Project Number QMSN Install Basewide EMCS System Moffett Federal Airfield, California

Transcription

1 1. Energy Management and Control System 1.1. Project Objective Project Number QMSN Install Basewide EMCS System Moffett Federal Airfield, California The objective of this project is to provide a complete and fully capable, OPC-compliant Automated Logic Corporation (ALC) brand Energy Management Control System (EMCS) across nine of the California Air National Guard s (ANG) facilities (listed below) located in and around the ANG Cantonment Area at Moffett Federal Airfield (Moffett Field), Santa Clara County, California. The facilities to be included under this Statement of Work (SOW) are Buildings 683, 680, 681, 650, 653, 654, 656, 662 and 663. The project will conclude with the most current version of ALC hardware and software being installed in each of the buildings in this statement of work and all communicating via the base s existing fiber optic backbone; the server shall be located in the ANG s Base Network Control Center (BNCC) located in building 680 and the master controller to be located in building 683 (Controller). The completed project shall see the EMCS monitoring and controlling all existing HVAC equipment through the use of existing sensors connected to existing building-by-building DDC systems plus new supply air and smoke detectors that shall be installed by the Contractor in all building zones. Programming shall provide for a sequence of operations that allows the ANG to operate the mechanical and electrical systems of each building and to maintain building temperatures in the most energy efficient manner possible with the existing equipment in the facility. The Contractor shall provide 3-D graphics that show the operating status of the mechanical and electrical components in the building to assist ANG personnel with the troubleshooting of equipment issues. All work performed under this SOW should be accomplished in a manner that compliments the Direct Digital Control (DDC) installation (sequence of operations, programming, etc.) that is or will be installed in the new operations and training facility(building 663) to the greatest extent permissible with the existing equipment installed in these facilities. The environmental management systems in building 663 and building 653 (not included under this SOW) shall be connected to the EMCS and shall report to the Controller. Additionally, these systems shall be configured to allow them to be controlled and adjusted by the Controller. The Controller shall include graphics for these two facilities which should be similar to those provided for the other facilities. Each of the remaining buildings included under this SOW shall have an ALC building controller (Subordinates) installedat a location to be identified by the 129th Civil EngineeringFlight. The Subordinates shall be able to control that building s systems and have

2 the capacity for two way communications with the Controller. Computer and software requirements for the Subordinates will be the same as that of the Controller. The Contractor shall also connect all electric, gas, and water meters to be tied into the EMCS with the EMCS saving at least ninety (90) days worth of consumption data for each of the utilities before being over-written. The EMCS shall provide the capability for graphically representing this data via charts and graphs. The Contractor shall be required to provide the system network certifications, all background paperwork, the system architecture and any other documentation to the 129th Communications Flight (CF) in sufficient time and in order to get the system operating on the communications cabling on the base. Individual addresses and connectivity at each facility will require coordination with the CF. The contractor shall investigate any rebates potential, fill out any required paperwork and provide any calculations then submit to the Government representative for signature and submission. The contractor is encouraged to propose their most cost effective solution to meet the requirements of this Statement of Work Scope A. Design, furnish, install, and test a complete and operational EMCS. Provide complete engineering, programming, design, installation, setup and commissioning services for development and installation of a basewide EMCS DDC on and around the ANG Cantonment Area of Moffett Field. Work includes investigative services requiring a survey and analysis of existing HVAC equipment systems and facilities. Work also includes removal and proper disposal of existing DDC equipment that cannot be reused in this contract which includes all the hardware and software from the building controllers of non-alc systems. B. Services shall include the development of specific sequences of operational control for each Subordinate system. Contractor shall develop plans that include sequences of operations, elementary ladder control diagrams, and details, schematics, and controls plans for each Subordinate system. Services shall include development of detailed lists of analog and digital input/output (AI/AO and/or DI/DO) points for each connected system or facility. C. Submittals for controls shall conform to the requirements of part 2, EMCS System Commissioning, of this SOW. This includes a required preliminary plan (Preliminary Submittal) to be submitted to the ANG for approval prior to beginning construction. The Preliminary Submittal shall be an executive summary that includes, but is not limited to, an outline plan and description of the EMCS and the local facility control systems, descriptions of the proposed network setup, strategies for connectivity (to include required base infrastructure if necessary), ordered priority of facilities, and definitions of the ALC (protocol, hardware and software to include version). The Preliminary Submittal shall include the Commissioning Agents Coordinator's resume listing applicable experience for review and approval by the ANG s designated representative. The Preliminary Submittal shall also include a complete list of the project managers and subcontractors, to include the test and balancing contractor. At a

