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General Commissioning Procedure For Economizers: CXTPL Upgrade Project Oct. 31, 2001
General Commissioning Procedure For Economizers: CXTPL Upgrade Project Oct. 31, 2001
Prepared for:
Pacific Gas & Electric Company,
Customer Energy Management Non-Residential New Construction Program
Development of a Commissioning Test Protocol Library Project
Alyssa Newman, Project Manager
Ken Gillespie, Project Lead
Prepared by:
Pacific Gas & Electric Company,
Technical and Ecological Services, Performance Test and Analysis Unit
Richard Fromberg
Legal Notice
Pacific Gas and Electric Company (PG&E) makes no warranty or representation, expressed or
implied, with respect to the accuracy, completeness, or usefulness of the information contained in
this report, or that the use of any information, apparatus, method, or process disclosed in this
report may not infringe upon privately owned rights. Nor does PG&E assume any liability with
respect to use of, or damages resulting from the use of, any information, apparatus, method, or
process disclosed in this procedure.
CONTENTS
General Commissioning Procedure for Economizers
FOREWORD .1
I. PROJECT / BUILDING DESCRIPTION...2
II. SEQUENCES OF OPERATION...4
III. ACCEPTANCE AND RESPONSIBILITIES...5
IV. VERIFICATION CHECKS FOR REQUIRED DOCUMENTATION AND
TRAINING.6
V. VERIFICATION NAMEPLATE DATA CHECKS..7
VI. VERIFICATION INSTALLATION CHECKLIST.10
VII. VERIFICATION CONTROLS SENSOR CALIBRATION CHECKS.....13
VIII. VERIFICATION BALANCE REPORT CHECKS. 14
IX. VERIFICATION OPERATIONAL CHECKS
1) EXERCISE DAMPERS15
2) FIRE ALARM ECONOMIZER DAMPER POSITIONS.17
3) ECONOMIZER MODE CHECKS....18
4) CONTROLS PROGRAM CHECKS.20
X. FUNCTIONAL CHECKS FORCED RESPONSE AND SEQUENCE OF
OPERATION TESTING FANS ON/OFF, MORNING COOL-DOWN OR
WARM-UP, NORMAL OPERATING MODES, FIRE/SMOKE ALARM,
FREEZE PROTECTION AS-BUILT RECORDS ..21
XI. FUNCTIONAL TESTS ECONOMIZER PERFORMANCE TEST....25
XII. FUNCTIONAL TESTS ECONOMIZER OPERATIONAL TREND TEST..26
XIII. FUNCTIONAL TESTS M&V SAVINGS CALCULATION USING
PERFORMANCE TRENDING TESTS ..27
XIV. COMMISSIONING REPORT OUTLINE29
XV. REFERENCES USED TO DEVELOP THE ECONOMIZER PROTOCOL30
FOREWORD
This procedure provides example protocols for two fictitious buildings (one located in
Sacramento and the other in San Francisco) for steps that need to be taken to fully commission
their air handling systems economizers. Variations are provided when requirements between the
two examples differ. Each building has integrated, built-up economizers, with return, exhaust
and outside air dampers, but different sequences of operation and designs.
In commissioning an economizer, the intent is to optimize the use of outside air for cooling a
building, in order to minimize energy use, while maintaining good indoor air quality. Our
primary goal is to verify that the economizer is working as specified, while looking for
opportunities to improve upon its intended operation. This procedure was developed with the
assistance of PG&Es Commissioning Test Protocol Librarys Templates. Following is an
outline of what protocols are included here:
Project/Building Description
Description of Systems Under Test
Equipment Covered by this Protocol
Sequences of Operation
Acceptance and Responsibilities
Verification Checks
Checks for Documentation and Training
Nameplate Data Checks
Installation Checklist
Controls Sensor Calibration Checks
Balance Report Checks
Operational Checks 1) Exercise dampers
2) Fire Alarm Economizer Damper Positions
3) Economizer Mode Checks
4) Controls Program Checks
Functional Tests
Forced Response and Sequence of Operation Testing Fans On/Off, Morning Cool-down or
Warm-up, Normal Operating Modes, Fire/Smoke Alarm, Freeze Protection
Economizer Performance Test
Economizer Operational Trend Test
M&V Savings Calculation using Performance Trending Tests Outline of Procedure
References Used to Develop the Economizer Protocol
Results and Recommendations Report
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APPLICATION #: 1
NAME & FIRM OF PERSON(S) DOING TESTS: JR Doolittle, Hotwire Commissioning Services
PLANNED DATE(S) OF TEST: December 21-23, 2001
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Equipment Covered by this Protocol: Economizers of AHUs 1, 2, and 3 at the SSC and AHU-1 at the PEC.
