Why Commission Systems Beyond Just HVAC

Why Commission Systems Beyond Just HVAC

The basis of Commissioning efforts historically have been performed on HVAC systems since they have the most issues surrounding their ability to work correctly, which directly affects the comfort of the occupants and has the greatest impact on energy consumption. HVAC systems have become very complex, and are installed by multiple contractors and vendors, which makes achieving full functionality difficult, if not properly tested and managed to completion. That, coupled with the fact that most general and mechanical contractor’s personnel do not fully understand the operation of the systems they and their subcontractors or vendors are installing, leads to systems not performing correctly. Building owners assume that the general contractor and his subcontractors always deliver fully functional systems, which is absolutely not true. This is the reason Commissioning was created, to provide a responsible party to verify that performance is delivered.

One reason commissioning of other systems has not been totally accepted by building owners is that the effectiveness of most existing commissioning efforts is not obvious due to most commissioning providers depending upon paper validation of contractor testing. We call this “Process Based Commissioning”

The better way to commission a building is by “Technical Based Commissioning”. Technical Commissioning relies on actual 3rd party testing done by the commissioning provider and their team. Technical Commissioning takes a little longer but actually provides true operability and functionality of systems. It is of little value to do Process Based Commissioning on any system, especially on  other systems beyond HVAC.

Most building owners or developers understand the basic need to commission HVAC systems but do not understand that other building systems also affect HVAC system performance and energy & water efficiency and can also cause operational issues on their own. Over time, building owners are starting to see the value in commissioning other systems beyond HVAC. Let’s look at the other systems that should be included in the commissioning effort and why:

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1.      Building Enclosures

Building enclosures are always inspected and managed by the project architect for appearance and compliance to the design. The architect will inspect the enclosure to see if it complies with the design documents, but probably will not provide a detailed inspection of all installation locations.

Commissioning of Enclosures includes:

  • Assist the design team in specifying the commissioning process of the enclosure and specifying the building test parameters to meet national standards. Verify the design drawings and adequality communicate contractor installation requirements.
  • Air barriers and vapor barriers must be inspected at installation, and prior to covering, to verify that all joints and penetrations are sealed. Special attention is given to transitions at walls to floors, walls to roofs, and walls to windows and doors. Air seals at the bottom plate and top plates are inspected, which are normal air leak points.
  • Inspection of exterior cladding installation and sealing is done to verify there are no openings for snow, ice or water to enter the enclosure.
  • Inspection of exterior wall and roof insulation installation is done to verify there are no voids. Special attention is given to door, window and corner framing where there is insufficient space to install the specified insulation.
  • Inspection of roofs and flashings is performed to verify they are installed correctly and there aren’t any issues that will lead to premature failure or increased maintenance, such as incorrect slope to drains, sharp transitions of the underlying structures and incorrect fastening of the membrane to the structure. Flashings are inspected to verify they are continuous and will deflect all water from entering the structure.
  • Inspection of doors and window installation are performed to verify they are installed as specified and installed correctly to prevent water and air intrusion. Special inspection is done for water channels in windows and store fronts. Doors are inspected for correct weather seals and sweeps.
  • Performance or verification of air pressure testing and water and thermal intrusion testing. Like all other systems, if you do not test the system, you probably will not get the specified performance. All new building enclosures should be pressure tested to verify total air leakage and thermally tested to verify a continuous insulation barrier. Other standard testing that can be performed is water intrusion testing, pull testing, and roof water intrusion testing.
  • Functional testing of operable enclosure components such as auto doors, windows or shades. Any system that has controls should be tested and that includes automatic doors, automatic windows and automatic shades. These are tested for correct operation as specified.

How Enclosures Impact other systems and Energy and Water usage:

Failure of the enclosure to contain water, air, vapor, thermal and sound intrusion can impact the performance of the facility as follows:

  • Water, Air, Vapor and Sound intrusion can affect occupant comfort, which causes the occupant or operators to adjust the room operating conditions to compensate for the intrusion increasing the energy usage of the system. If the HVAC system has water cooled condensing systems, then the water usage of the facility is also increased.
  • Thermal intrusion caused by air leaks or deficiencies in the insulation barriers increase the HVAC load, which then increases the system electrical and water usage.
  • Enclosures that allow water to penetrate the exterior boundary can lead to serious maintenance issues with degradation of the structure or mold growth in the wall cavities which leads to added maintenance and operational costs.