3 minimum, one copy of all submittals shall be provided via an electronic, commercially-available format that is suitable for long-term electronic archive. Submittals may be secured to protect the contents from further editing or modification so long as such protections don t preclude the transmission of the document to a Government storage facility or server. As an instrumentality of the United States Government, such protections shall not be construed to abridge the Government and/or ANG s rights of ownership or propriety. D. Commissioning services shall be performed by a certified Commissioning Agent and Authority (CAA) IAW the requirements of the SOW. The CAA shall act as the project Commissioning Coordinator. The CAA s qualifications shall be presented to the ANG or the ANG s designated representative prior to commencement of any commissioning work. Services shall provide for the development of scenarios for HVAC system optimization; the improvement of energy conservation, scheduling, or alarm notification; maintenance messaging; demand limiting; equipment duty cycling; load shedding; electrical demand side management; use with backup generators and backup fuel supply. Services may require coordination with local utility companies. E. The system shall establish a central EMCS Controller to be located on a personal desktop computer that will be located in building 683. The ANG shall determine the location. Licensed, electronic copies of all vendor software, to include programming tools, operating software, and extension software, shall be provided to the ANG on portable computer disks. Software shall be loaded and configured on the Controller; the Controller shall be configured for immediate use upon delivery to the ANG. To the greatest extent possible, the Controller and vendor software shall be configured to provide a customized, easily-understood, graphical user interface (GUI) with point and click features. Customized graphical representation of each facility and each controlled system within the facility shall be accurately created and completely depicted. GUI shall display current readings of attached utility meter readings (including both master and sub meters) for electric, gas, water. F. Services shall include any and all necessary verification and investigation of existing and planned HVAC systems in the identified facilities. The required work (EMCS and DDC) at each of the facilities shall be ordered in priority and approved by the 129th Civil Engineering Flight, or the ANG s designated representative Basic Description of the System A. The EMCS and DDC system shall remotely control and monitor base HVAC systems. The systems to be controlled include but are not limited to HVAC Systems, Plumbing Systems, and Utilities Master Meters, Facility level Meters, and Sub Meters B. Design shall incorporate state of the art direct digital control system and shall be manufactured by ALC and must be compatible and integratable with the protocol of the DDC system installed or being installed in building 663. The system must be expandable and upgradable to incorporate additional facilities that may be constructed in the future. Design must employ the base standard system of protocol for interfacing DDC systems to the EMCS using BACNET.

4 C. EMCS system shall interface with and remotely monitor and gather base utility consumption data at master meters and facility sub meters. Utilities to be monitored include gas, water, and electricity. D. Design shall include interface with duct-mounted smoke detectors and separate fire alarm panels for the monitoring and relaying of HVAC shut-down sequence in emergency conditions. E. Design shall include interfacing with existing chillers, boilers, and modular boilers in a staged sequence for efficient partial load matching. F. Design shall include status and start/stop control of electric motor on pumps, fans, air conditioning units, chillers, computer room air conditioners, cooling towers, air handling units, fan coil units, variable speed drives, variable air volume boxes, and other HVAC equipment. G. Design shall include interfacing with separate, existing, proprietary control panels and management systems for infrared heating in the maintenance hangar, backup power panels, generators, and other panels. H. System shall be programmed for night and weekend setbacks as prescribed by the 129th Civil Engineering Flight and shall provide for manual overrides as well as simple reprogramming to allow for schedule changes. I. Design shall provide a single point shut off for all mechanical systems in all buildings from the Controller and one auxiliary to be located in the 129th Security Forces Squadron s Base Defense Operations Center (BDOC) in building 653. J. Software shall include but not be limited to backup program disk, all necessary information to install or update software, all access devices (i.e. keys) necessary to install and/or operate system. K. Provide all necessary programming of each individual facility to properly identify the device and transmit the data indicated in part 1.1., Project Objective. L. Provide master updated copy of control drawings for entire base in binder with dividers and table of contents. Provide equipment datasheets in separate binder with table of contents and binders. M. Controller and Subordinates shall be provided by the Contractor and shall be laptop or desktop computers. N. The Contractor shall provide a rough-in riser system architecture diagram which details point operation of the systems as depicted in the example for each facility: (See Attachment 1). O. The Contractor shall also provide an input/output schedule that delineates various pieces of equipment operations concerning input, output, alarms, and functions etc. for each facility.

