TRAINING SESSION_HVAC SYSTEM COMMISSIONING

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1 Presentation On COMMISSIONING OF HVAC SYSTEM By Y. S. RAO Certified Energy Manager yashwantsubashrao@gmail.com Training Session: COMMISSIONG OF HVAC SYSTEM

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2 Training Session: COMMISSIONG OF HVAC SYSTEM Introduction Activities Assessment of Equipments Points to remember

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3 Introduction Definition Process by which an equipment, facility, or a plant(which is installed, or is complete or near to completion) is tested to verify if it functions according to its design objectives or specifications.

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4 Introduction HVAC Components Chillers Primary Chilled Water Pumps Secondary Chilled Water Pumps Air Handling Units Air Washers Ventilation & Exhaust Fans Cooling Towers

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5 Introduction Tools & Instruments Clamp Meter Infrared Thermometer Sling Psychrometer Micron Guage Pressure Guage Manifold Psychrometric Chart Anemometer Megger

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6 Introduction Role of a Commissioning Engineer / Professional Commissioning Engineer / Professional is the key person who cross checks the installations, physically verifies the data on the equipment and confirms that the installation is up to the mark. Commissioning Engineer / Professional is the first person to identify the calculation mistakes done at the Preliminary Design Stage.

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7 Introduction Role of a Commissioning Engineer / Professional Commissioning Engineer / Professional is the person who identifies the mistakes and loop holes while Project Execution. Commissioning Engineer / Professional is the first person to establish the quantity of refrigerant gas required to charge a Refrigeration system.

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8 Introduction Role of a Commissioning Engineer / Professional Commissioning Engineer / Professional is the first person who can predict/forecasts the repeated / frequent problems that can occur in the system in the future. Commissioning Engineer / Professional is the first person to identify the energy saving opportunities.

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9 Training Session: COMMISSIONG OF HVAC SYSTEM Introduction Activities Assessment of Equipments Points to remember

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10 Activities Activities can be classified broadly under following categories : . Pre- Commssioning activities involve Inspection and Physical Verfication . . Post Commissioning activities involve Testing, Adjusting & Balancing, Performance / Seasonal Test.

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11 Pre – Commissioning Activities Inspection of the complete Installation. Refer the Drawing & check whether all the installations are as per the approved drawings. Check the quality of water (Water Analysis Report) and ensure that the water quality is matching with Manufacturer’s requirement. Carry out the hydro pressure testing as per the recommended standards by-passing the coils.

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12 Pre – Commissioning Activities Refer the Manufacture’s catalogue and check whether the installation is done as per the standards recommended by the manufacture. Space Clearance around the equipment. Height / Depth at which the equipment is recommended to be installed. Extra accessories recommended to be installed at site. Check whether Recommended Accessories are installed at proper location.

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13 Pre – Commissioning Activities Check whether the sizes of the power cables installed and connected to the equipment, starter panel and panel board are of suitable capacity and can meet the requirement under adverse condition. Check whether Control cabling is done properly and all the extra accessories are taken into loop.

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14 Pre – Commissioning Activities Check whether Control cabling is done properly and all the extra accessories are taken into loop. Check the Megger value of all the motors, Power Panels & Power cables wherever used. Carry out cold test for checking the shorting of any contacts by Continuity Tester.

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15 Pre – Commissioning Activities Check for proper voltage across the terminals of the Load. Check the Voltage imbalance and calculate the % of Voltage imbalance across the load. Check for Proper earthing of all the electrically operated equipments.

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16 Pre – Commissioning Activities Air Handling Units Check the capacity and identify whether the same AHU is reflecting at the same location as per drawing. Check the condition of the belts. Check the condition of air filters. Check and ensure that the Pressure Guages installed are calibrated.

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17 Pre – Commissioning Activities Air Handling Units Check whether rubber pads / vibration isolators are installed beneath the AHU. Check whether flexible connectors are installed at the mouth piece of the AHU. Check the pipe connection of the Coil. Check whether Volume Control Dampers are installed wherever required.

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18 Pre – Commissioning Activities Pumps Check the Inlet and Outlet Piping connection with reference to the drawing. Check whether NRV is installed on the discharge side and Stainer is installed on the suction side. Check for proper alignment of coupling using a dial gauge. Check for free rotation of pump shaft.

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19 Pre – Commissioning Activities Cooling Tower Clean the cooling tower basin and ensure the proper & free drainage of the cooling tower water. Check and ensure the installation of stainer on the inlet side of the cooling tower. Check for proper alignment of Fan Blades. Check spray nozzles and ensure that there is no blockage.

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20 Pre – Commissioning Activities Chillers Check whether Flow switches are installed at proper location and is connected to the control circuit. Check whether Inlet and Outlet water pipe connections of are done properly. Ensure the hydro-pressure testing of chilled water pipe lines and condenser water pipe lines are done properly .

