PSPC Commissioning Manual (CP.1)

Appendix A - Sample of specification for integrated systems test for laboratory

Table of Contents

  1. General
  2. Purpose
  3. Commissioning agency
  4. Acronyms
  5. Design criteria, design intents
  6. Application tolerances
  7. Timing
  8. Seasonal constraints
  9. Engineer's responsibilities
  10. Systems to be tested
  11. Commissioning procedures - EMCS
  12. Commissioning procedures - Integrated VAV HVAC and exhaust systems
  13. Commissioning manifolded laboratory exhaust systems
  14. Laboratory airlocks
  15. Pressure decay tests of welded ducts
  16. Other laboratory exhaust systems
  17. Records of tests
  18. Air systems - Stable operation
  19. Normal laboratory operation
  20. BSC and LFH failure
  21. Supply fan failure
  22. Laboratory supply air failure
  23. Maximum supply air to laboratory
  24. Exhaust fan failure
  25. Laboratory exhaust air failure
  26. Maximum exhaust from laboratory
  27. Electrical power failure to laboratory
  28. Building power failure
  29. Activities upon completion of commissioning
  30. Commissioning Reports
  31. Training
  32. Commissioning activities during Warranty Period
  33. Laboratory training upon occupancy and during Warranty Period

1. General

  1. In accordance with Section 01810 - Commissioning: General Requirements, supplemented as specified herein

2. Purpose

  1. To determine:
    1. Operation of all systems working in unison.
    2. Response to normal, emergency and "what if" conditions which may occur during laboratory operations
    3. the ability of the EMCS to perform as designed under change-over conditions from normal power to emergency power
    4. that performance of integrated system is as designed and with proper interaction between related systems, equipment and components.

3. Commissioning agency:

  1. To be [independent Commissioning Agency] [__]
  2. Responsibilities to include
    1. Coordinate and conduct tests and fine-tuning of integrated systems
    2. Correct deficiencies identified during integrated systems testing and fine-tuning
    3. Diagnose problems
    4. Modify operating parameters as necessary to satisfy fine-tuning requirements required by Engineer so as to satisfy proper system operation, including adjustments which may become apparent as testing proceeds, modifications to suit changes in system operation as equipment settles down during the "running-in" period.

4. Acronyms:

BSC
Biological Safety Cabinet
DBT
Dry bulb temperature
DP
Differential pressure
EA
Exhaust air
EMCS
Energy Management & Control Systems
FA
Fire alarm
HEPA
High Efficiency Particulate air
HVAC
Heating, Ventilation, Air Conditioning
LFH
Laboratory Fume Hood
NC
Noise criteria
PD
Pressure drop (pressure difference)
PV
Performance Verification
SA
Supply air
SP
Static pressure
TAB
Testing, Adjusting and balancing
WBT
Wet bulb temperature

5. Design criteria, design intents

  1. DBT, WBT, noise levels, space differential pressure to be maintained in each laboratory at all times within specified tolerances: Refer to Design Criteria and relevant PV Report Forms
  2. Laboratory Differential pressure must not be permitted to go to zero or into opposite pressure values.

6. Application tolerances:

  1. For negatively pressurized laboratories:
    1. SA systems: Plus [0] %; minus [10]%
    2. EA systems: Plus [10]%; minus [0] %.
  2. For positively pressurized laboratories:
    1. SA systems: Plus [10] %; minus [0]%
    2. EA systems: Plus [0]%; minus [10] %.

7. Timing:

  1. Perform tests only after:
    1. Architectural finishes completed.
    2. TAB of HVAC systems successfully completed.
    3. TAB of smoke control systems successfully completed.
    4. Commissioning of FA systems successfully completed.
    5. Commissioning of emergency electrical power systems successfully completed.
    6. Commissioning of all BSC's, LFH, snorkels, other laboratory exhaust systems successfully completed.
    7. EMCS is completed and commissioned to point where it may be used for recording system data and dynamic step response data.
  2. If necessary, occupancy to be coordinated so as to avoid interference with, or interruption of, any integrated systems tests.

8. Seasonal constraints

  1. Notwithstanding all-inclusive requirements specified herein, additional separate cycles of Integrated Systems Testing may be necessary during opposite seasons for equipment and systems whose full operation is dependent on seasonal conditions.
  2. This may necessitate carrying out one of these tests after occupancy and during the Warranty Period.