5 Attachment 2 is provided as an example of what points should be incorporated; this is merely an example and is not all-inclusive. P. The Contractor shall draw and load color graphics for all new controllers and their controlled HVAC system, to include meters, and load the drawings on to the controllers. Drawings should include the facility floor plan with room numbers, FCUs (numbered), and the temperature at each sensor. The system shall incorporate thermo-coded graphics whereby an area is depicted as too hot (red), at set point (green) or too cold (blue). Q. The Contractor shall replace three pneumatic controls in building 650 with digital controls and connect them to the EMCS system. R. Design shall include a single fiber solution for connectivity between facilities System Performance The communication speed between the controllers, gateways, network interface devices, and operator interface devices shall be sufficient to ensure a fast system response time under any loading condition. This includes when system is collecting trend data for commissioning and for long term monitoring. The contractor shall configure the DDC and/or EMCS and network as necessary to accomplish the performance requirements System Hierarchy Air handling systems serve a collection of Isolation Areas which in turn are a collection of zones. Each Isolation Area can have a different occupancy schedule, allowing the system to serve only a small number of spaces for off-hour energy savings. For small systems and for single zone systems, there may be only one Isolation Area but the basic logic shall be applied GUI Software The GUI software shall provide easy-to-read graphical shortcuts and links between connecting equipment, systems, facilities, and auxiliary or operational features. The GUI shall encompass graphical methods for setup of occupancy, scheduling, trending, alarms, and messaging. The GUI shall depict real time operating conditions and settings. The GUI shall employ color coded building graphics, and color shading to depict operating conditions. Changes in color shall depict deviation from acceptable operating levels; such deviation away of acceptable zone temperatures, or higher demand levels, or active alarms. GUI shall be a laptop in a docking station and include all tools and connectors necessary to completely service the system at the main location or remotely in the buildings. Monitor shall be 30 minimum with resolution of 2560 x 1600, rotatable display, adjustable height and tilt, similar to Dell Ultrasharp U3014. Laptop shall have minimum specifications of 1 TB hard drive, 8 GB memory and windows 7-64 bit operating system. A. Trends. Trending setup for both commissioning and normal operation is required.

6 1. Trending and trend analysis capabilities are considered critical to system performance. The system shall be designed to upload and record large amounts of point data without causing network bottlenecks or affecting proper system operation. 2. Every point, both real and virtual, shall be available for data reading. 3. Trending software shall be capable of recording point values and time on a user specified regular time step and on a change-of-value (COV) basis at the user s option. Sampling intervals shall be as small as one second. Each trended point shall have the ability to be trended at a different sampling interval. 4. Trend data shall be sampled and stored in control panel memory. There shall be no limit to the amount of trend data stored at the Operator Workstation other than hard disk limitations. 5. Trends shall conform to the BACnet Trend Log Object specification. Trends shall both be displayed and user configurable through the GUI. 6. Provide software to archive trend data to CD or other storage media. 7. Viewing trends. a. Trend data shall be displayed graphically by the GUI. This shall be a capability internal to the workstation software and not a capability resulting from download of trend data on a third-party spreadsheet program unless such transfer is automatic and transparent to the operation and the third-party software is included with the workstation software package. Additionally, such third-party software must be commercially available and the data easily transcribed between formats (i.e., comma separated values, plain text, rich format text, etc.). b. The software shall be capable of dynamically graphing the trend logged object data by creating two-axis (x,y) graphs that simultaneously display values relative to time for at least eight objects in different colors, even if objects have been trended at different time intervals. c. Trends shall be able to dynamically update at operator-defined intervals, including on a 1 second interval for loop tuning. B. Data storage and analysis by other software. Data shall be stored in or be exportable to one or more of the following formats for: Text (Comma or tab delimited with text delimiters), MS Excel, MS Access, dbase, and SQL. Stored data shall not have duplicate records, and have an individual or unique time/date stamp for a specific point, and the data shall be fully contained in a single file or table for each point. Data shall not span multiple files or database tables. C. Security Access. At a minimum, the EMCS security protocols shall comply with DIACAP requirements for password length, complexity, and change frequency. Integration of Common Access Cards (CACs) is desirable. See ATO testing procedures for more information.

7 D. Reporting Software/Alarms/Maintenance Messaging. The EMCS shall have the capability to generate energy reports in the form of bar charts, pie charts, and trend lines. ALC Energy Reporting package shall be included and configured into the EMCS under this SOW Sequence of Operation A. General 1. All setpoints, timers, deadbands, PID gains, etc. listed in sequences shall be capable of being adjusted by the operator without having to access programming whether indicated as adjustable in sequences or not. Software (virtual) points shall be used for these setpoints. Fixed scalar numbers shall not be imbedded in programs unless the value will never need to be adjusted. 2. Reset control shall be applied as appropriate and shall include but not be limited to Hot Water temperature/boiler Reset, Chilled Water temperature/chiller Reset, Supply Air temperature Reset, Duct Static Pressure Reset, and Hydronic system pressure Reset. a. Where zone data (i.e., damper or valve position, control loop signal) is used for reset of the AHU/pump system serving the zone, the zone tag (name) and damper/valve position shall be recorded when it is the zone driving the reset. This data shall be available for Reports so that zones that are undersized or otherwise driving the system can be identified for remediation if required. The position of the most open damper/valve is also critical for commissioning the reset sequences. c. Unless otherwise indicated, control loops shall be enabled and disabled based on the status of the system being controlled to prevent wind-up. B. Zones: This section applies to all single zone systems and sub-zones of air handling systems, such as VAV boxes, fan powered boxes, etc. 1. Setpoints a. Each zone shall have separate unoccupied and occupied setpoints, and separate heating and cooling setpoints. b. Where the zone has a local occupant adjustable setpoint adjustment knob/button, the adjustment shall be capable of being limited in software. If a demand limit setpoint adjustment is in place or the door or window switch indicates a door is open, the local setpoint adjustment shall be disabled. c. Demand limits setpoint adjustment. Cooling setpoints shall be increased upon demand limit requests from the associated Isolation Area. i. At Demand Limit Level 1, increase current setpoint by 1 F. ii. At Demand Limit Level 2, increase current setpoint by 2 F.

