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General Commissioning Procedure for Economizers

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General Commissioning Procedure for EconomizersFOR,For,for

CxTPL Upgrade Project Oct. 31, 2001

    GENERAL COMMISSIONING PROCEDURE FOR ECONOMIZERS

    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

    The project “Development of a Commissioning Test Protocol Library” is funded by California utility customers and administered by Pacific Gas & Electric Company under the auspices of the California Utilities Commission.

    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.

CxTPL Upgrade Project Oct. 31, 2001

    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 DAMPERS…………………………………………………15

    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 OUTLINE……………………………………29

    XV. REFERENCES USED TO DEVELOP THE ECONOMIZER PROTOCOL…30

    General Commissioning Procedure for Economizers October 31, 2001

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 system’s 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&E’s Commissioning Test Protocol Library’s 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

    Richard Fromberg 1 726396407.doc

    Pacific Gas and Electric

    rrf2@pge.com

General Commissioning Procedure for Economizers October 31, 2001

I. PROJECT / BUILDING DESCRIPTION

BUILDING NAME and ADDRESS: APPLICATION #: 1

     Case 1) Sac’s Service Center (SSC)

     4444 Perk Road, Sacramento CA 95826

     and

     Case 2) Pete’s Excellent Cuisine (PEC)

     185 Energy Street, San Francisco, CA 94102

BUILDING CONTACT PERSONS and PHONE NUMBERS: 1) Zachery Sac, 916-123-4567

     2) Peter Cook, 415-123-4567

NAME & FIRM OF PERSON(S) DOING TESTS: JR Doolittle, Hotwire Commissioning Services

PLANNED DATE(S) OF TEST: December 21-23, 2001

    Description of Systems Under Test:

    1) The SSC has three air handler units (AHU’s) #1, #2 and #3, which serve the north, south, and southeast sections of the

    main building. Supply and return fans are VFD controlled. A DDC system controls separate actuators on the outside

    air, return air and exhaust air dampers. AHU#1 and AHU#2 are roof mounted; AHU#3 is floor mounted at the east

    end of the building.

    The air handlers are designed to provide hot and cold duct air flows that will maintain 0.25 “wg supply air duct static

    pressures and a supply air temperature set point of 55?F. Minimum supply air rate is limited to 25% of the total

    capacity. The sequence of operation for each AHU is the same, except for scheduling differences. The environment is

    a hot/dry central valley climate with seasonal temperatures ranging from 15?F -105?F and the cooling load is ~75 tons

    @ 40,000 cfm per AHU.

    2) The PEC has one air handler unit, AHU-1, which serves a multi-zone, single duct, reheat system that conditions the

    whole building. AHU-1 is a central station, pull-thru type, roof mounted air handling unit complete with economizer

    (return, outside, exhaust) damper section, filter section, chilled water cooling coil section and fan section with variable

    frequency drive (VFD) control of the supply fan motor. Exhaust fans are propeller type fans within the air handler

    exhaust section.

    The air handler is designed to provide conditioned air at the temperature and pressure required by the variable volume

    (VAV) terminal units and outside air as required for (IAQ) ventilation. It also provides exhaust air as required to

    maintain a slight building positive pressure during economizer operation. The environment is a coastal climate with

    typically mild temperatures ranging from 35?F to 95?F and the cooling load is ~60 tons max @ 32,000 cfm.

    The air handler is designed to provide air flow that will maintain between 1” and 2”wg supply air duct static pressure

    and supply air temperature set point between 65 and 55?F.

    Richard Fromberg 2 726396407.doc

    Pacific Gas and Electric

    rrf2@pge.com

General Commissioning Procedure for Economizers October 31, 2001

    Economizers of AHU’s 1, 2, and 3 at the SSC and AHU-1 at the PEC. Equipment Covered by this Protocol:

    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 don’t 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.

Richard Fromberg 3 726396407.doc

    Pacific Gas and Electric

    rrf2@pge.com

General Commissioning Procedure for Economizers October 31, 2001

II. SEQUENCES OF OPERATION

    Case #1 - The economizer air dampers (outside, return and exhaust) shall be modulated by an analog output from the DDC system to maintain the desired cold deck temperature set point. A minimum of 45F mixed air temperature will be maintained at all times.

    Cooling supply air temperature shall be maintained by first modulating the outdoor air damper open via the economizer mode and then secondly modulating the chilled water valve open. When the outdoor air temperature is within 2F (adjustable) below the warmest zone space temperature, the outside air damper shall go to the minimum position setting and the return damper shall open to maximum position. The heating supply air temperature shall be reset downwards to the return air temperature as required to maintain a zone temperature of 70F(adjustable) in the colde