9. Engineer's responsibilities

  1. To include:
    1. Witness tests and certify results
    2. Provide instruction at the same time as the integrated system performance tests
    3. Provide direction and instruct Commissioning Agency so as to satisfy operating requirements
    4. Fully document results, details of adjustments, changes in system operation as systems settle down.
    5. During Warranty Period:
      1. Take environmental measurements as necessary to identify existing and potential problems.
      2. Conduct User surveys to determine degree of satisfaction.

10. Systems to be tested

  1. These tests shall be applied to all Laboratory HVAC and exhaust systems and related systems.

11. Commissioning procedures - EMCS

  1. With the EMCS in full operation, change over to emergency power and
    1. change from normal operation to operation in fire alarm mode.
    2. change from normal operation to smoke exhaust mode.
  2. Return to normal power and simulate failure of EMCS to test operation of smoke exhaust system without EMCS.
  3. Perform following during integrated system tests:
    1. Perform diagnosis of problems which become apparent during testing
    2. Make adjustments which become apparent as testing proceeds
    3. Make modifications to suit changes as equipment settles down during the "running-in" period
  4. Carry out fine-tuning and adjustment of systems as needed.

12. Commissioning procedures - Integrated VAV HVAC and exhaust systems:

  1. Commissioning Agency to become fully cognizant of all Design Criteria and Design Intents. These may include:
    1. Assumed diversity of LFH, BSC, snorkel, other exhaust system usage
    2. LFH operating parameters such as types, face velocity, normal operating and maximum sash heights, minimum flow rate through hood with sash fully closed, etc.
    3. Need for redundancy of exhaust systems
    4. Type of LFH exhaust system.- manifolded or dedicated
    5. If manifolded, is the general laboratory exhaust on same system
    6. If room exhaust system is separate from LFH exhaust system and if LFH exhaust fan goes down or LFH exhaust air valve fails, possibility for air to be drawn from the LFH into the room.
  2. The following commissioning procedures are basic only. They may have to be modified for each laboratory, type of LFH, BSC, other exhaust system, supply system, controls, type of supply and exhaust tracking systems used.
  3. Commissioning to include
    1. verification of the integrity of the laboratory envelope
    2. performance verification of maintenance of design DBT, %RH and noise levels in each laboratory at all times while at the same time maintaining design offset between supply air and exhaust air:
      1. at maximum and minimum supply and exhaust air flow rates,
      2. at various part load conditions of heating and cooling,
      3. in "occupied" and "unoccupied" modes,
      4. with LFH's at varying sash positions,
      5. with BSC's in various modes of operation,
      6. with other laboratory exhausts in various modes of operation, and
      7. at various combinations thereof
    3. Verify tracking of LFH VAV EA flow rate with SA flow rate from maximum to minimum and record pressure conditions at all exhaust system air valves.
    4. Track laboratory supply system from maximum to minimum flow rates and record pressure conditions at all supply system air valves and outlets.
    5. Verify integrity of control system and response to within ±5%.including:
      1. Verify stability of zero drift, span shifts, laboratory Differential pressure.
      2. Investigate all possible control scenarios to determine if there is any one sequence of operations which will cause lab Differential pressure to go to zero or into opposite pressure values.
      3. Using repeated cycling of controls, determine if the control loops will require periodic re-calibration
    6. Using recording instruments, challenge LFH face velocity by:
      1. raising and lowering the sash quickly implementing emergency purge procedures
      2. simulating EA failure through LFH by exhaust fan or air valve failure
      3. simulating SA failure by supply fan or VAV box failure
    7. Track laboratory Differential pressure under all possible combinations of operating conditions, such as:
      1. All LFH sashes fully open or fully closed
      2. Maximum heating and cooling, minimum heating and cooling.
      3. LFH sashes randomly ion partially closed and open positions.
    8. Identify the position of the sash below which the face velocity rises above the maximum design face velocity or fall below the minimum design face velocity.
    9. Verification of direction of air flow through doors into the space. This can be by propping the door open about 100 mm, and measuring velocity and direction of air flow through the opening every 150 mm from top to bottom.
    10. Measure all LFH exhaust duct flow rates and velocities and ensure that each stack discharge is in excess of required velocities.
    11. Performance verification and demonstration of speed of response (in seconds) in the event of:
      1. Failure of LFH or BSC air valve to minimum and to maximum,
      2. failure of laboratory supply air valve, exhaust air valve to minimum and to maximum,
      3. failure of supply fan, exhaust fan,
      4. failure of normal electrical power and transfer to emergency power
      5. partial and total failure of EMCS
      6. major chemical spills, where the operation of an emergency pull station maximizes exhaust from the laboratory, increases the negative pressure in the laboratory and informs the central control facility.
      7. fire or smoke emergency conditions, in which the FA system stops supply fans serving the fire zone, maximizes general exhaust systems so as to increase the negative pressure in the fire zone relative to surrounding fire or smoke control zones.
    12. Verification that all exhaust fan discharge ducts in Mechanical Room are fully welded and have been pressure tested and that shaft seals of exhaust fans are tight.
    13. Verification that indirect connections between BSC's and the manifolded exhaust system will never permit any spillage
    14. PV of all snorkels and other exhausts for design exhaust flow rates at all times,
    15. Survey of supply air to ensure that air velocity and air flow patterns in vicinity of LFH and BSC are within parameters of The Standard,
    16. Examination of very low leakage dampers on inlet to each exhaust fan for leakage when closed, to permit removal of exhaust fan from the system and to permit O&M personnel to service same without exposure to exhaust air,
    17. Examination of manifold exhaust ducting for condensation under low flow conditions,
    18. Verification that exhaust stack discharge exceeds 15 m/s (3000 FPM) at all times,
    19. PV of lead-lag arrangements for exhaust fans, including automatic change-over
  4. Measurement of Differential pressure: Either directly or indirectly depending upon design requirements:
    1. Direct measurement of Differential pressure between laboratory and reference point
    2. Indirect measurement by maintenance of differential between SA and EA flow rates using air flow measuring stations in all ducts.
  5. Multi-point data loggers may be used to:
    1. log each exhaust, laboratory supply, response time
    2. track exhaust system from design maximum flow rate to design minimum flow rate by monitoring conditions at the most remote LFH or BSC.
    3. track supply system from design maximum flow rate to design minimum flow rate by monitoring conditions at the most remote supply air valve.
    4. record DBT, %RH and total offset between supply air and exhaust air.