8 iii. At Demand Limit Level 3, increase current setpoint by 4 F. d. Hangar door switches and facilities with large overhead doors. Large maintenance zones and aircraft hangars shall have indicator switches that when large doors indicate that they are open, the heating setpoint shall be temporarily set to 40 F. e. Occupancy sensors. For zones that have an occupancy switch associated with the zone, when the switch indicates the space is unoccupied during the Occupied mode, the heating setpoint shall be reset to 4 F lower than the active setpoint, and the cooling setpoint shall be reset to 4 F higher than the active setpoint and the ventilation shall be shut off. VAV flow shall go to 0, and fan coil unit shall turn to auto. f. Hierarchy of setpoint adjustments. The following adjustment restrictions shall prevail in order from highest to lowest priority: i. Setpoint overlap restriction ii. Door switches iii. Demand limit iv. Occupancy sensors v. Local setpoint adjustment vi. Scheduled setpoints based on zone mode 2. Local override. Thermostat override buttons shall be sent up for the Isolation Area override control for 60 minutes. 3. Control Loops. Two separate control loops shall operate to maintain space temperature at setpoint, the Cooling Loop and the Heating Loop. Both loops shall be continuously active. The Cooling Loop shall maintain the space temperature at the active cooling setpoint. Mode. 4. Zone Modes shall consist of a Heating Mode, Cooling Mode, and Deadband 5. Alarms a. Inhibit alarms after zone setpoint is changed for a period of 10 minutes per degree of change and while Isolation Area is in Warm-up or Cool-down Modes. b. If the zone is 2 F above cooling or below heating setpoint. c. If the zone is 4 F above cooling or below heating setpoint. d. For zones with CO 2 sensors, if the CO 2 concentration is less than 300 ppm, or the zone is in unoccupied mode for more than 2 hours and zone CO 2 concentration exceeds 600 ppm, generate a level 3 alarm, indicating sensor may be out of calibration.

9 e. For zones with door switches, generate an alarm if the door switch is open and the zone is in unoccupied mode. C. VAV with reheat boxes. 1. Design airflow rates: Zone design maximum cooling and maximum heating airflow setpoints may be initially as scheduled on as built plans; but final airflow CFMs shall be determined by the commissioning Agent or coordinator. Typical minimum levels are as follows: a. Zones with CO 2 controls and occupancy sensors; zone minimum; 0.15 cfm/ft 2 times the room area. b. Zones without CO 2 controls or occupancy sensors; zone minimum; 0.15cfm/ft 2 times the room area or 15 cfm per person, whichever is larger. c. If the zone has a CO 2 sensor, during Occupied Mode, a P-only loop shall maintain CO 2 concentration below 1000 ppm. 2. Alarms required: a. Low airflow b. Low supply air temperature c. Floating damper alarm, generate an alarm indicating a control stability problem and excess damper motor wear. D. Isolation Areas 1. Each system shall be broken into separate Isolation Areas composed of a collection of one or more zones served by the air handling system. 2. Individual Isolation Areas shall be as follows: a. Each floor b. All 24/7 areas, such as computer rooms c. Other areas as required. Make sure they are not so small that fan or cooling stability problems arise. 3. Each Isolation Area shall have separate occupancy schedules and operating modes from other Isolation Areas served by the air handling system. All zones in the Isolation Area shall be in the same operating mode. 4. Each Isolation Area shall be a separate zone with respect to the occupant override system. Occupant interface software shall be programmed to allow occupants to override normal schedule programming to operate the system during off hours for a period set by the occupant, within software time limits adjustable by the operator.

10 modes: 5. Isolation Area Operating Modes: Each Isolation Area shall have the following a. Normal b. Warm-up mode c. Cool-down mode d. Setback mode e. Setup mode f. Unoccupied mode 6. Air Handling Unit System Modes: AHU system modes are the same as the mode of the Isolation Areas served by the system. When Isolation Areas served by an air handling system are in different modes, the following hierarchy applies (highest one sets AHU mode): a. Occupied mode b. Cool-down mode c. Setup mode d. Warm-up mode e. Setback mode f. Unoccupied mode E. VAV Air Handling System 1. Supply fan control a. AH fan start/stop b. Static pressure setpoint reset c. Supply fan speed 2. Minimum outdoor air control a. CO 2 controls under VAV zone controls b. Open minimum outdoor air damper when the supply air fan is proven on and the system is not in warm-up, cool-down, setup, or setback mode. Damper shall be closed otherwise. 3. Supply air temperature control a. Cooling supply air temperature b. Supply air temperature setpoint 4. Economizer lockout. The normal sequencing of the economizer dampers (above) shall be overridden and economizer outdoor air dampers shall be shut whenever the outdoor air temperature is greater than return air temperature. 5. Return fans