2.      Electrical Power and Emergency Power Distribution Systems

Since LEED has added power distribution systems to their requirements, more electrical commissioning is being done. Normally, the electrical engineer of record is required to inspect the power distribution system before it is powered up to verify it is ready for power, but most engineers do not inspect all aspects of the system. Electrical systems are code verified by the Authority Having Jurisdiction (AHJ), but a code inspectors’ purpose is safety, not performance, which directs his inspections. Relying on code inspection for system performance will not achieve the design intent for performance without proper testing and validation.

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Commissioning of Electrical Systems includes:

  • Assist the design team in verifying the design adequately defines all integrations to the electrical systems and that the drawings adequality communicate contractor installation requirements.
  • Inspecting wire and raceway installations are done to verify that it is installed as specified and the cable is inspected to verify that there is no overpull damage and the color or phase tape is correct. Ground systems are verified that all devices are grounded and continuous grounds are present as specified.
  • Inspection of the installation of switchgear, distribution board and panel board to verify they are installed as specified and are complete before powered up. Final inspection verifies all equipment has been programmed or adjusted in accordance with the coordination study and that all panel labels and arc flash warning stickers are applied.
  • Inspection of all transformers to verify they are installed as specified and no wire is installed in the temperature restricted area of the transformer.
  • Verify that the contractor has properly torqued and resistive tested all bolted connections. Also verify that the electrical contractor has megger or Hi-Pot tested all conductors as specified.
  • Verify that the contractor has performed all circuit breaker injection testing as specified.
  • Lighting systems are verified and lighting control systems are tested and verified to be fully functional.
  • ·Verify the electrical contractor has tested each connected device as they are electrified and has performed a power quality test on the completed system.
  • Provide a final functional test of the emergency power system by performing a drop test to verify generator operation and all ATS switch operations. Also, all emergency lighting and other emergency circuits are verified during the power drop test. Automatic restart of all power systems is verified after the system is back on normal power.

How Electrical Systems Impact other systems and Energy and Water usage:

It is obvious that without electrical power the HVAC system does not operate but there are other aspects of electrical power that have a negative impact on HVAC systems:

  • Out of balance electrical phase, low voltage, low power factor or poor frequency response can lower the performance of HVAC systems leading to more repairs, maintenance and higher energy usage. These issues may be difficult for operators to diagnose, leading to added operations and maintenance costs.
  • Overpowered circuits can also impact the performance of HVAC systems leading to increased maintenance and energy usage.
  • Improperly programmed ATS switches can damage mechanical equipment when returning to normal power, increasing system maintenance costs.
  • Emergency power systems that do not provide repeatability in providing backup or emergency power due to lack of testing creates added operations and maintenance costs.

3.      Plumbing Systems

Plumbing systems have traditionally been ignored by commissioning efforts due to being code driven and most issues are assumed to be obvious, such as leaks or nonoperational fixtures, but the truth is, there are many things hidden in regards to plumbing systems and they really need to be commissioned, such as water pressure, landscape irrigation and fixture flow balance. Water costs continue to increase and are becoming important to total facility operating costs.

Commissioning of Plumbing Systems includes:

  • Assist the design team in verifying that the design drawings adequality communicate contractor installation requirements.
  • ·Inspecting both drain and water piping installation for correct material, installation practices, correct slope and compliance to the specifications.
  • Inspect fixture installation for the correct fixture and that it is correctly installed.
  • Once systems are operational, verify total building water pressure, test auto flow faucets for distance of detection and test fixtures flush valves for flow amounts and proper valve adjustment. 
  • Verify water heater, circulation pump startup and verify mixing valve temperatures have been correctly adjusted.
  • Verify that pressure pumps have been programmed or adjusted correctly by testing the systems
  • Verify all other plumbing systems have been started up and performance verified such as water softeners, RO/DI systems, water recovery systems, sewage ejectors and sump pumps.
  • Test and verify landscape irrigation systems by testing each zone and emitter for proper programming and flow. For normal buildings, water used for landscape is the largest use after fixtures.

