BUILDING COMMISSIONING:

The Value of Commissioning

CaGBC Building Advisor ProgramOctober, 2012John Kokko, P.Eng., CCP, LEED APjkokko@enermodal.com519-743-8777 x2424

LEARNING OBJECTIVES

What is building commissioning

What are the steps required by LEED

Why is it important What results can we expect

NEW BUILDING CX

LEED Credits

EAp1 – Fundamental Cx (Prerequisite)

Deals mainly with construction and getting the building operating before hand-over

EAc3 - Enhanced Cx (Credit) Deals with design and post occupancy operation

WHAT IS NEW BUILD COMMISSIONINGDefinition:

To bring a new project or facility on line

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Hands over a

building that gives the owner what he paid for.

NAME FROM SHIP BUILDING

A commissioned ship is one deemed ready for service. Must pass several milestones. Equipment is installed and tested, problems are identified and

corrected, and staff are extensively trained. A commissioned ship is one whose materials, systems, and staff have

successfully completed a thorough quality assurance process. Commissioned ship is one ready to sail safely and reliably

VISION OF COMMISSIONINGTake the owner’s needs and wants► Ensure requirements properly articulated

Through the minds of the consultants► Ensure designs properly reflect OPR

Through the hands of suppliers and contractors► Ensure building is properly built

Deliver a properly performing building► Ensure all systems operate as intended

BUILDING Cx = QC FOR CARS? Similar to a QC

process for cars Note similarities in: Work area Tools Assembly

techniques Workers’

responsibilities

WHY IS COMMISSIONING NEEDED Don’t the design and construction teams already

do this? Everyone wants to do a good job. But two constrains:

1. Scope included with fees2. Knowledge of the state-of-the-art

Low price generally gets the job Designers responsible for code Site review for conformance to

drawings and specs Not performance beyond obvious

faults and complaints after the fact

UP-TO-DATE KNOWLEDGE Innovation moving extremely fast Innovative equipment and

systems are relatively unfamiliar to designers, contractors, operators and even manufacturers agents

Energy efficiency, integrated systems, imported design concepts and computerization have multiplied levels of complexity

WHAT IS INNOVATIONMULTIPLE MARRIED TECHNOLOGIES

ADDED COMPLICATIONS

Radiant heating Radiant cooling Condensing boiler Water-side economizer Building automation systems

INNOVATION INCREASING EXPONENTIALLY

Direct and indirect evaporative coolingOptimum startCascading PID loopsStratified thermal storageDaylighting controlLON and BACnetIntegration

And on and on and on ….

CONVENTIONAL COMMISSIONING

• Start-up and basic check out of equipment• Testing, Adjusting and Balancing (TAB)• Begins after systems in and ready for

start-up• Verify individual components function as

components• Performed by installing contractor or

manufacturers rep

TOTAL COMMISSIONING (LEED™)

A systematic quality assurance program

Starts at concept design and concludes at end of warranty

Includes all phases concept design, detailed design, construction, start-up, 1 year operation

Commissioning verifies energy performance and comfort maintenance

TOTAL COMMISSIONING (LEED™)

Includes reviews through all stages Includes participation of consultants, trades,

O&M staff Includes detailed reviews design, shop draw, install Expanded installation verification and start-up checks O&M documentation more centralized Whole system performance vs. component checks

COMMISSIONING COMPARISONTOTAL COMMISSIONING

Concept Design ReviewsDetailed Design ReviewsShop Drawing ReviewsSite Installation VerificationEquipment Start-Up Verification

Balancing VerificationFunctional Performance TestDocumentation and Operator

TrainingTrending and Seasonal FPTWarranty and Occupant

concerns

TRADITIONAL COMMISSIONING

No Cx. Consultant self-checks. No Cx. Consultant self-checks. No Cx. Dwgs & specs met only. No Cx. Dwgs & specs met only. Contractor or Manufacturer only. No

systems interoperability

No Cx. Contractor self-checks.No Cx. Contractor self-checks.No Cx. Contractor self-checks.

Owner verifies acceptability.Contractor seldom returnsNo Cx. Respond to complaints only.

VALUE OF Cx

Largest study to date Mills, LBNL July 2009 http://cx.lbl.gov/2009-assessment.html 643 buildings, 26 US states 561 existing and 82 new buildings 37 Cx firms 99 M ft2, $2.2 B construct 90.4 M ft2 existing, 8.8 M ft2 new construction $43 M Cx costs

NEW BUILDING Cx MEDIANS

Cx cost, $1.16/ft2 or 0.4% of overall construct cost ($290/ft2) (Range $0.60 - $2.15)

Number of deficiencies identified, 3,528(about 1/3 of projects reported deficiencies)

Energy savings 13% (Range 9% - 29%) Payback time, 4.2 years (Range 1.7 to 11.4 yrs)