11 a. Return fan operates whenever associated supply fan is proven on. b. Return fan speed shall be controlled to maintain return fan suction pressure at setpoint. c. Relief/exhaust dampers: Control of building static pressure to avoid over-pressurizing the building. Control building static pressure in a slightly positive overpressure status by controlling the fresh air intake. d. If there are several air handlers serving a common atmosphere, control all relief fans together to avoid hunting. 6. Alarms a. Maintenance interval alarm for number or run hours, and failed starts. b. Fan alarm. c. Filter pressure drop exceeds alarm limit. d. High supply air temperature off cooling coils. e. If the temperature drops across the cooling coil while cooling valve is closed, an indication of a leaking valve should be noted. f. If mixed air temperature abnormal range indicating economizer damper control problems. g. Low static pressure. F. Boilers and Pumps 1. All boilers and pumps shall be sequenced and staged for efficient partial load matching. Boiler operating hours shall be evened out by switching lead and lag boilers, as determined by cumulated run hours or by cumulated number of starts. 2. Local boiler control panels and local boiler controls and burner management shall be mapped to the EMCS for remote monitoring. The EMCS shall not be allowed to interfere with boiler safety controls. G. Air conditioning systems, Chillers, Condenser water System, and Pumps 1. Generally, chilled water [and large condenser water, cooling tower water] hydronic systems shall vary water flow by employing circulating pumps with variable frequency drives in lieu of three way control valves. 2. On board chiller control panels and panels for other Air Conditioning systems such as water loop heat pump systems, packaged unitary air conditioning systems, and computer room air conditioning systems shall map all critical maintenance and critical operating points and parameters to EMCS for remote monitoring. 3. Special care to map points for interface and control of chillers such that full remote operation and monitoring can be accomplished through the EMCS. The EMCS shall not be allowed to interfere with chiller safety controls.

12 Part 2. EMCS System Commissioning 2.1. Work Included This section applies to all EMCS components/equipment in all facilities/associated systems on this contract. The intent of this section is to deliver a detailed and documented performance functional test and commissioning of all contracted components and systems that clearly verify the entire EMCS system is fully operational in accordance with this contract: 2.1. Including but not limited to the following: A. EMCS and equipment testing and start-up B. Development and validation of control operating sequences C. Validation of proper occupant ventilation airflow rates D. Validation of proper and thorough installation of EMCS and equipment E. Functional testing of control systems F. Demonstration testing of control systems G. Documentation of tests, procedures, and installations H. Coordination of EMCS training I. Documentation of EMCS Operation and Maintenance materials J. Training K. Reference Management Manual for Retro-commissioning 2.2. Sequencing A. The following list outlines the general sequence of events for submittals and commissioning: 1. Submit Preliminary Submittal Package, including Commissioning plans and Qualifications; and receive approval. See part 1, Energy Management and Control System for the Preliminary Submittal Package requirements. 2. Submit Commissioning Submittal Package, 1, for Hardware and Shop Drawings and receive approval. 3. Initiate installation of EMCS hardware, devices and wiring. 4. Develop point database and application software. 5. Simulate sequencing and debug programming off-line to the extent practical. approval. 6. Submit Submittal Package 2 (Programming and Graphics) and receive 7. Complete installation of EMCS hardware, devices and wiring. 8. Install point database and application software in field panels.

13 9. Submit Submittal Package 3 (Functional Testing) and receive approval. 10. Perform EMCS Pre-functional Tests (start up, calibration and tuning) and submit Pre-functional Tests for approval. 11. Field test application programs prior to functional testing. 12. Receive EMCS Pre-functional Test Report approval and approval to schedule Functional Tests. approval. 13. Perform and record functional tests and submit Functional Test Report for 14. Assist TAB contractor in TAB tests and determine setpoints as specified in Section Submit Package 4 (Training Materials) and receive approval. 16. Receive EMCS Functional Test Report approval and approval to schedule Demonstration Tests. 17. Perform Demonstration Tests to Commissioning Coordinator and Owner Representatives and submit Demonstration Test Report. 18. Receive acceptance of Demonstration Tests. 19. Train Owner personnel on EMCS operation and maintenance. 20. Substantial Completion 21. Prepare and initiate commissioning Trend Logs. 22. Submit Trend Logs in format specified for review and approval. 23. Receive approval of successful Trend Log tests, or retest as required. 24. Provide administration level password access to the Owner. 25. Prepare and provide the Reference Retro-Commissioning Management Manual, Submittal Package 5, and receive approval. Contractor shall provide a backup copy of the final EMCS sequence of operations to the government on a medium that can be stored for later use. 26. Final Acceptance 27. Begin Warranty Period. 28. Prepare and initiate post-occupancy Trend Logs.

