PROJECT: Universiti Teknologi Petronas R & D Center (Block A&B, Ground, First & Second Floor) COMMISSIONING PLAN PROPOSED BY PATHFINDER M & E SDN BHD (First Draft for discussion only, may subject to change) For Air-Conditioning & Mech. Ventilation Systems (Package no: ) 19 November, 2015 Sequence: 01 Laboratory Ventilation System (Air-side only) (Other sub-systems will be address by separate submission) | Prepared by Reviewed by: | r i | PATHFINDER ME SON BHD / || 6bJalan Teknologi 3/5 | | | | Pusat Teknologi Sunsuria PIU S | | Kota Damansara, 47810 Petaling Jaya. |__| Tere0-261502200 Faxe60-361509100. | | Date: 19" Nov, 2015 |SYSTEM DESCRIPTION This Building is equipped with multiple fume exhaust cupboard, local exaust ventilation hood and general ventilation. ‘There are large manifold ducted systems with active and passive air-control & movement devices to achieve the design objectives. One of the system is as shown on the left: ‘The exhaust & supply ar fans are located at | i the higher floors than the location of fume cupboards (FC) & LEV (local exhaust ventilation} hoods. These fans are inverter driven with variable speed. Each alr-system Geniben Fans Greeti Fans _ FA casey) EA palvicny | has 3 nos. of fan while one is the back-up 7 : unit. Operation of 2 nos. of exhaust fans shall be sufficient for the maximum Llw, mente operation of al FC & LEV ofa system SenoRE {an “absolute minimum” set point of exhaust * cee fan speed that need to maintain minimum eee 2 _ stack exit velocity for partial operation. of { pen | Theteis no bypass damper installed at the 1 Een | exhaust fan for this minimum setting and | LnA. ra | the intial testing & commissioning | | “ag gRPREL | procedure shallverify the necessity of such | | | Hitaaon SS ‘bypass damper or other means. | Fume cup ‘The operation of fans shall be controlled by | | (LEV pressure static sensor in the duct which is af | | Peers, directly proportional to the demand of. sememmvarerens) || Bagg | Ventilation capacity required by operation of electrical switches at respective room. The ‘maximum nos. of fans running at atime is only two and shall be run at equal speed However, the “absolute minimum” for single ‘& dual fan operation must be determined separately during testing and ‘commissioning. The exhaust point at each location can be CAV (constant volume) or VAV (variable vol) a | | Lge The baseline duct static pressure shall be determined in the routine below. But in view of the high static pressure provided for fans (up to 1,000 Pa max} a static reset Fume cup algorithm may be written during Integrated fem ey ir paca test or subsequent fine tuning, not only for om _mncucecnenceen| on amy seshem the energy use reduction but also lessen the possibility of exhaust duct damage due to excessive pressure, Any crack in the massive manifold ducting system can be a safety issue. ‘There are all together 6 ait-systems in this project for Laboratory Ventilation System (Air-side} as below: « System2A: This system serves Block A labs in Ground & First Floor with approx. 28,900 cfm capacity. ‘+ System2B: This system serves Block B labs in Ground & First Floor with approx. 26,200 efm capacity. ‘+ System3A: This system serves Block A labs in Second Floor with approx. 14,240 cfm capacity. ‘+ system3B: This system serves Block 8 labs in Second Floor with approx. 27,080 cfm capacity. ‘+ System LRA: This system serves Block A labs & offices in 3,2,186 floor with approx. 6,700 cfm capacity. «System LAB: This system serves Block B labs & offices n 3,2,18G floor with approx. 6,400 cfm capacity, The details are listed in the Excel file attached. Construction team to verify with the as-built status,COMMISSIONING OVERVIEW: ‘The commissioning process shall generally be divided into the following stages: 1. Pre-function test of equipment & system components This stage involve procedural testing & inspection such as hydrostatic proof test of piping, leakage test on ducting, continuity & insulation test on electrical wiring, point-to-point test of automation control system, factory assessment test, chemical flushing of pipes, etc. This stage was reported to have been completed by the construction team. Copy of Test Data Sheets will be compiled and submitted to respective consultant for reviewed and will be incorporated into the future System Manual. 