General Notes:
1. This commissioning procedure addresses verification checks and functional testing of moderately sized packaged or
built-up air handlers.
2. In all test sections, circle or highlight any results that indicate deficiencies (i.e. responses that dont meet the criteria
for acceptance). Acceptance requires correction and retest of all deficiencies, as defined in each test section under
Criteria for Acceptance or Acceptance. Attach all retest data sheets.
3. This Commissioning Procedure does not comprehensively address fire and life safety or basic equipment safety
controls.
4. To ensure that this Commissioning Procedure will not damage any equipment or affect any equipment warranties, have
the equipment manufacturers representative(s) review all test procedures prior to execution, and be present if possible.
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ALARM SETPOINTS:
Building Static Pressure DPX-1: 0.07 wg.
Supply Air Duct Static Pressure, High: 2.4 wg, Low: 0.06 wg
Supply Air Temperature TS-3, Low: 50F
Return Air Temperature TS-4, High: 76F, Low: 60F
Mixed Air Temperature TS-2, Low: 50F
Filter (Dirty) Differential Pressure DPS-2: 1.0 wg.
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3. Name: JR Doolittle
Company name: Hotwire Commissioning Services
Responsibilities:
Verification Checks: Complete the commissioning plan, ensure that all corrections are made, retest if necessary,
use best engineering judgement to achieve design intent.
Functional Testing: Complete the commissioning plan, ensure that all corrections are made, retest if necessary, use
best engineering judgement to achieve design intent.
Signature:
Richard Fromberg
Pacific Gas and Electric
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Equipment
Dampers
Actuators
Control
Wiring
Programming
Actuators
Control
Wiring
Programming
Equipment
Dampers
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As specified
As submitted
As installed
Manufacturer
Model #
Serial #
Type
Maximum CFM
Minimum CFM
Damper Size (_____ x _____)
Maximum Velocity (fpm)
Maximum Pressure Differential (in. Wg.)
DESCRIPTION
As specified
As submitted
As installed
Manufacturer
Model #
Serial #
Type
Maximum CFM
Minimum CFM
Damper Size (_____ x _____)
Maximum Velocity (fpm)
Maximum Pressure Differential (in. Wg.)
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DESCRIPTION
As specified
As submitted
As installed
Manufacturer
Model #
Serial #
Type
Maximum CFM
Minimum CFM
Damper Size (_____ x _____)
Maximum Velocity (fpm)
Maximum Pressure Differential (in. Wg.)
DESCRIPTION
As specified
As submitted
As installed
Manufacturer
Model #
Serial #
Type
Electrical Data (i.e. signal range)
Maximum Position
Minimum Position
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DESCRIPTION
As specified
As submitted
As installed
Manufacturer
Model #
Serial #
Type
Electrical Data (i.e. signal range)
Maximum Position
Minimum Position
DESCRIPTION
As specified
As submitted
As installed
Manufacturer
Model #
Serial #
Type
Electrical Data (i.e. signal range)
Maximum Position
Minimum Position
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SSC
AHU3
PEC
AHU1
General Installation
General appearance good, no apparent damage
Environment clean
Good access for maintenance
Access doors close tightly no leaks
Equipment labels affixed properly
Economizer installed in accordance with manufacturers specs and
drawings
The installation and location of the economizer are in a neutral
zone of the building (i.e. there are no undo pressure restrictions or
drops that hinder air movement)
Outside air intake is located away from pollutant sources and
exhaust outlets
Damper Installation
Dampers and linkages installed in accordance with drawings
Dampers are properly linked, and move in the right directions
Linkages have minimum play
Installed dampers match specifications
Dampers move freely without binding and are fully operational.
There are no unusual noises when operating.
Actuators are mounted to maximize torque available to the damper
and to maximize linearity between the blade position and the
actuator stroke.
Multiple section dampers with multiple actuators need to have
identical actuators and linkages to make each sections
characteristics consistent.
Blade lengths of 48 inches or less are desirable, to reduce flutter and
improve sealing.
Dampers close tightly
Dampers are lubricated. Vertical blades have thrust bearings.
Outside air and return air dampers mounted to promote thorough
mixing of the two airstreams prior to entering coils
Dampers are pointing in the direction that facilitates efficient air
movement
Verify that damper actuators are marked as follows: 0% position
where the damper is closed, XX% position for the damper
minimum air flow position, and 100% position where the damper is
fully open.
Ductwork
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Comments
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The checklist items are all successfully completed for given trade.
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CALIBRATION
SENSOR VALUE
DIFFERENCE
ACCEPTABLE
DIFFERENCE
ACCEPTABLE? /
COMMENTS
SF(.5F),Sac(1F)
1F
SF(.5F),Sac(2F)
0.2 inH2O
Filter Differential
Pressure
COMMENT
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Acceptable?