How Plumbing Systems Impact other systems and Energy and Water usage:

It is obvious that without water the facility would not be occupiable, but other aspects of the plumbing systems that are not obvious may impact the facility as follows:

  • High water pressure can cause fixtures to flow more water than intended, increasing the total cost of water. Water pressure should be limited to what is required at the top floor of the building (normally 35 PSI for plumbing fixtures).
  • Water heater temperature adjustment must be high enough to prevent growth of legionella bacteria but low enough to save as much energy as possible. Normally we see 125⁰ for distribution and 90⁰ mix at the fixture and 180⁰ for food service. Hot water circulating systems need to be balanced to provide no more flow than is necessary to prevent the main pipe to cool. If the flow is too high, excess energy is wasted in heating the return line, and if it is too low then water is wasted waiting for hot water at the fixture.
  • Leakage of fixture valves or gaskets can cause undetected water usage. Poorly adjusted flow valves or auto faucets can cause excessive water usage if they stay on too long.
  • Water leakage or unintended use of landscape irrigation system waste excessive amounts of water. Verify the watering schedule meets landscape needs, but does not over-water, which wastes water and may possibly damage the landscape. It is common for landscapers to ignore small leaks and not plug emitter on areas where plants have been removed, or adjust schedules for changing conditions.   

4.      Fire Alarm Systems

Fire alarm systems are also code driven and normally are fully inspected by the AHJ or Fire Marshal, but there remain several integrations between fire alarm and other systems that normally are not fully tested by fire alarm contactors or code officials. These untested integrations can cause serious operating conditions for facilities and should be fully tested and commissioned.

Commissioning of Fire Alarm Systems includes:

  • Assist the design team in verifying the design adequately defines all integrations to the fire alarm system and that the drawings adequality communicate contractor installation requirements.
  • Inspecting cable and raceway installation for compliance to specification and quality installation practices.
  • Inspect all fire alarm panels and devices for compliance to the specification for type and capability.
  • Test and verify all input signal devices for proper operation, such as smoke detectors, heat detectors, door pulls, flow switches, and tamper switches.
  • Test and verify all output alarm devices such as strobe lights, horns/sirens and local alarm bells. Verify voice messages if it’s a notification system.
  • Verify emergency power integration points for proper operation for normal and emergency operation.
  • Verify elevator integration points for proper operation for normal and emergency operation.
  • Verify HVAC integration points for HVAC equipment response to alarm conditions. Also, test and verify any alarm notification sent to HVAC controlling systems.
  • Test and verify off-site UL notification system response.

How Fire Alarm Systems Impact other systems and Energy usage:

Fire Alarm systems are safety notification systems and most problems with FA systems is false notification, which disrupts occupant’s productivity and increases operations costs. FA systems also can impact other systems as follows:

  • Fire alarms are normally integrated with the HVAC equipment for proper shut down on smoke or fire detection. If shut down is caused by improper programming or false alarms, lost productivity will increase operations cost. False alarms can also impact energy costs since normal space temperature control is overridden during an event getting the space back to setpoint requires additional energy.
  • Fire alarm integration with laboratory ventilation systems can trigger building low pressure events caused by shutting down supply systems but not exhaust systems. This has caused instances where operators could not exit the building because they could not open the exit doors due to pressure. These were safety issues cause by lack of proper commissioning.

5.      Security Systems

Security systems consist of intrusion detection systems, closed circuit TV systems and door access systems. Security systems are not code directed and are normally installed and tested by the installing contractor without validation by a 3rd party, unless the owner has a special security process, such as the Federal Government.

Commissioning of Security Systems includes:

  • Assist the design team by verifying the design adequately defines all integrations to other systems and that the drawings adequality communicate contractor installation requirements.
  • Inspecting cable and raceway installation for compliance to specification and quality installation practices.
  • Inspect all security panels and devices for compliance to the specification for type and capability.
  • Test and verify all input signal devices for proper operation such as cameras, card access controllers, alarm detectors and duress alarm switches.
  • Test and verify all output and alarm devices such as security stations, strobe lights and horns/sirens. Verify voice messages if it’s a notification system.
  • Verify HVAC system integration points for proper operation.
  • Verify electrical lighting system integration for proper operation.
  • Verify elevator integration points for proper operation for normal and emergency operation.
  • Test and verify off-site UL notification system response.

How Security Systems Impact other systems and Energy usage:

  • Security systems may have integration into HVAC and lighting systems where access is restricted to certain areas of a building during unoccupied hours. These unoccupied access sequences should be tested for correct operation. If these don’t work correctly, occupant productivity will be affected.
  • Access systems may be integrated with HVAC systems for restricted space temperature control. Incorrect operation of these systems may impact occupancy and energy usage.