2. Functional test of equipment & system components By running the equipment and verifying parameters against design intent such as running current, vibration level, noise generated, running current, etc. This stage has been reported to be near completion at this time. All active elements in the system such as fans, AHUs, electrical panels, DDC controllers, etc. were ‘well terminated with electrical wiring, mechanical piping and ducting, etc. Power supply is available to most of the equipment and the dry-run test have been carried out. 3. Performance test of system By running the equipment & system and taking readings with specific instrument to verify performance parameters. These shall include the balancing & adjustment of proper air & water flow rate, pressure, etc. The procedural testing below shall be relevant to this submission are: © Testing of fans against fan curve for EAFs and FAFS * Verifying airflow of CAV devices, calibrate & adjust these wherever discrepancy is too wide, «Verifying preset airflow rate of VAV devices, calibrate & reprogram K-factor to these wherever discrepancy is too wide © Recheck setting of manual air balancing devices such as dampers, etc 4, Integrated test ‘Testing of installed system with ather related systems such as furne cupboard system, building automation, LEV, electrical switching system, etc, 5. Preparation of System Manual ‘The system manual is an effective reference for future Operation & Maintenance personnel. This section shall be elaborated in subsequent submission. Updated Commissioning Plan will frm an important part of system Manual. 6. Training of Operation Staft Overseeing the Training of Operation & Maintenance personnel. This section shall be elaborated in subsequent submission. 7. Handing Over & Post Occupancy Follow-Up Fine tuning of system for several months (during DLP} to achieve Owner's Project Requirements including energy efficiency goals and indoor environmental parameters. Preparation of Final Report. This section shall be elaborated in subsequent submission, At this stage of Commissioning Process, we shall only elaborate item 3 & 4 of the above mentione in the subsequent paragraphs, before updating the Commissioning Plan in the next phase.Performance test of system: A. Tracing of main fans performance of with fan curves for EAF and FAl Intent & Requirements: ‘The basis of design of the air systems rest heavily on the precise provision and controls of airflow. As the ‘main fans are the driving active elements of each air system, the site performance of EAF and FAF must be ascertained prior to evaluation of performance of whole system, Prerequisite: Power supply to main fans, operative VSD (variable speed drive}, operative modulating dampers, adequate straight length of duct for Pitot tube traverse. Procurement of hand-held manometer and Pitot tube. Procedure! The illustration for System 2A is as in below. tt shall be genericto other air-systems. 1. Check all CAV and VAV devices of the air-cystem are at full open status and isolation motorized damper is functioning and in full open position. 2. Check all manual dampers of the air-system are at full open status, For electronically controlled VAV devices, either open them through BCS or manually through local bypass provision. 3, Test each fan separately first. 4, Ramp up the main fan slowly from stationary (0 Hz). This can be done Through BCS. It can be done even if BCS is not ready, by procuring local external resistor (generally 1 KQ or 10KO) or by regulated external 0-10V DC supply. Advice from VSO Vendor shall be sought. 5. Recheck the system operation for every 5 Hz increment. Thete shall be no abnormal operational noise fr excessive current intake. Monitor the run current of the fan and adjust the modulation damper of main duct for fan inlet to keep running current in range. Run the system until full speed (50H2) fA Probable Pitot duct traverse exp oc Lisa aa Wisi (ate HRW-2A-1 (DUTY) [ Hrew~24-2 (ouTy) ; yt ; | 3 Main duct Modulating dampers 6. Maintain the system running at 50 Hz (100%). Then adjust main duct modulating damper until the designed parameters are reached (for example, for EAF for System 2A, it shall deliver 14,450 clm @ 4"wg,). The determination of static pressure shall be done according to the diagram below and the airflow volume shall be taken by Pitot tube traverse at suitable location of the main ductFan Static Pressure (SP) Fan static pressure (Figure 5-19) is the fa total pres- sure less the fan velocity pressure. It can be calculated by subtracting the total pressure at the fan inlet fiom the statio pressure at the fan outlet, This isa source of — | pay | STAN TURE some confason within te ids bt, by definon: — ]/ . Fan SP = Fan TP (oatlet) ~ TP (inlet) ~ Vp (out ie) \ Also, TP (outlet) ~ $1 aR (outlet) = Vp (outlet) | and substituting: Fan SP = SP (outlet) — TP (inlet) Whore itis possible to take field measurements, care | ‘must be taken fo measure fan focal pressure atthe fan FIGUAE 6-19 FAN STATIC PRES- inlet duct rather than fan static pressure SURE (SP) ser enna de emp and nambrofreaigs 20 2 2 2 see ‘ 2 5 7. Without further adjusting the main duct modulating damper, ramp down and maintain the fan speed to 37.5 Hz, 25 Hz and 12.5 Hz. At each of these points, take the fan static pressure developed and resultant airflow. 