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Comprehensive Commissioning Process for India

By Maija Virta Santrupti engineers

maija@santrupti.com

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C O M M I S S I O N I N G

Commissioning Process to assist

Main Processes

Design Owners

Project

Requirements

Const-

ruction Start-up

RESULT:

Well-

performing,

sustainable,

high value

building

Operation &

Maintenance

Key Performance Indicators (KPIs)

“Coaching” – best practices, templates

“Checking & Testing”: check lists, measurement procedures

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Why Commissioning in India?

3

Enegy for All Save People

LEED Commissioning Requirements 1/2

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LEED Commissioning Requirements 2/2

5

Comprehensive Commissioning Process

beyond LEED Requirements

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Initial

Commissioning

1 Target setting

2 Commissioning planning

3 Review or designs and installation

4 Start-up of components / systems

5 Performance testing

6 Systems O & M manual

7 O & M Personnel Training

8 Operation review after 10 months

Seasonal

Commissioning

1 Walk-through in building

2 Follow-up of KPIs

3 Follow-up of maintenance procedures

4 Performance tests

5 Update of systems operation manual

6 O & M Personnel Training

Continuous

Commissioning

1 Assessment of Building & Systems

2 Follow-up of KPIs

3 Repair / Retrofit Planning

4 Execution of Plans

5 Annual Reporting

6 O & M Personnel Training

7 Continuous Monitoring

Commissioning Process

• Starts in the pre-design phase, latest in the design

phase of project

• More focus on planning: coaching!

• Meetings are important: coaching!

• Documentation

• Becomes continuos commissining practice after 1 year

of operation.

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2nd Cx

meeting:

Design review

• CxA REVIEWS CONTRACTOR SUBMITTALS;

• CONTRACTOR INSPECTS ALL

INSTALLATIONS ;

• CxA REVIEWS INSPECTION.

• CONTRACTORS START UP SYSTEMS ;

• CxA WITNESS THE BEGINNING OF EACH

START-UP;

• CxA REVIEW ALL START-UP DOCUMENTS;

• CxA, DESIGNER AND CONTRACTORS

TOGETHER CARRY OUT FUNCTIONAL

PERFORMANCE TESTS.

Design

Installation

Start-up Operation

Pre-design Air conditioning

Ventilation

DHW (+ heating)

BMS

On-site energy production

Water and plumbing

Lighting

• OWNER NOMINATES THE COMMISSIONING

AUTHORITY (CxA);

• OWNER PREPARES OWNER’S PROJECT

REQUIREMENTS (OPR);

• DESIGNERS (MEP & LIGHTING) PREPARE

BASIS OF DESIGN (BOD);

• CxA REVIEWS OPR AND BOD;

• CxA REVIEWS PRE-DESIGN DOCUMENTS.

• CxA PREPARES A COMMISSIONING PLAN;

• CONTRACTORS (MEP & ELECTRICAL) PREPARE

INSTALLATION, PRE-COMMISSIONING, START-UP

AND OPERATION CHECK-LISTS AND PROCEDURES;

• CxA REVIEWS CHECK-LISTS AND PROCEDURES;

• CxA REVIEWS DESIGN DOCUMENTS;

• CxA PREPARES PERFORMANCE TESTING PLAN;

• IAQ MANAGEMENT PLANS AND MEASUREMENT &

VERIFICATION PLAN ARE DEVELOPED.

• O&M PERSONNEL TOGETHER WITH CONTRACTOR CARRIES

OUT SEASONAL COMMISSIONING;

• CxA REVIEWS THE KPIS AND SYSTEM OPERATION

TOGETHER WITH CLIENT, DESIGNERS AND CONTRACTORS;

• SYSTEM O&M MANUAL IS UPDATED;

• O&M SYSTEM TRAINING AND TROUBLESHOOTING SESSION.

• CONTRACTORS PREPARES THE O&M-MANUAL;

• SYSTEM O&M MANUAL IS PREPARED;

• DESIGNERS AND CONTRACTORS ORGANIZES THE

TRAINING FOR O&M PERSONNEL;

• CxA REVIEWS THE O&M MANUALS AND TRAINING.

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3rd Cx

meeting:

Installation

review

4th Cx

meeting:

Performance

review

Final Cx

meeting:

Operation

review

1st Cx

meeting:

Start-up

Commissioning Plan 1/4

1. Project Definition

a. Background

b. Functional Description of the Building

2. Project Site Location & Team Members

a. Project Site Address

b. Project Team Member Directory

3. Project Schedule

4. Objective and Goals of Commissioning

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Commissioning Plan 2/4

5. Systems to be Commissioned

6. Commissioning Authority

7. Commissioning Process, Milestones and Meetings

a. Start-up meeting

b. Design review meeting

c. Installation review meeting

d. Performance review meeting

e. Final operation review meeting

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Commissioning Plan 3/4

8. Commissioning Process Activities

a. Review of Owners Project Requirements and KPIs

b. Review of Basis of Design

c. Review of Pre-Design Documents (HVAC&R, Plumbing, Lighting)

d. Review of Design Documents (HVAC&R, Plumbing, Lighting)

e. Review of Contractor’s Start-Up Procedures and Check Lists

f. Review of Contractor Submittals

g. Installation Inspection

h. Review of Start-up Procedures

i. System Functional Performance Tests

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Commissioning Plan 4/4

9. Creation of O&M Manual and System O&M Manual

10.Training of O&M Personnel

11.Commissioning Final Report

12.Seasonal Commissioning

13.Operation Review after 10 Months of Use

14.Expected work products / deliverables by each party

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Contractor to Prepare Start-up Procedures and Checklists 1/4

