cx Authority participates recommends OK

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Acceptance (contd)

• Certification form at both Substantial and
  Final Completion
• By contractors that work is complete
• By designers that work meets contract
  requirements
• By Owner accepting the completed project.

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Section 14 O M Training

• Description of the training process
• Lists systems to be included in training
• Training agenda specific to each system
• System demonstration capabilities and
  limitations
• Start/stop normal/abnormal/emergency operation
• Maintenance requirements
• Include time allocations
• Record of attendance
• Both trainers and learners

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Section 15 Documentation in Commissioning Report

• Table of contents for the Commissioning Report
• Based on the Commissioning Plan