8, Plot the reading onto the fan curve. The 50 Hz design point shall be met, while other reference points at 375 He, 25 Hz and 12.5 Hz may have some disparity as the assumption on duct resistance against modulating damper flow characteristic may have some marginal variation. 9. Confirm with this procedure for basic performance of all EAFS and FAFs. Data compiled for subsequent testing reference. B. Establishing the “absolute minimum” set point of exhaust fan speed that need to maintain minimum stack exit velocity for partial operation: Intent & Requirements: This exercise is necessary only if the System Designer wants to impose a minimum airflow throughout the system. Probably, this is the condition for operation of a single fan. The minimum requirement is to prevent fan surging situation at ultra-low speed or aims to maintain good stack exit velocity. To sustoin the‘minimum speed, either bypass damper to be installed at vicinity of fan or minimum nos. of CAV or VAV devices to be operated through setting in BCS (pre-configured). The site fan performance data may be reviewed by the System Designer to determine the minimum airflow requirement, if any. e fan ‘Tracing of other fans & AHUs performance of with respe intent & Requirements: This performance of individual airflow equipment Is best to be evaluated separately prior to overall system test with the above mentioned procedure. However, such exercise can be lengthy due to the large number of equipment. However, such performance test can be done during system air balancing check, thus, performance separate test at this stage for individual airflow equipment is optional, D. Establishing baseline set point for main duct static pressure sensors: Intent & Requirements: ‘The operation of each main fan is controlled by 2 nos. of static pressure sensors, one at the top of main duct and another at the end of main duct. These sensor will feed signal into DDC/BCS, which is controlling the fan speed against a pressure set point. This set point will determine the availability of adequate airflow to each CAV and VAV control devices. ‘This procedure shall establish baseline set point for initial testing and operation of the air-system, Subsequent trend logging of duct static pressure can be done with operational BCS that will help to establish more rational set points or even dynamic set point for highest performance of the system. Prerequisite: Power supply to main fans, operative VSO (variable speed drive) and VAV boxes, operative CAV devices, operative modulating dampers, adequate straight length of duct for Pitot tube traverse, Procurement of hand-held manometer and Pitot tube. Reading from pressure sensors preferably to be read from BCS. However, a hand held manometer of proper range can be used to take main duct pressure readings at the vicinity of pressure sensors as alternative mean. Working with walkie-talkie for technician to adjust fan speed according to main duct static pressure, this alternative mean can be more effective Procedur ‘The illustration for System 2Ais as in belovr. It shall be generic to other air systems. 1. Check all CAV and VAV devices of the air-system are at full open status and isolation motorized damper is functioning and in full open position. 2. Check all manual dampers of the air-system are at full open status. For electronically controlled VAV devices, either open them through BCS or manually through local bypass provision. 3. Option A: Each air-system must be tested with 2 nos, of BAF and 2 nos. of FAF running at the same time with doors of all door closed. 4. Ramp up the 4 nos. of main fans slowly from stationary until 10 Hz. This can be done Through BCS. It can be done even if BCS is not ready, by procuring local external resistor (generally 1 KA or 10KA) ot by regulated external 0-1OV DC supply. Advice from VSD Vendor shall be sought. 5. At10 H2 (2096 capacity) the minimum airflow to each air control device might have been met. Maintain at this speed and check pressurization or deOpressurization of each room. Careful not to result excessive pressure and damage to Magnehelic gauge at each room, 6. There shall be no abnormal operational noise or excessive current intake, Monitor the running current of the fans. 7. Check airflow volume at each CAV & VAV device. Perform summation on total volumetric flow of these devices. Check against the measured total volumetric flow to that of rated airflow. For System 2A, the rated airflow for EA is 28,00 cfm and rated airflow for FA is 26,400 cfm. 8. Check the measured airflow through each device is within +10% of the rated airflow of each device. 