14 and approval. 29. After 6 months of operation, submit Trend Logs in format specified for review 30. Receive approval of successful Trend Log tests, or retest as required. 31. Two months prior to end of Warranty Period, submit Trend Logs in format specified for review and approval. 32. Receive approval of successful Trend Log tests, or retest as required. 33. Revise and submit record documents and O&M Manuals. 34. Update all software as specified. 35. End of Warranty Period 2.3 Functional Test Documentation A. Pre-functional Tests 1. Prepare forms to document the proper startup of the EMCS. 2. All equipment shall be included on test forms including but not limited to: verification a. Digital outputs: proper installation, normal position, response b. Digital inputs: proper installation, device test, response verification min stroke c. Analog outputs: proper installation of devices, verification of max and d. Analog inputs: proper installation of sensors, calibration e. Wiring connections and other electrical issues f. Panels g. Alarms and safeties h. Loop tuning i. Network traffic

15 3. Each form shall have a header or footer where the technician performing the test can indicate his/her name and the date of the test. 4. Submit forms for approval in Submittal Package Complete work, document results on forms, and submit for approval as Prefunctional Test Report. B. Functional Tests 1. Prepare functional testing forms after Submittal Package 2 has been reviewed and approved. Tests will be designed to test all sequences in a formal manner with simulations and expected outcomes. 2. Contractor shall prepare functional testing forms and test all sequences in a formal manner. Test forms shall include at a minimum: a column indicating the tests and simulations to be performed, the expected outcomes, the actual outcome, and check box indicating whether the system passed or failed. All forms shall be given to the government representative and all functional tests that do not pass, the contractor shall make appropriate adjustments until the system passes retests. 3. All control sequences shall be functionally tested. For systems that use identical control logic (e.g. VAV boxes, identical air handler), only one subsystem needs to be tested. Any changes to programming resulting from tests shall be made to all identical applications. 4. Each form shall have a header or footer where the technician performing the test can indicate his/her name and the date of the test. 5. Submit forms for approval in Submittal Package 3 6. Complete work, document results on forms, and submit for approval as Functional Test Report Instrumentation A. All instrumentation required to verify readings, to calibrate sensors, and to test the system and equipment performance shall be provided by Contractor. B. All equipment used for testing and calibration shall be NIST/NBS traceable and calibrated within the preceding 6-month period. Certificates of calibration shall be submitted. C. Test equipment used for testing and calibration of field devices shall be at least twice as accurate as respective field device (e.g. if field device is ±0.25% accurate over same range) Testing

16 2.5.1 Pre-functional Tests A. General 1. Inspect the installation of all devices. Review the manufacturer s installation instructions and validate that the device is installed in accordance with them. 2. Verify proper electrical voltages and amperages, and verify that all circuits are free from faults. 3. Verify integrity/safety of all electrical connections. 4. Verify that shielded cables are grounded only at one end. 5. Verify that all sensor locations are as indicated on drawings and are away from causes of erratic operation. 6. Ensure that minimum speed settings programmed into variable speed drive are at or below the minimum speed settings in control sequences. B. Digital Outputs 1. Verify that all digital output devices (relays, solenoid valves, two-position actuators and control valves, magnetic starters, etc.) operate properly and that the normal positions are correct. C. Digital Inputs 1. Adjust setpoints where applicable a. For current switches used as status on fans, adjust current set point so that fan status is off when fan discharge damper (if present) is fully closed and when belt is broken (temporarily remove belt). b. For current switches used as status on pumps, adjust current setpoint so that pump status is off when pump is dead-headed (temporarily close discharge valve). c. For differential pressure sensors on pumps and fans, set so that status is on when pump is operating with all valves open (out on its curve). D. Analog Outputs 1. Verify start and span are correct and control action is correct. 2. Check all control valves and automatic dampers to ensure proper action and closure. Make any necessary adjustments to valve stem and damper blade travel.

17 3. Check all normal positions of actuators with spring return. 4. For outputs to reset other manufacturer s devices (e.g. chiller setpoint) and for feedback from them, calibrate ranges to establish proper parameters. 5. Test and document actual spring range of pneumatic actuators from full open to full close and reflect this in pneumatic output ranges. E. Analog Input Calibration 1. Sensors shall be calibrated. Calibration methods shall be one of the following: a. Factory: Calibration by factory, to standard factory specifications. Field calibration is not required. b. Handheld: Field calibrate using a handheld device with accuracy meeting the requirements of Paragraph 2.1. c. Drywell Bath: Field calibrate using a 2-point procedure, using a drywell calibrator block constructed for that purpose, or an ice bath with a reference standard. 2. The calibrating parameters in software (e.g. slope and intercept) shall be adjusted as required. A calibration log shall be kept and initialed by the technician showing date and time, sensor and hand-held readings, and calibration constant adjustments and included in the Pre-functional Test Report. 3. Inaccurate sensors must be replaced if calibration is not possible. F. Alarms and Interlocks 1. A log shall be kept and initialed by the technician showing date and time, alarm/interlock description, action taken to initiate the alarm/interlock, and resulting action, and included in the Pre-functional Test Report. 2. Check each alarm separately by including an appropriate signal at a value that will trip the alarm. 3. Coordinate and interface with life safety systems and fire alarm contacts. 4. Interlocks shall be tripped using field contacts to check the logic, as well as to ensure that the fail-safe condition for all actuators is in the proper direction. 5. Interlock actions shall be tested by simulating alarm conditions to check the initiating value of the variable and interlock action. G. Tuning

