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Comprehensive Commissioning Process for India
By Maija Virta Santrupti engineers
1
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
4
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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