9, For simplicity, the airflow measurement can be done by flow-hood or anemometer for manual CAV devices or simply read out the alrflow from electronically controlled VAV devices.10. If the measured total volumetric flow is below that of total rated airflow, then the VSD shall be ramped Lup to increase the airflow. This comparison and re-adjustment shell be done whether it is for EA or FA system, Increment of speed must be cone in step of not more than 5 Hz at a time. Increment in {quantum by proportional projection can be done to save time but the testing agent must be absolute sure that such quantum will not result in damage of the ducting system or any device After each increment, recheck the pressurization or deOpressurization of each room. Careful not to result excessive pressure and damage to Magnehelic gauge at each room, 12, After system stabilization, re-measure total volumetric flow and compare to that of total rated airflow. Increase the VSD towards the total rated airflow. Again, increment of speed must be done in step of not more than 5 He at a time. increment in quantum by proportional projection can be done to save time but the testing agent must be absolute sure that such quantum will not result in damage of the ducting system or any device. 13. Repeat the above procedure until the total volumetric flow is closed to that of total rated airflow, for EA and FA sub-system. At this time, record all parameters including the VSD speed, pressure sensor reading, airflow volume through each device, motor running current, Magnehelic gauge reading at each room, etc. 14, Re-check the measured airflow through each device is within +10% of the rated airflow of each device, 15, Ifthe above conditions are fulfilled, the baseline duct static pressure set point is considered established with the readings taken from the 2 pressure sensors at each EA or FA subsystem. ‘This baseline set points should be closed to that in actual operation but it can be re-adjusted during the subsequent Integrated Test of the system or during Fine-Tuning process in Post-Occupancy mode, whereby BCS will be able to trend log the duct static pressure against usage profile. 1 E. Verifying performance of CAV & VAV devices for each room against room pressure set point: Intent & Requirements: Each room is a discrete compartment in the system design. The devices inside each room have respective rated airflow, whether as EA or FA. The actual measured volumetric airflow of each device has to closely meet the rated airflow {within System Designers tolerance, normatly 5-10%). Thus, actual volumetric airflow has to be measured with method of relatively higher accuracy to verify the “preset” value of CAV & VAV devices, Adjustment to CAV & VAV devices may be necessary under the prescription of respective manufacturer not to resolve manufacturing defects but to compensate for site constraints such as availability of ideal upstream straight length, ranges of pressure supply, etc. With all adjustments done, the room pressure has to be within specification of the System Designer (typically several Pa below that of exterior, but not having differential more than 50Pa}. if the designed condition is not met, review on the situation shall be done by System Designer to re-establish originally assumed parameters such as infiltration, Prerequisite: Performance Test in Section A-D must have been carried out and baseline duct static pressure establish Check on each ducting to each CAV & VAV device has adequate straight length of duct for Pitot tube traverse air measurement. ‘The Fume Cupboard and other LEV equipment must be hooked up the ventilation ducting. All relevant rooms in finished condition with doors & windows installed ad closed. Procedur During the test, the baseline duct static pressure must be maintained, either by full functioning of BCS system or by manually adjusting local external resistor (generally 1 KD or 10KN) or by regulated external O- 10V DC supply by test agents using walkie-talkie. Advice from VSD Vendor shall be sought. The illustration for System 2A is as in below. It shall be generic to other alr-systems. We shall illustrate for typical room:hem 1 + GS Het ao cru Ta on ote g eset IE) Mi aA 1.795 CFM |_ICANLfep 285 CFM 7D ~ G04 : Manual VCD Fume Cup board SPLACEMENT LAB (GA04) 533' © CAV-M bo» 1. Referring to the example at lower left corner for fume cupboard EA, with a properly maintained EA duct static pressure, the motorized damper is opened fully manually or electrically 2. The volumettic airflow readings through CAV-M box is then measured by Pitot tube traverse. 