6.      Communication Systems

Communication systems are not code directed and are normally components that are tested separately since there are many different vendors devices using the communication backbone. If the communication system backbone is not properly tested it will affect all connected systems and devices. Almost all systems are now network-based so the communication system has become critical to facility operations.

Commissioning of Communication Systems includes:

  • Assist the design team in verifying that the design adequately defines all systems that will utilize the main communication networks and that the drawings adequality communicate contractor installation requirements.
  • Inspecting cable, fiber and raceway installation for compliance to specification and quality installation practices.
  • Inspect all IT cable racks and terminations. Inspect all IT data rooms and closets for correct installation and for compliance to the specification.
  • Verify that the installing contractor has performed all required cable and fiber tests on network cabling systems. Contractors normally test network cables for continuity and signal strength and perform OTDR tests on fiber optic cable.
  • All cable and switch racks are inspected for correct installation and quality cabling practices.
  • Since each system that connects to the network has different programming and operating characteristics, commissioning is limited to the operability of the network to transmit and receive packets and not the actual operation of the connected systems.

How Communications Systems Impact other systems:

  • Since all technical systems within a modern building depend upon the communication system for operation, the communication systems are critical to the functionality of all of the systems.
  • It is important that the communication systems be secure and as redundant as possible for dependability and very low-down time. Since communications are critical, the installation needs to be as high of quality as possible and fully commissioned. Any lack of functionality will have a major impact on the occupants of the facility and their productivity.

7.      Fire Protection Systems

Fire protection systems consist of water-based fire protection systems and gas-based fire protection systems. Fire protection systems are code directed and are normally inspected and tested by the AHJ or Fire Marshal.

Commissioning of Security Systems includes:

  • Assist the design team in verifying that the design adequately defines the required systems and that the drawings adequality communicate contractor installation requirements.
  • Inspecting all pipe and fire protection equipment and devices for compliance to specification and quality installation practices.
  • Inspect all fire pumps and storage tanks for compliance to the specification for type and capability.
  • Inspect gas fire protection system equipment and installation for compliance to the specifications and quality installation practices.
  • Test and verify fire pump flow and pressure. Calibrate the fire pump flow meter.
  • Verify fire protection system automatic operation by performing a detection event.
  • Verify fire alarm integration during the detection event test.
  • Test and verify off-site UL notification system response.

8.      Vertical Transportation Systems

Vertical transportation systems consist of elevators, escalators, moving walkways and dumb waiters. Vertical transportation systems are code directed and are normally inspected and tested by State elevator inspectors.

Commissioning of Vertical Transportation Systems includes:

  • Assist the design team in verifying that the design adequately defines all integrations to other systems and that the drawings adequality communicate contractor installation requirements.
  • The elevator or escalator code authority will test the vertical transportation systems for safe operations by testing:
  1. Elevator rate of speed and acceleration and escalator speed and hand rail speed. Verify governor calibration.
  2. Inspect and test guide ways for normal operation and emergency brake drop operation. Verify controller programming.
  3. Inspect and test door speed and close pressure.
  4. Verify and test emergency operation with fire alarm systems.
  • Since most of the safety operations of the elevator are performed by the code authority, most commissioning efforts are directed at operating parameters and integrations that the code authority does not specifically test. These inspections and tests include:
  1. Inspecting and testing elevator pit sump pumps.
  2. Inspecting elevator shaft HVAC tempering systems and relief systems.
  3. Verify elevator signage is in place and the required code paperwork has been supplied to the owner.
  4. Verify security system integration by testing elevator operation during security control.
  5. Verify elevator cab telephones work correctly and that the operator knows what elevator cab you are in.
  6. Re-verify the cab is level with door thresholds at each floor.

I hope this article helps you understand that other systems beyond the HVAC system also need 3rd party technical commissioning to properly verify that these systems are operating correctly and producing the desired performance.

If I can be of assistance please call me.

Thanks for reading!

Jim Bochat, LEED AP, NEBB Cx, NEBB RCx, NEBB TAB, NEBB BET

KFI Engineers

jwbochat@kfi-eng.com

(602) 758-0501

© James Bochat 2020


Dave Stark, P.E.

Consultant and Mentor at Semi Retired

3y

Great summary on commissioning of all building systems. An independent effort as described helps owner confirm he is getting what he paid for. Plus lays out a baseline of system performance that is critical as owner integrates his systems with building systems Owner staff should also participate in commissioning to get better understanding of how it all works

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