AREAS OF BENEFIT

Construction Cost Savings Equipment downsizing and trade-offs

Energy Savings - $0.05 to $0.45/ft2 Peak demand reductions Maintenance and replacement costs reduced Increased productivity and reduced liability

Indoor environmental quality maintenance

Carbon emissions reductions

COMMISSIONING PROCESS OVERVIEW

LEED Cx OUTLINEDesign and Construction Phases EAp1 – Fundamental Cx EAc3 – Enhanced Cx

Design Owner documents OPR Before 50% CD Owner designatesCxA

Construction Documents Designers incorporate Cx specs into Construction Docs

CxA presents Cx Plan

50% CD CxA conducts 50% design review

Post Contract Award Owner designates CxACxA presents Cx Plan

CxA reviews shop drawings

Installation CxA performs/oversees installation verification

Start-up CxA performs/oversees functional testing

CxA reviews O&M ManualsCxA oversees staff training

Substantial Completion CxA prepares Draft Final Report CxA prepares Systems Manual

Post Construction CxA performs/oversees deferedtesting

Occupancy CxA delivers Final Report CxA provides Warranty and occupant concerns review

OWNER & DESIGN TEAM DOCUMENTATIONOwners Project Requirements (OPR)► Owner and User requirements► Environmental sustainability goals► Energy efficiency goals► Indoor environmental quality requirements► Equipment and systems expectations► Building occupant & O&M personnel requirements

Basis of Design (BoD)► Primary design assumptions► Standards► Narrative descriptions

Cx DURING DESIGN

Work with design team to define measurable energy and indoor environmental quality goals

Discuss alternatives to traditional design solutions Provide support for unfamiliar technologies Review to verify design meets objectives and technologies

properly implemented Review to verify equipment specified meets goals and

objectives

COMMON DESIGN ISSUES

No design target for energy use Lighting power density not identified No heat recovery Condensing boilers not considered Variable speed pumps and fans

ECM motors not incorporated 20°F rather than 40°F design

temp drop design used Undersized piping and

ductwork

Cx PLAN

Overview of Cx Process List of equipment and systems to be Cx Cx Team and responsibilities Management, Communication and Reporting Overview Cx Process Overview (Outline above) List of deliverables Milestones

Cx MEMBERS & RESPONSIBILITIESCOMMISSIONING AGENT Owner’s rep leading commissioning Reviews and produces most paperwork Directs testing Ensures LEED™ requirements are metOWNER Provide support as required to ensure Cx

proceeds smoothly FM Staff?Consultants Provide documentation as required for review Attend commissioning meetings as required

GENERAL CONTRACTOR► Ensures contractors meet commissioning

requirements

M&E CONTRACTORS► Completes start-up, installation verification lists► Operates equipment for Performance Testing► Produces O&M manuals, Provides owner trainingCONTROLS CONTRACTOR► Operate controls for Performance Testing, produce

O&M materials for controls

Cx MEMBERS & RESPONSIBILITIES

Cx SPECIFICATIONS

Contractor responsibilities Submittal review process Meetings IVC process Start-up process Balancing reviews FPT process O&M manuals requirements Training requirements Warranty review

Cx DURING CONSTRUCTION

Verify equipment installed per drawings and specs, manuf’rs requirements and proper industry practice and standards

Verify equipment is, set-up, adjusted, balanced, controlled and operated to provide expected comfort and energy performance

Provide owner complete systems O&M docs Provide owner’s operating personnel

adequate training to understand, operate and maintain equipment

COMMON INSTALLATION ISSUES

Coils piped backward Maintenance access not

provided Pumps with shaft oriented

improperly Thermostats located adjacent

to heating/cooling diffusers Insulation missing Sensors improperly located

COMMON FUNCTIONAL TESTING ISSUES

Controls functions not matching sequence

VFDs do not modulate Outdoor damper minimum

position Control valve action reversed

TRAINING TOPICS

General purpose of system Use of O&M manuals Operation of systems under all conditions Interaction with other systems Adjustments and optimization for efficiency Health and safety Special maintenance and replacement resources Occupant interaction Controls training

SYSTEMS MANUAL

Final BoD System single line diagrams As-Built sequences, set-points, etc. System operating instructions Maintenance schedule Retesting schedule

Cx AFTER OCCUPANCY

Follow trends on BAS to ensure ongoing operation Completion of deficiencies remaining after

construction Follow-up on warranty issues arising Follow up on occupant concerns during warranty

and first year occupancy Verify that issues are cleaned up by the end of

warranty

FINAL REPORT

OPR Design and shops review summary Cx specifications IVC results FPT results O&M evaluation Value achieved through Cx Outstanding issues

