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Projeto Demonstrativo para o GerenciamentoIntegrado no Setor de Chillers
Commissioning Chilled Water SystemsFrom Design to Occupancy
Execução Implementação Realização
Anthony Avendano – Horizon Engineering Associates LLP
31/03/2016 – Fortaleza, CE
1
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90% of business is commissioning
10 offices; 75+ employees
Established in 199520 years of building commissioning
Expert Knowledge of LEED450+ LEED projects
OUR COMPANY
Who We Are
Professional certifications andregistrations
Strong Operational Background
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Objective• What types of Equipment is part of the
Chilled Water System• What are the advantages of
commissioning a chilled water system• What is the commissioning process of
chilled water systems• What is required to effectively commission
a chilled water system
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Chilled Water Systems
• Central Plant CHW– CHW distributed to constituents
• Equipment Served– AHUs– FCUs– Secondary Loops– Tertiary loop
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CHW Generation
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CHW System Overview
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Types of CHW SystemFlow• There are two basic types of CHW flow
systems1. Constant flow CHW2. Variable Flow CHW
• Constant flow for smaller systems, notused much today due to energy
• Variable flow for larger systems– Can be primary secondary loop– Good for green design
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Primary Secondary Loop
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Connected Loads - Dual Temperature
• Different types of systems when theheating and cooling distribution systemsare combined
1. Two pipe system2. Four pipe systems
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Two Pipe System
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Four Pipe System
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Chiller Types
• Reciprocating Liquid Chillers
• Centrifugal Chillers
• Modular Chillers (scroll, screw, magneticbearing)
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Reciprocating Chiller
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Centrifugal Liquid Chillers
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Modular ChillersBank of Chillers Compressor Types
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Condenser Water• Used to remove heat from chiller and reject to
another location• Examples:o Air Cooledo Cooling Towero Natural Water Source
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Cooling Tower - Installed
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Heat Exchangers
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Free Cooling
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• The United Nations (UN) complex spansover 17 acres and includes 6 buildingstotaling 2.7 million sf, originally built in 1950
• UN’s problems were associated with agingbuilding system and not the basicconstruction, a renovation of the complexwas the most cost-effective way of replacinginefficient equipment.
• UN’s chiller plant utilizes condenser waterby two methods: a river water system and acooling tower condenser water system.
• Under normal operation, river water is useddirectly as condenser water utilizing a waterside economizer mode.
Project Profiles
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Why Commission yourChilled Water System?• System Integration
– Individual pieces of equipment are not the wholesystem, e.g., chillers, cooling towers, pumps, heat
exchangers, thermal storage tanks, etc.
• Efficiency– Design conditions
• Safety– Personnel and property protection
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CommissioningDefinitions• Definition - “The Commissioning Process is a quality-
oriented process for achieving, verifying, anddocumenting that the performance of facilities, systems,and assemblies meets defined objectives and criteria.”
- ASHRAE Guideline 0• Sets clear measurable goals for everyone
• Verifies that the owner’s requirements are beingmet throughout the design and construction phases
• Establishes accountability• Changes the way people perform• Allows designers and contractors to measure
success as well as deficiency
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• Training of operationsstaff
• Maximizing energy usage(utilities)
• Higher value of rentableSF
• Reduction in commondeficiencies for typicaldesign / install programs
• Peer review of existingoperating protocols
Value to Property Owners
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1 Identify potential issuesduring design
2 Identify/resolve issues duringconstruction
3 Successful Day 1operations. Confirmbuilding equipment andsystems operate andperform properly
4 O&M documentation iscomplete
Value of Commissioning
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5 Operating staff is trainedproperly
6 Reduces operating andmaintenance costs
7 Improves IAQ, occupantcomfort and productivity
8 Reduces project closeoutissues
Value of Commissioning
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What is the Commissioning Processfor a Chilled Water System?