Maximum outside air flow with outside air damper full open,
100% supply air flow
Minimum outside air flow with outside air damper at minimum
and supply fan at 100%
Minimum outside air flow with outside air damper at minimum
and supply fan at minimum RPM
Test and balance report is verified to be in agreement with economizer design specifications? ___ YES ___ NO
Test and balance report is verified to be in agreement with system minimum outside air design specifications?
___ YES ___ NO
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Check
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The checklist items are all successfully completed for given trade.
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Check
The checklist items are all successfully completed for given trade.
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Check
Disconnect power to supply and exhaust fans to make sure that they do not
turn on throughout the following tests.
Set BAS to Unoccupied (Fan Off) Mode
Verify that outside air damper is closed.
Verify that return air damper is open.
Verify that exhaust air damper is closed.
Set BAS to warm-up mode.
Outside and exhaust air dampers closed?
Return air damper open?
Set BAS to cool-down mode.
Set outside air temp to 65F
Outside and exhaust air dampers are full open?
Return air damper is closed?
Set outside air temp to 75F.
Outside damper is at minimum and exhaust damper is closed?
Return air damper is full open?
Set BAS to Occupied Mode
(For the SSC) Set outside air temp to 3F less than the warmest zone
temperature.
(For the PEC) Set the outside air temp to 71F or 1F less than the return air
temp, whichever is less.
Verify that outside air damper is full open.
Verify that return air damper is closed.
Verify that exhaust air damper is full open.
(For the SSC) Set outside air temp to 1.5F less than the warmest zone temp
(For the PEC) Set the outside air temperature to 73F.
Verify that outside air damper is at minimum.
Verify that return air damper is full open.
Verify that exhaust air damper is closed.
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(For the SSC) Check that the minimum mixed air temperature is
maintained. Set the mixed air temp to 2F less than the minimum set point
for mixed air temp of 45F.
(For the PEC) Check that the supply air temp set point can be controlled.
Set the supply air temp to supply air temp set point minus 2F.
Set the outside air temperature to 40F and the return air temperature to 70F.
Verify that outside air damper is closed.
Verify that return air damper is open.
Verify that exhaust air damper is closed.
(For the SSC) Set the mixed air temp to 47F.
(For the PEC) Set the supply air temp to supply air temp set point plus 2F.
Verify that outside air damper is full open.
Verify that return air damper is closed.
Verify that exhaust air damper is full open.
Release the mixed, supply, and outdoor air temperature overrides and the
BAS to its normal state.
The checklist items are all successfully completed for given trade.
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Have flow charts and/or other documentation of the software specific to the
SSC and PEC been provided?
Check the logic diagrams for the economizers. Do they accurately model the
sequences of operation, as follows:
Shut down?
Warm-up?
Cool-down?
Occupied Mode?
Economizer Mode (free cooling)? Is the logic set up to modulate the
economizer to maintain supply air temp (PEC) or a minimum mixed air
temp (SSC)?
Minimum Outside Air Mode?
Fire/Smoke Alarm Mode?
Freeze Protection?
Check the building occupancy schedules. Is the PEC M to F 7:00A to 6:00P
and is the SSC M to F 6:30A to 5:30P, with AHU#3 24-7?
Is the warm-up or cool-down mode scheduled to begin 1 hour before
occupancy?
Are there alarms set for economizer malfunctions?
Have graphics screens of the economizer and associated temperatures and
damper positions been set up?
Are the graphics screens easy to access from other graphics screens?
Are trends set up to store economizer data?
Can 48 hours of data be retrieved and plotted conveniently from the BAS for
each economizer?
Is the % outside air to total air calculated?
The checklist items are all successfully completed for given trade.
COMMENT
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X. Functional Checks Forced response and sequence of operation testing - fans on/off, morning CoolDown or Warm-up, normal operating modes, Fire/smoke alarm, freeze protection
The functional tests that follow include forced response tests and sequence of operation tests. Protocols for operational
trend tests follow.
General Instructions: The following sections are a series of field tests that are intended to verify that the economizer, as
installed, operates as it was intended to operate by the designer. In general, these tests are best done with the building
unoccupied or lightly occupied. Environmental conditions will be affected. If that is not possible, the commissioning agent must
devise tests that are not intrusive. Some tests may involve trending normal operation over a long enough period to observe the
conditions and modes of operation desired.
Attach to this form all relevant field data, monitored data, graphs, trend logs, and so forth. Annotate any data and graphs so that
it is clear what the data are proving. EMS trend logs of EMS outputs, program print-outs, or schedule and setpoint print-outs
are not acceptable as proof of operation, unless the information is first verified to be accurate and documentation is attached.
Trend logs of sensor inputs to the EMS are acceptable. If you were not able to complete a test, explain in a comment.