MULTI-FUNTION AHU

DESIGN ISSUES Dehumidifying only

outdoor air reduces size of equipment and increases efficiency of equipment

Using heat recovery to reduce load on cooling coil

Using indirect evaporative cooler to increase HX eff’yhumidity carried outdoors

MULTI-FUNCTION AHU

INSTALLATION ISSUES No radiation shield on sensor by flame No maintenance access to some

sensors Installation of single point sensor

where averaging required Reset button set tight and vibration

causing unit to cut out Overloads not set properly

BOILERS

DESIGN ISSUES No check valves would

required both boilers operate in parallel

Independent controllers would not have been coordinated

Primary only loop with DHW would have required continuous minimum 160F

BOILER

INSTALLATION ISSUES Water treatment eliminated by

aluminum boiler manufacturer. But piping not protected

OA reset not programmed because tech believed it would not save energy

Control sensor located in single boiler supply rather than common header

RETIREMENT RESIDENCE

HVAC SYSTEM

Ground loop coupled distributed heat pumps with supplemental gas-fired heating.

One AHU with heat recovery and HP htg/clg for fresh air distribution to corridors and common areas

One AHU with WLHP htg/clg for Kitchen

Individual HRVs for ventilation and WLHPs for htg/clg in each room

RETIREMENT HOME

DESIGN ISSUES

Heat injection before rather than after ground loop

Moved to eliminate boiler heating ground

HX between building loop and ground loop removed

Reduced capital cost and increased efficiency

RETIREMENT HOME Cont’d

Dedicated DHW heaters simplified boiler loop controls, allowed summer shutdown and allowed primary loop OA reset and condensing

Cascading different temperature loops ensured cold return water temps

40°F temp rise drop reduced pipe and pump sizing

SHOP DRAWING REVIEW FINDINGS1. 3 re-submittals of heat wheel shop drawings required

before a workable defrost strategy provided.2. Shop drawing coil performance based on water while

system will used propylene glycol.3. Coils have greater air-side and water-side pressure

drops than specified.4. Controls sequences were carbon copy of engineer’s

general wording rather than converting to specifics that can be programmed. Heat wheel, heating coil and cooling coils shall be

sequenced to provide energy efficient operation

AIR HANDLER

SERVICES and REPAIR BUILDING

HVAC SYSTEM

Ground Source Heat Pump Radiant floor heating Dedicated outdoor air ventilation with heat recovery Supplemental fan coils for cooling

SERVICE and REPAIR BUILDING

HVAC System

SMALL SERVICES BUILDING

Functional Testing

System relied on heat pump circulator but never programmed to operate when heat pump off

PID loops needed tuning to provide stable operation Radiant floor valve found with wire not connected leaving

valve open and space overheating

SERVICE AND REPAIR BUILDING CASE STUDYFUNCTIONAL TEST Storage room hot, office cool. Found crossed floor loops. Office

t’stat controlling floor heat in storage room. Loops not labelled

Heat pump constantly tripping. Supplier blamed system but did not measure any parameters. Cx measurements showed water flows ok. Heat pump diagnostics finally found faulty TX valve and low refrigerant.

Controls are probably the single most important item in ensuring successful system operation for comfort and energy savings.

CC programmed system heating water temps lower than specified because this works better

Improperly programmed 24 hr moving average outdoor temp caused the system to flip-flop between heating and cooling

REAL PERFORMANCE

What is the energy use of typical buildings?

0

100

200

300

400

500

600

700

800

All Bldgs (ON)

C&I Accom (ON)

Offices (ON)

Offices (CAN)

GoG

AnnualEnergy

ekWh/m2

All data (except GoG) from NRCan Survey (CIBEUS, 2000).

RETIREMENT RESIDENCE AActual Performance

0

50

100

150

200

250

300

Dec '04 (SL) Nov '05 (SL) Nov '05 (CBIP) Jul '06 (Review) Apr '07 to Mar '08

Simulated

Actual

AnnualEnergy

ekWh/m2

Floor Area = 5348 m2

0

50

100

150

200

250

Aug '04 (SL) Feb '06 (CBIP) Aug '06 (Review) Aug '07 to Feb '08

Simulated

Actual

RETIREMENT RESIDENCE BActual Performance

Floor Area = 11702 m2

AnnualEnergy

ekWh/m2

LABORATORY BUILDINGActual Performance

AnnualEnergy

ekWh/m2

0

100

200

300

400

500

Aug '04 (SL) Aug '06 (CBIP) Feb '07 (Review) Dec '07 to Feb '08 Mar to May '08

Simulated

Actual

Floor Area = 9350 m2

COMPARISON

AnnualEnergy

ekWh/m2

Actual energy use compared to typical buildings

0

100

200

300

400

500

600

700

800

All Bldgs (ON)

C&I Accom (ON)

Offices (ON)

Offices (CAN)

GoG VA SSJ KPHQ TRCABuildingA

BuildingB

BuildingC

BuildingD

MMM Group Limited100 Commerce Valley Drive WestThornhill, ON Canada L3T 0A1t: 905.882.1100 | f: 905.882.0055e: mmm@mmm.ca