• Phases– Pre-Design Phase CX– Design Phase CX– Construction Phase CX– Post-Construction Phase CX
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Commissioning Pre-Design Phase
• Document/review owner’s projectrequirements
• Scope and budget for commissioning• Select CxA• Create commissioning plan• Working with the owner to select design
strategies and goals
PRE-DESIGN DESIGN CONSTRUCTION OCCUPANCY & OPS
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User Requirements
• Design Intent Document is the place todocument the performance requirementsof the central systems as defined to meetthe needs of the users
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Installation Types
• New Installation– All components are new installation
• Existing– Repurposing existing equipment of spaces for
a new design
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Design Intent
• The chiller plant is useless as a stand-alone monument. It needs to meet theneeds of the building users in order to beconsidered successful.
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Common Design Issues
• Pumps controlled by load differentialpressure (dP), not staged with chillers
• Low Flow Bypass is critical to maintainminimum chilled water flow through thechillers (Overboard/Bypass Valve)
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Chilled Water Flow Considerations
• Differential Pressure (dP) pumping control• Low Flow Bypass controls• Chiller staging effect on flow through
chillers• Chiller modulating flow control valves to
balance flow through multiple chillers inoperation
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Controls• Limit the speed at which the chilled water
pump VFDs can speed up and down• Limit the time span the chilled water flow
control valve actuators can stroke from min tomax
• Review the system dPs and how the pumpstrack to maintain the lowest from setpoint
• Put in a dead band so the pumps are notalways hunting due to system size andcomplexity
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Commissioning - Design Phase
• Document/review basis of design• Refine the scope of commissioning• Perform design review• Update the commissioning plan• Include commissioning requirements in
construction documents– Including pre-functional checklists and
functional performance test procedures
CONSTRUCTION OCCUPANCY & OPSPRE-DESIGN DESIGN
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Design Review• Review of the design must be in conjunction
of the OPR.• The review should be done with the mindset
of an operator and not a designer. We needto bring a completely different perspective tothe table. We don’t want to duplicate efforts.
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Design Review• Design Review
– “It’s cheaper to change it on paper than afterit’s built”
– Should be completed before CD’s are issued– Otherwise will lead to contractor change
orders– “Remember, we want Cx to save the project
money not cause it to cost more”!
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Submittals andDocumentation• Submittals - CxA requests all necessary
documentation required to properlycommission the project through the CM– May include: manufacturer installation, O&Ms,
performance data, control drawings• Pre-functional and Functional Checklists
– Provides a full range of checks to determinethat individual components, equipment andsystems operate in accordance with the plansand specifications
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Commissioning - ConstructionPhase
• Update commissioning plan and schedule• Review submittals against commissioning
plan, OPR, and BOD• Review control sequences• Update test procedures• Document construction observations• Develop systems/O&M manuals
DESIGN OCCUPANCY & OPSPRE-DESIGN CONSTRUCTION
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Factory Testing
• Review controls• Gather information• Simulate conditions that may not be
possible in field installation• Ask questions
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Simulated ControlsTesting
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Representing a Bank ofModular Chillers
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Sample Test Procedure• Simulate testing conditions not possible/safe in
field
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Checklists
• The components of the checklist:– Installation– Pre-functional– Functional and performance testing– Acceptance testing
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Checklists• Developing Cx Checklists
– Checklists should document the entirehistory of a piece of equipment as it shouldhave installation, pre-functional andfunctional checks within its fields.