3. If readings is unstable, probably due to excessive pressure, then the manual VCD has to be closed further to reduce the pressure differential across the CAV-M box. 4, If readings is unstable, probably due to inadequate pressure, then the manual VCD has to be opened further to increase the pressure differential across the CAV-M box. Repeat until measured readings by Pitot tube meet the specification of CAV-M box. Repeat for other CAV fume cupboard or LEV equipment. The baseline EA duct static pressure may have to be increased if readings is insufficient due to inadequate pressure differential across the CAV-M box with manual VCD fully opened. 8, The requirement for verification of airflow through CAV-M box may be waived by the System Designer who has review the technical submittal of the factory assembled and tested CAV-M box. CAV-E box & AHU-GA04: 1. The AHU is started with properly maintained FA duct static pressure, Adjust all operating parameters of AHU to specification with all accessories such as filter installed, 2, The volumetric airflow readings through CAV-E box is then measured by Pitot tube traverse 3. The airflow reading is taken by CAV-E box electronic display or link to hand held device such as laptop. 4, The two set of readings shall be close. Re-calibrate of K-factor for CAV-E box can be necessary if discrepancy is wide, more than 10% of any lower value. Advice has to be sought from manufacturer for such recalibration, 5, Ifthe two set of readings are close and meeting rated airflow in specification, then the process is. considered completed for CAV-E box & AHU-GAOA.6. if readings is unstable, probably due to excessive differential across the CAV-E box, then the manual VCD may have to be installed upstream of CAV-E box to reduce pressure differential across the box. 7. Repeat for other CAV device & equipment of the FA system. 8, The baseline FA duct static pressure may have to be increased if readings is insufficient due to inadequate pressure differential across the CAV-E box with its damper fully opened 9. The requirement for verification of airflow through CAV-M box may be waived by the System Designer who has review the technical submittal of the factory assembled and tested CAV-M box. Room Pressure: With the above steps being carried out, the room pressure with respect to exterior shall be measure by hand held micro-manometer. This reading shall be compared with the reading of Magnehelic gauge installed at the room. The readings shall be very close. Review with the System Designer if the intended room cannot be maintained with all airflow devices well set Room 1A03 "TO BCS (TOTAL FA REQ. & ACT. FLOW) SWITCH ancy CHAD A Re) Oly coon (ge fr {rit 470 cFw = Fo Local 00C Rae © trea reer Aloe) g 120-820 074 ©] Sif vay Li. gM 8+ 23m hu x AHU ~ 1403 AFB AT BY a VAV Lik saontao ora Pie Fume cup a EOR CHEMICAL SYNTHESIS (1403) This room is the only room of Air-system 2A with VAV fume cupboard and thus VAV FA supply. The procedure for Performance Test is similar to that for Room GA04, except the following: VAV-FC box: 1. Referring to the example at lower left comer for fume cupboard EA, with @ properly maintained EA duct static pressure, the motorized damper is opened fully manually or electrically 2. VAV-FC box is then set to minimum airflow with BCS or any link of it to hand held device (laptop, ete.). 3. The volumetric airflow readings through VAV-FC box is then measured by Pitot tube traverse. 4, tfreadings is unstable, probably due to excessive pressure, then the manual VCD has to be closed further to reduce the pressure differential across the VAV-FC box. 5. if readings is unstable, probably due to inadequate pressure, then the manual VCD has to be opened further to increase the pressure differential across the VAV-FC box. 6. Repeat until measured readings by Pitot tube meet the specification of VAV-FC box. 7. Repeat for maximum airflow setting of VAV-FC box. 8. The baseline EA duct static pressure may have to be increased if readings is insufficient due to inadequate pressure differential across the CAV-M box with manual VCD fully opened, 9, The requirement for verification of airflow through CAV-M box may be waived by the System Designer who has review the technical submittal of the factory assembled and tested CAV-M box. The above procedure can be repeated for VAV box upstream of AHU-1A03.Integrated test: Intent & Requirements: The integrated test shall be the final “hooked-up"” test of the system prior to handing over. It isa test that verifying the basis of design, control philosophy and control strategies of the system design, Prerequisite: The air-system has fully undergone all Performance Tests of sub-systems and have maintain the required room pressure as stipulated in the specification. “The BCS is fully completed and commissioned with input ofall verified parameters from air-system including all actual readings from CAV