13. Commissioning manifolded laboratory exhaust systems:

  1. Exhaust systems to include general laboratory exhaust, LFH, BSC, snorkels, (elephant trunks), other special exhausts.
  2. Establish SA and EA flow rates at design conditions. Set LFH sashes to design position. Measure Differential pressure or SA-EA flow rate offset. Make necessary repairs and/or seal leaks until design values are achieved.
  3. Measure Differential pressure or SA-EA flow rate offset for all other possible operating conditions such as:
    1. sashes on all LFH CLOSED, cooling load at MAX.
    2. sashes on all LFH OPEN, cooling load at MIN.
    3. sashes on all LFH CLOSED, cooling load at MIN.
  4. Determine response time (ion seconds) while:
    1. raising and lowering LFH sash quickly
    2. implementing emergency purge conditions
    3. simulating LFH EA failure
    4. simulating general EA failure
    5. simulating SA flow rate failure.
  5. Using multi-pen data-logger to record:
    1. SA, LFH EA, general EA flow rates
    2. differential pressure
    3. response time (in seconds).
  6. Track entire exhaust system from design maximum flow rate to minimum flow rate by monitoring SP at most remote EA valve and face velocity at most remote LFH.
  7. Track entire supply supply system from design maximum flow rate to minimum flow rate by monitoring SP at most remote SA valve and face velocity at most remote LFH.
  8. Record DBT, WBT and Differential pressure on 7-day strip chart recorder.