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ElectricalConsiderations• Plant Operations-Emergency Power,
critical systems etc. (i.e. server rooms)• Uninterrupted Power Supplies• Plant Safety-Lighting / Exit signs
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Installation Review
• Design Details• Specifications• Submittal Requirements• IOMs• Code Compliance• Mock-ups• Good Practice (recommendations)
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Installation Comments# Tag Floor /
Coordinate Trade FoundBy
DateFound
ApplicableSpec
Issue / Impact /Recommendation Action
1 HX-402B-4 MR-50 Mechanical AA 02/26/15 Drawing
M501 detail 6Vent not installed athigh point as specified
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Pre-Functional
• Static Testing• Testing and Balancing (TAB)• Vendor check-out sheets• Point to Point
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Functional
• Sequence of Operations (SoO)• Safeties• Performance• User Interface
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Sequence of Operations
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Mode Flow Schedule
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Control Valve Schedule
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Automatic Control Valve
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CHW System SampleChecklist
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Cx Reports• Field Observation Report (FOR) or Site
Inspection Report– Documents each visit– Filled out each time the site is visited
• Deficiency Sheet– Must be completed with each deficiency– All data should be filled
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On Site• Communication - Team leader/PC/Owners Rep• Scheduling your site visit• Pre-planning precautions
– Is a shut down required?– Disruption of service
• Notify CM/owner of your presence• Report any issues found to appropriate PIC• Note deficiencies• Complete field report
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Required Resources toCommission• Team Participation and cooperation• Checklist-Detailed bases of field visits• Testing Equipment
o PanametricoHDMoData Loggerso Sensors
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Panametrics-Verify Flow Readings
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Hydro Data Meter (HDM)
• Pressure readings and the performancecurve:
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Hydro Data Meter (HDM)• Pressure readings and the performance
curve:
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Hydro Data Meter (HDM)• Circuit Setters
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Data Logging
• Utilized for the following Cxactivities:– Trending of relative humidity and
temperature of individual VAVs, AHU,RTU, AC Units, etc.
– Verify motor operation (typicallycondensate pumps, air compressors,fuel oil pumps, etc.)
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Additional Test Equipment in CxAgents toolbox
• Sound meters• Multi-meters• Infrared Thermometer• UE2000 Ultraprobe
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Commissioning - Occupancy andOperations Phase
• Assist with maintenance managementprogram
• Adjust for occupancy/warranty period• Off-season testing• Optional: lessons-learned meeting• Optional: periodic re-commissioning
DESIGN CONSTRUCTIONPRE-DESIGN OCCUPANCY & OPS
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Acceptance• The process of turnover and accepting the
equipment. It is permissible to accept equipmentprovided that the items left to complete areidentified and required to be completed
• When is system complete?• Who signs-off?
― Construction Manager― Installing Contractor― Design Professional― CxA
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As-Built Review
• Prior to completion of the project, HEAshould review the as-built documentationfor thoroughness and completion prior togoing to the design team for finalapproval
– How should this be performed?
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Occupancy Phase
• Post occupancy• Seasonal testing• Warranty• Training• Ongoing Cx efforts
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Warranty Management
• Warranty management is broken into twostages
1. The 10 month back check and interviewprocess that is required by LEED to ensurethe building is working correctly
2. The second part is if in fact there was aissue after the building was in operation, wewould go back to verify the issue
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Warranty Phase
• CxA role• Deliverables• Specification• Extended warranty items• Documentation of warranty periods• Equipment and systems acceptance• Warranty issues and review
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Seasonal Testing
• Seasonal Testing― Seasonal testing should be done on heating
and cooling systems. This test is done onthe system within its season of operation.Cooling tests in summer and heating tests inthe winter. Try to use “design days”.
― There is the issue of fan coil units and heatpumps operating in the shoulder season.These units should also be checked duringthese off seasons.
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Training
• Training Requirements• Training Documents• Syllabus Creating• Documenting Training Sessions
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Training• Gives building operators chance to
walkthrough operations and maintenancewith the construction team to relay allapplicable knowledge
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Conclusions
• Proper commissioning of your chilledwater system is essential to verify:– System operates per design intent– System run/performs efficiently– The staff are properly trained for turnover– To minimize call back for arising issues
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Email: [email protected]: www.horizon-engineering.com
• New York, NY• Long Island, NY• Albany, NY• Syracuse, NY• Charlotte, NC• St. Louis, MO• Baltimore, MD• Salt Lake City, UT• Detroit, MI• Boston, MA
THANK YOU
QUESTIONS?
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Execução Implementação Realização
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