18 1. Tune all control loops to obtain the fastest stable response without hunting, offset or overshoot. Record tuning parameters and response test results for each control loop in the Pre-functional Test Report. Except from a startup, maximum allowable variance from set point for controlled variables under normal load fluctuations shall be as follows. Within 3 minutes of any upset (for which the system has the capability to respond) in the control loop, tolerances shall be maintained (exceptions noted): Controlled Variable Control Accuracy Duct Pressure ±0.1 w.g. Building and relief plenum ±0.01 w.g. Airflow ±10% Laboratory fume hood and make-up See airflow Space Temperature ±1.5 F Chilled Water Temperature ±1 F Hot Water Temperature ±3 F Duct Temperature ±2 F Water Differential Pressure ±1.5 psi Others ±2 times reported accuracy H. Interface and Control Panels 1. Ensure devices are properly installed with adequate clearance for maintenance and with clear labels in accordance with the record drawings. 2. Ensure that terminations are safe, secure, and labeled in accordance with the record drawings. 3. Check power supplies for proper voltage ranges and loading. 4. Ensure that wiring and tubing are run in a neat and workman-like manner, either bound or enclosed in trough. 5. Check for adequate signal strength on communication networks. 6. Check for standalone performance of controllers by disconnecting the controller from the LAN. Verify the event is annunciated at Operator interfaces. Verify that the controlling LAN reconfigures as specified in the event of a LAN disconnection. 7. Ensure that buffered and/or volatile information is held through power outage. 8. With all system and communications operating normally, sample and record update/annunciation times for critical alarms fed from the panel to the Operator Interface. I. Operator Interfaces

19 1. Verify that all elements on the graphics are functional and are properly bound to physical devices and/or virtual points, and that hot links or page jumps are functional and logical. 2. Verify that the alarm printing, logging, paging, ing etc. is functional and per requirements. J. Trending/Network Traffic Test. Perform tests to verify that system has been designed adequately to simultaneously capture trends and allow proper operation of the control system. operational. 1. Tests shall be performed after the verification trends have been set up and are 2. Randomly select a device whose failure will generate an alarm and manually shut it off. The status points for the device must indicate the change of state of the device at the Operator Workstation within 5 seconds. The test shall be repeated for four devices in each building. 3. Test the clock signal from a field controller randomly selected. Test is considered acceptable if the local clock signal is no more than 2 seconds off of the system clock. 4. If the system fails any test, the system architecture shall be revised as required (e.g. more trend memory, more controllers with trend storage capability, network repeaters to allow an increase in network speed, etc.) followed by additional tests TAB Tests A. Setpoint Determination 1. Assist the TAB contractor in determining fan and pump differential pressure setpoints, outdoor air damper minimum positions and DP setpoints, and Testing, Adjusting and Balancing (TAB). operational. leaking valve. B. Coil Valve Leak Check 1. Coordinate test procedures concurrent with Testing, Adjusting and Balancing. 2. Test conditions for each hydronic system a. Tests shall be done when central plant cooling and heating systems are b. Close all control valves c. Start all fans associated with control valves d. Open bridge connection control valve e. Start both pumps f. Observe flow meter. If reading changes after pumps start, there is a

20 g. Observe supply air temperature at each coil after test starts h. Should any supply air temperature rise, close the isolation valves to the coil to see if temperature changes. If so, this validates that the valve is not fully closing. Remedy the condition by adjusting the stroke and range, increasing the actuator size/torque, replacing the seat, or replacing the valve as applicable Functional Tests A. Test schedule shall be coordinated with the Commissioning Coordinator. B. Tests may be witnessed by an Owner Representative at the Owner s option. C. All approved Functional Tests shall be conducted by the EMCS Contractor with results confirmed and signed by the Contractor s start-up technician. D. Test documentation shall be submitted to the Owner for review and approval Demonstration Test A. Demonstration tests consist of a small representative sample of functional tests and systems randomly selected by the Owner. Tests will be designed to occur over no longer than [Select: 2 days commonly, 4 days for complex systems] days. B. Schedule the demonstration with the Owner s representative 1 week in advance. Demonstration shall not be scheduled until the Functional Test Report has been approved. C. The contractor shall supply all personnel and equipment for the demonstration, including, but not limited to, instruments, ladders, etc. Contractor-supplied personnel shall be those who conducted the Functional tests or who are otherwise competent with and knowledgeable of all project-specific hardware, software, and the HVAC systems. D. The system will be demonstrated following procedures that are the same or similar to those used in the Pre-functional and Functional Tests. The Owner s representative will supply the test forms at the site at the start of the tests. E. Contractor shall conduct tests as directed by and in the presence of the Owner s representative and complete test forms. Completed forms shall be submitted as the Demonstration Test Report to the Owner and Commissioning Coordinator after tests are complete. F. Demonstration Tests shall be successfully completed and approved prior to Substantial Completion Trend Log Tests A. Commissioning (Post Construction) Trend Test