• Ventilation system: 1. TFA and AHU installation; 2. TFA and AHU pre-commissioning; 3. TFA and AHU panel wiring; 4. TFA and AHU start-up; 5. TFA and AHU operation; 6. VFD - Pre-commissioning, Commissioning & Operation; 7. VAV-damper pre-commissioning, commissioning and operation; 8. Ductwork air leakage test method; 9. Exhaust fan installation, commissioning and operation; 10. Fire damper installation and operation; 11. Ductwork balancing method;

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Contractor to Prepare Start-up Procedures and Checklists 2/4

• High side cooling:

1. Chiller installation

2. Chiller pre-commissioning;

3. Chiller start-up;

4. Cooling tower installation and pre-commissioning;

5. Cooling tower start-up;

6. Pump installation and pre-commissioning;

7. Pump start-up;

8. Pipe work flushing and chilled water quality test;

9. Chiller, cooling tower and pumps operation;

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Contractor to Prepare Start-up Procedures and Checklists 3/4

• Low side cooling and air conditioning: 1. Chilled ceiling / beam installation and pre-commissioning,

commissioning and operation; 2. Pipe work pressure testing; 3. Pipe work balancing method; 4. Room air conditioning unit (split, multi-split, etc.) installation,

pre-commissioning, commissioning and operation; 5. Precision air conditioning unit installation, pre-commissioning,

commissioning and operation;

• Building management system: 1. Installation of BMS; 2. Installation and operation of measurement sensors; 3. Installation and operation of weather station.

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Contractor to Prepare Start-up Procedures and Checklists 4/4

• Lighting: 1. Installation and pre-commissioning of lights and emergency lights

(indoors, external); 2. Operation of lighting controls and emergency lights; 3. Measurement of lighting levels in working and other area;

• Water and sewer systems: 1. Installation and pre-commissioning of water supply shut-off valves

and water meters; 2. Water quality testing; 3. Operation of water consumption measurement.

Contractor shall also provide the list of measurement equipment used during the commissioning and valid calibration certificates.

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Commissioning Team

Commissioning organization which is adapted in term of cost and benefit to the complexity and quality expectations of a given project.

Leader: CxA Commissioning

Authority

Client Architect

Contractor HVAC&R

Designer

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Team work

Interaction

Cooperation

Product

Suppliers

Commissioning Authority CxA

• Is leader of the commissioning team

• Works directly for the owner and is independent of

designers, contractors, vendors and suppliers on the

project

• Is totally objective in leading the commissioning

process

• Maintains an unbiased approach to problem solving

and conflict resolution

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Skills of CxA

• Have knowledge of HVAC systems, covering design, common

control strategies, installation, operations and maintenance

• Experienced in controls for HVAC systems, including familiarity

with current technology

• With practical background in field construction

• Demonstrated ability to organize many specific activities into a

coherent commissioning plan

• Have good communications skills, both written and verbal

• Proficient in documentation

• Experienced in working with multi-disciplinary teams

• Familiarity with testing and balancing

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Role of Component Suppliers

• To deliver desired performance and benefits sold to customer

• Especilly with new products / solutions in Indian market

• To provide all necessary documents and information

– Commissioning checklists;

– Functional performance testing;

– O&M manual: Just a product leaflet or something more?

– Training material:

• O&M personnel

• Users

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Commissioning Areas

• Commissioning needs may differ from project to project.

• To meet the LEED EA prerequisite 1 or the LEED-NC credit

3, commissioning must be completed, at a minimum, for:

1. HVAC&R systems;

2. Lighting and day-lighting controls;

3. Domestic hot water systems;

4. Renewable energy systems.

• What about:

1. Plumbing;

2. Water;

3. ?

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Functional Performance Testing 1/4

• Evaluation of results is the final step.

• System functional performance testing occurs once all

system components are installed, energized,

programmed, balanced and otherwise ready for

operation under part - and full-load conditions.

• Systems performance testing is performed by the CxA,

the installing contractor, and designer.

• It may reveal problems with the performance of the

commissioned systems and may require significant

follow-up and co-ordination among members of the

project team.

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Functional Performance Testing 2/4

• Each component has a well-defined function inside the whole HVAC system. Any malfunction can compromise the correct behaviour of the entire system. The malfunction may be due to:

– Design faults

– Selection or sizing mistake

– Manufacturing fault or initial deterioration

– Installation fault

– Wrong tuning

– Control failure

– Abnormal conditions of use.

• The functional performance testing (FPT) is devoted to the detection of such possible malfunction and to its diagnosis.

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Functional Performance Testing 3/4

• The test can be "active" or "passive", according to the way

of analyzing the component behaviour.

– Active test to assess performance by analyzing data obtained from

systems that are subjected to artificial changes in operational

conditions.

– Passive test to assess performance by analyzing data obtained

from systems operating under normal conditions

• Active tests are mostly applied in initial commissioning,

i.e. at the end of the building construction phase.

• Later in the Building Life Cycle a passive approach is

usually preferred in order to preserve health and comfort

conditions inside all the building occupancy zones.

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Functional Performance Testing 4/4

• CxA provides a plan of functional performance test of key equipment and systems during design phase and carries on the performance testing together with contractor and designers.

• Two key areas:

– Ventilation and Cooling System Operation (operation of TFAs, AHUs, exhaust fans, chiller, cooling tower and pumps as system with different weather and occupancy conditions)

– Overall Performance of Room Systems in different occupancy conditions:

• Monitoring of Room Conditions: temperature, CO2, relative humidity

• Monitoring of Operation of Critical Components like VAV-dampers.

• Operation of Lighting System in case of power failure, different occupancy and outdoor lighting conditions.

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LEED Buildings => Buildings?

• ISHRAE Good Practise of Commissioning?

• Awareness building?

• Training?

• Accreditation of professionals?

• Part of ECBC?

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Thank you for attending

maija@santrupti.com

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