14. Laboratory airlocks:

  1. Purposes: To demonstrate directions of air flow towards space of highest contamination when entering or leaving laboratory.
  2. Applicable air lock systems: [refer to PV Report Forms] [__].
  3. Timing: After integrated systems tests for stable operation and laboratory operations have been successfully completed.
  4. Conditions at time of tests:
    1. Supply and exhaust air systems functional, airlock entry controls operational.
    2. Laboratory operational, functioning normally, including monitoring.
    3. Adjacent areas operating normally
  5. Design intents:
    1. Entry/Exit process to be bi-directional.
    2. In either entry or exit, it must be possible to turn around and return to starting point
    3. If access is denied, it must be possible to turn around and return to starting point.
    4. In event of fire conditions, door controls to be released, access to be available in either direction.
  6. Procedures:
    1. Start air systems, allow to stabilize, continue to operate for [60] minutes, then shut down.
    2. Execute entry and exit sequences according to established operational protocols.
    3. Using instrumentation and smoke tests, monitor and record flow and pressure variables and response time for laboratory and associated air locks throughout +entry and exit protocols.
  7. Acceptance requires that:
    1. Directional air flow in laboratory to be maintained throughout tests.
    2. Pressure in all laboratories associated with air system serving this laboratory remain as designed.
    3. Safe egress to be maintained at all times. Force on doors to conform to requirements defined in PV Report Forms.

15. Pressure decay tests of welded ducts

  1. Apply this test only to those portions of laboratory ducted air systems required to be welded for contaminant containment purposes.
  2. Perform pressure decay test as described in ANSI/ASME N510-1989, section 6.5.3 "Duct and Housing Leak Rate Test (Pressure Decay Method)".
  3. Ductwork to be closed off and sealed between HEPA filter housing and room by closing airtight dampers or, in absence of dampers, by sealing openings to ductwork.
  4. Application tolerances: Not more than 0.2% of the flow rate at 500 Pa.

16. Other laboratory exhaust systems

  1. Application tolerances: Plus [10]%; minus [0]%.
  2. Standard: As for HVAC systems
  3. TAB procedures:
    1. TAB as per standard
    2. Plugs for test openings: To match duct materials specifications.
    3. Upon completion of TAB, perform activities specified this section.

17. Records of tests

  1. Use EMCS to record systems data and dynamic step response data.
  2. Where EMCS points not available, use manually recorded parameters.
  3. Monitor, record effects, note response times of various operational and failure conditions on systems.
  4. Measure variable on real-time basis. Utilizing this data, make fine-tuning adjustments as necessary.
  5. Present test data and results in data file and graphic format.
  6. Engineer to develop project-specific PV forms

18. Air systems - Stable operation:

  1. Purpose:
    1. To demonstrate operation and accuracy of air systems
    2. Applicable air systems: All systems in the new facility
  2. Conditions at time of tests: All equipment and systems to be operational in automatic mode.
  3. Procedures: Start air systems run for [60] minutes to stabilize conditions.
  4. Conditions for Acceptance: Requires:
    1. Control of variables associated with test.
    2. Stable and dynamic system response to laboratory disturbances to permit performance of remaining tests.
    3. Maintenance of standard steady state conditions listed in PV Report Forms.

19. Normal laboratory operation

  1. Purpose: To demonstrate that laboratory and associated BSC's, LFH's and snorkels are maintained in safe condition during normal laboratory operation.
  2. Applicable laboratories: All laboratories in this facility.
  3. Timing: Perform these tests after tests for stable operation (specified this section) successfully completed.
  4. Required steady state conditions: Refer to Performance Verification (PV) Report Forms.
  5. Conditions at time of tests: Laboratory supply and exhaust systems to be operational.
  6. Procedures:
    1. Assume PD across HEPA filters = 250 Pa
    2. Start air systems, allow to stabilize, run for [60] minutes, then shut down.
    3. Monitor, record flow and pressure variables, response times for lab to reach steady state conditions.
    4. Using instrumentation, smoke tests, demonstrate directional air flow.
  7. Acceptance: requires that:
    1. Directional air flow to be maintained.
    2. Pressure in all laboratories associated with air system serving this lab remain as designed.
    3. Safe egress to be maintained. Force on doors to conform to requirements defined in PV Report forms.

20. BSC and LFH failure

21. Supply fan failure

22. Laboratory supply air failure

23. Maximum supply air to laboratory

24. Exhaust fan failure

25. Laboratory exhaust air failure

26. Maximum exhaust from laboratory

27. Electrical power failure to laboratory

28. Building power failure

29. Activities upon completion of commissioning

30. Commissioning Reports

31. Training

32. Commissioning activities during Warranty Period

33. Laboratory training upon occupancy and during Warranty Period

End Sample of Specification for Integrated Systems test for Laboratory
End of Appendix A

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