21 completed. 1. Trend logging shall not commence until Demonstration Tests are successfully 2. Contractor shall configure points to trend as required for Commissioning Trends including: a. For equipment of identical function, such as VAV zones and AHUs with identical components and control sequences, only a sample of such equipment need to be trended. The sampling shall be 10% of the identical components, but no more than 10 and no less than 3. Review with Owner representative before setting up trends. b. Where zone data (e.g. damper or valve position, control loop signal) is used for reset of the AHU/pump system serving the zone, the zone tag (name) and zone data (e.g. damper or valve position) shall be trended. c. All points trended for a single HVAC subsystem (e.g. air handling unit, chilled water system, etc.) shall be trended during the same trend period and the same time intervals so that data may be easily plotted using a spreadsheet. 3. Trends shall be uploaded to the Trend Historian Server in data format specified. 4. Trend logs of all points indicated above shall be collected for a (normally 2 or 4 week) week Trend Period. 5. At the completion of the Trend Period, data shall be reviewed by the Contractor to ensure that the system is operating properly. If so, data shall be submitted to the Owner in an electronic format agreed to by the Owner and Contractor (e.g. CD-ROM or via direct access to the Operator Workstation via the internet). 6. Data will be analyzed over approximately a two- to three-week period by an Owner representative. 7. The system shall be accepted only if the trend review indicates proper system operation without malfunction, without alarm caused by control action or device failure, and with smooth and stable control of systems and equipment in conformance with these specifications. If any but very minor glitches are indicated in the trends, steps 4 to 6 above shall be repeated for the same Trend Period until there is a complete Trend Period of error free operation. B. Post Occupancy Trend Tests 1. After successfully completing the Commissioning Trend Tests, the Contractor shall configure all points as required to trend for final Continuous Trending. 2. Archive trends up to the Operator Workstation without overwriting stored data for the entire Warranty Period. 3. Data will be reviewed by an Owner representative at the following intervals:

22 a. Approximately 6 months after system acceptance b. Approximately 2 months prior to the end of the Warranty Period Remedial Work A. Remedial work identified by site reviews, review of submittals, demonstration test, trend reviews, etc. shall be performed to the satisfaction of the Owner s representative, at no additional cost to the Owner Training Provide two (2) 16 hour training sessions for four people in the Civil Engineering facility. Contractor will provide the trainer and materials as part of the contract. The first training session will be immediately following successful commissioning of the DDC system and the second training session occurring approximately 6-12 months after the initial training session as requested and coordinated by the base personnel. 2.8 Retro-Commissioning Management Manual Prepare and submit a Reference Retro-Commissioning Management Manual containing the following information organized into a 3-ring binder with tabbed sections as listed. A. Design Intent: Final version of the owner s requirements and design basis narratives, including brief descriptions of each system. Shall also include a complete list of points of contacts for key personnel with all vendors and contractors, subcontractors including the Test & Balance contractors that were employed, consulted or referenced for completion of the project. B. Controls: 1. As-built sequences of operation for all equipment. 2. Controls drawings 3. A list of time of day schedules and a schedule to review them for relevance and efficiency. 4. A list of all user adjustable setpoints and reset schedules with rationale for their selection and range. C. Energy and Water Efficiency Measures: 1. A description and rationale for all energy and water saving features and strategies with operating and instructions. 2. Guidelines for establishing and tracking benchmarks for whole building energy use and equipment efficiencies of cooling, heating, and service hot water equipment.

23 3. Seasonal Issues. 4. Calibration: Recommendations for recalibration frequency of sensors and devices by type and use. 2.9 Warranty Contractor to provide a one (1) year warranty on all parts and labor and a five (5) year warranty on all sensors, valves, and actuators installed in this contract.

24 Bldg 650 Bldg 654 Bldg 656 Bldg 662 Bldg 680 Bldg 653 Bldg 663 Bldg 681 Bldg 683 Project Number QMSN Install Basewide EMCS System Facilities included in this Statement of Work: Bldg 653 has an ALC system installed. Contractor shall connect this building to the basewide EMCS and report to the controller. Operations and Training Facility under construction and will have an ALC system installed. Contractor shall connect this building to the basewide EMCS and report to the controller. Shall be an optional bid item Shall be an optional bid item.

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