and VAV devices. All fume cupboard ad LEV equipment are well installed and fully commissioned, The link from VAV fume ‘cupboards to DDC of 8S shall be established with a 0-10V signal, dictating the actual airflow requirement of each fume cupboard to BCS. Allelectrical switching circuit indicating operation of individual room shall be completed with vott-free contact signal to FFV of BCS. Procedure: The illustration for System 2Ais as in below. It shall be generic to other alr-systerns, Startup and control for fresh air & exhaust air for laboratory (lab) Room 1. The ventilation system for the specific lab, Room is switched "ON/OFF" by a local switch. Upon the local switch turned to "ON" position, the ventilation system shall be in operation accordingly. 2. Once the ventilation system is in operation mode, the ventilation system panel will send an "ON" signal to BCS system. BCS will compute the required ventilation capacity required based on the “pre-input” airflow parameters from air-systems, 3. The EA and FA air-system shall then be ramped up to “absolute minimum’ capacity while BCS is comparing the computed required capacity against “absolute minimum” capacity of the system. This, capacity is achieved by running the fan to specific speed and allowing more airflow into the system ether by operating additional bypass damper or forcefully operating some pre-configured CAV or VAV devices. The fan speed will then find its stay-point with the achievement of baseline duct static pressure. 4, If the computed capacity is less than the “absolute minimum” capacity, the system will stay at “absolute minimum” capacity with the specific fan speed maintaining the baseline duct static pressure, 5. If the computed capacity is more than the “absolute minimurn” capacity, the system will ramped up the actual capacity by increasing the fan speed of each sub-system until the baseline duct static set point is achieved. At the same time, CS will perform computation to either closing additional bypass damper or “dropping-off" some pre-configured devices that were forcefully operated beforehand to achieve the “absolute minimum” capacity. 6. As more and more devices come into operation, demand for more ventilation capacity, the BCS will either close all additional bypass dampers or “dropping-off” all pre-configured devices that were forcefully operated beforehand, while maintaining the baseline duct static pressure. From this point onwards, the fan speed shall be adjusted automatically to maintain the baseline duct static pressure at set point 8, The system is such that at “absolute minimum’ capacity, the developed duct static pressure is more than the baseline duct static set point. 9. The fan speed is proportional to the capacity. The computed ventilation demand by BCS will be shown alongside with rated total capacity of the airsystem. The ratio of present capacity to full capacity and ratio of present fan speed to full fan speed shall be in close range and will be displayed in BCS console for information and intervention of operator, 10.Random switching of CAV & VAV devices of the system will be carried out in the Integrated Test. 14. The success of Integrated Test shall be indicated with smooth ramp up/down of fan speed while maintaining stable duct static pressure. The airflow readings acquired from electronically controlled 7CAV and VAV boxes will be indicative to proper operation, while maintaining the stipulated room pressure differential against exterior. IMPLEIMETATION OF COMMISSIONING (Cx) PLAN: Suggested Cx Team: The following Commissioning Team shall be sufficient for updating of the Commissioning Plan’ 1), Representatives from Project Manager ~ KLCC Project Sd Bhd. 2}, Representatives from MBE Consultant & Lab Consultant, 3) ACMV & BCS contractors. 4}, Fume cupboard vendor and installer. The Commissioning Team members will be extended to include Representative from Electrical Contractors, or other Specialist Supplier and representative of future operation personnel in subsequent stages. Role & Responsibilities of Cx Team Members: KLCC Projeks Sdn Bhd : Leader & facilitator of the team Consultants: Provided latest update on DD development to detailed design & specification. Contractors: To update progress and report issue log if any, Tentative ti eline as below: SCHEDULE FOR DRAFTING OF COMMISSIONING PLAN - UTP R&D CENTER For Laboratory Ventilation System Only 8 z . Hie © & 8 zB 3 5 3 5 2 5 B precomm. § Subsystems §& ee 3:8 el %& & components 2 7 2 eS PE 2 eS tesing 5 sj BES v . Bos £3 6 L LI LJ \ S tetas 2 rewpet S Commissiong Warksho & S s ‘hae’ “hast S Conmssna wane atts ewe £ te § g 2 ‘Throughout the 3 months duration, we expect the Commissioning Plan & Commissioning Process can be completed by end of 2015.