Instructions: These functional checks augment the manufacturers instructions, and are to be performed when the system is
operational. Fill in the appropriate values if other information is requested, such as damper position (%) or temperature.
Identify responsible contractor.
Check Economizer Damper Responses when the Fans are Turned On and Off, then during Morning Cool-down and Warmup, then during Normal Occupied Operating Modes
These tests are to verify that the dampers respond properly to various input conditions in different operating modes. Follow the
steps in the table below for each economizer.
Criteria for Acceptance: Answers of Y (or NA, where not relevant) except where other criteria are noted.
Caution: Only qualified personnel familiar with the operation of the installed air handler, and the hazards involved, should
adjust, operate, test, and/or service the equipment. The commissioning agent should become familiar with the installation,
operation, and maintenance manuals prior to starting commissioning work. Failure to observe proper safety precautions could
result in damage to equipment, severe bodily injury, and/or loss of life.
Check
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Return the BAS and AHU to their normal operating modes, and release
the OAT, SAT, MAT, and set point overrides.
Are the fans on?
Are the dampers in their expected operating positions based on outside
air and return air temperatures? Record the OAT and RAT.
For the SSC:
Set the supply air temperature set point to 55F.
Set the return air temperature to 72F.
Set the outside air temperature to 74F.
Is the outside air damper at minimum, the return air damper full open,
and the exhaust air damper closed?
Set the outside air temperature to 70F.
Are the outside and exhaust air dampers full open and return air damper
closed?
Set the mixed air temperature reading to 43F (below the minimum mixed
air temperature set point of 45F).
Do the outside and exhaust air dampers modulate closed, and return air
damper modulate open to try to raise the mixed air temperature up to
45F?
Set the mixed air temperature reading to 35F, to check for freeze
protection.
Are the outside and exhaust air dampers fully closed, and return air
damper fully open, to protect the coil against freezing?
Set the fire/smoke detection signal to ON.
Do the fans turn off?
Do the outside air and exhaust air dampers close?
Return the BAS and AHU to their normal operating modes, and release
the OAT, SAT, MAT, and set point overrides.
Are the fans on?
Are the dampers in their expected operating positions based on outside
air and return air temperatures? Record the OAT and RAT.
Both Cases:
Set the BAS to heating mode.
Does the outside air damper go to its minimum position?
Is the exhaust damper closed and the return damper full open?
Return the BAS to its normal operating mode.
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Equipment->
SSC
AHU1
SSC
AHU2
SSC
AHU3
PEC
AHU1
Contractor
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Value/
Comments
Attach the time plots to this test form to document your test results.
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2. After the retrofit is completed, collect the same economizer data as well as supply fan RPM data. Data collected
during a wide range of outside air temperature conditions is preferable. Collect data for at least one month, for use
as an estimate of the savings. Collect data for one year for use in determining ESCO payments or utility rebates.
3. Create a model of the mixed air temperature minus what the MAT should be versus outside air temperature, for
both pre- and post-retrofit data.
4. Using fan performance curves, estimate the fan flow (in lbs/hour) from the RPM data that was collected during the
post-retrofit period.
5. Create a model of the fan flow as a function of ambient temperature for the post-retrofit period, for when the
building was occupied.
6. If a full year of data is not available, estimate how much energy will be saved from short-term data in a normal year.
Load TMY2 data for your site into a spreadsheet, and use the models to predict MAT deviations and supply airflows
using expected ambient temperatures.
7. Filter the ambient temperature data to include only data for when the building is occupied.
8. For each hourly reading of ambient temperature, calculate the energy saved due to the economizer retrofit, using
the following formula:
Energy saved(kWh) = [(MATdevpre MATdevpost) * Supply Air Flow(lbm/hr) * 0.24 (Btu/lbm*F)] /
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For each economizer, follow this procedure for determining annual energy and dollar savings:
Criteria for Acceptance: The calculated estimate of monthly savings meets the required minimum level and range of uncertainty.
Check
Equipment-> SSC
SSC
SSC
PEC
Contractor
AHU1 AHU2 AHU3 AHU1
Sum up the hourly energy savings for the nominal weather year to
calculate the expected annual energy savings (kWh/yr).
If actual savings are to be determined for ESCO payments or utility
rebates, repeat the above calculation using actual monitored data (for one
year of the post-retrofit period) and the model from the pre-retrofit test
period applied to the post-retrofit data.
To calculate the energy dollar savings, repeat the energy savings
calculation on an hourly basis, and apply actual electrical energy rates
(either TOU or other applicable schedule). Sum up the dollar savings for
the year for an annual amount.
Calculate the uncertainty (and confidence interval) in the results using
methods outlined in ASHRAE 14P.
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Value/
Comments
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