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21 Pre – Commissioning Activities Chillers Check whether flexible connectors are installed at Inlet and Outlet water pipe lines. Ensure proper flushing of chilled water pipe lines and condenser water pipe lines are done properly. Carry out Water analysis of water to be used and ensure that all the parameters of water are in line with the Manufacturer’s recommendation.

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22 Pre – Commissioning Activities Chillers Ensure Proper vacumization of the chiller prior to Refrigerant Gas charging . Carry out refrigerant gas leakage test and ensure there will be no leakage in the system. Use perforated sheet at the Inlet water Pipe connections to ensure thorough water filtration . Energise the Oil Heater / crank case heater 24 Hrs. prior to Chiller start-up.

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23 Post – Commissioning Activities Air Handling Units Measure and record the Voltage and the Current. Measure and record the Current imbalance. Measure the Filter section. Measure and record the velocity across filter section and calculate the CFM.

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24 Post – Commissioning Activities Air Handling Units CFM can be calculated by the following formula : CFM = Area x FPM where CFM = Air Flow Rate FPM = Velocity of Air Area = Filter cross section area in Sq. Ft.

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25 Post – Commissioning Activities Air Handling Units Measure and record the DBT & WBT on the Return Air Side or in the mixing Chamber/Box. Measure and record the DBT & WBT on the Supply Air Side near the coil.

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26 Post – Commissioning Activities Air Handling Units Calculate the load across the coil by the following formula. LOAD (TR) = 4.5 x CFM x (h2 – h1)/12000 where h2 and h1 are the enthalpies before and after the coil.

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27 Post – Commissioning Activities Pumps Measure and record the Voltage and the Current. Measure the Pressure difference across the pump i.e. on the suction side and discharge side. Observe for any current fluctuation. Check and compare the actual current with the rated current on the pump motor.

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28 Post – Commissioning Activities Measure and record the Voltage and the Current. Measure the WBT, Inlet and Outlet Water Temperatures. Calculate the Range and check with the manufacturer’s specification. Range = Inlet Water Temp. – Outlet Water Temp. Cooling Tower

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29 Post – Commissioning Activities Cooling Tower Calculate the Approach and check with the manufacturer’s specification. Approach = Outlet Water Temp. – WBT Measure the CFM of the Cooling Tower Fan and check with manufacture's specification. Ensure that the there is no over flow of water from the sump by adjusting and balancing the flow of water.

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30 Post – Commissioning Activities Measure and record the Voltage and the Current. Measure the Inlet and Outlet Water Temperatures. Measure the Pressure drop across Inlet and Outlet of Water pipe lines. Check the Flow /pressure drop graph provided in the manual by manufacturer. Chillers

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31 Post – Commissioning Activities Chillers Adjust the pressure drop across Inlets and outlets of water and achieve the desired flow rate. Check and measure the sub-cooling Temperature and Superheat. Top up the system with refrigerant gas as specified by the manufacturer with reference to sub-cooling temperature / Superheat.

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32 Post – Commissioning Activities Calculate the Load on the Chiller by the following formula: Load (TR) = 500 x USGPM x (Chilled Water Inlet Temp. - Chilled Water Outlet Temp)/12000 Cross verify the Load on the chiller with sum total of all the connecting loads. Chillers

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33 Post – Commissioning Activities Calculate the total power consumed of the Chiller package unit by the following formula: Power (KW) = Voltage x Amps x 1.732 x Power factor / 1000 Derive the Specific Power Consumption of the Chiller package unit i . e. KW/TR Chillers

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34 Post – Commissioning Activities Chillers Calculate the Coefficient of Performance of the Chiller package unit by the following formula: COP = Load (TR) x 3.516 / Power (KW) Run the whole HVAC System continuously for 72 Hrs. and record the parameters at regular intervals.

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35 Training Session: COMMISSIONG OF HVAC SYSTEM Introduction Activities Assessment of Equipments Points to remember

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36 Assessment The most essential point part of commissioning the system is to assess the system performance. Example : In case of DX systems, If . T across the Grill Temp. and the Room Temp. exceeds beyond 12 °C and the Superheat is also higher than specified then the system is under designed or over loaded.

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37 Training Session: COMMISSIONG OF HVAC SYSTEM Introduction Activities Assessment of Equipments Points to remember

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38 Points to remember Flow Switch Ensure that the flow switch is installed at least 1 meter away from the bends or reduces or tapings on the water pipe lines to avoid frequent fluctuations due to turbulence of flowing water. A nuisance or a safety device .

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39 Points to remember Pressure Gauges An erratic measuring instrument / device or a curse. Ensure that the Pressure Gauges are installed at least 1 meter away from the bends or reduces or tapings on the water pipe lines to avoid frequent fluctuations due to turbulence of flowing water.

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40 Points to remember Megger An erratic measuring instrument / device is a curse for any professional . Never carry out megging of compressor motor under vacum ( for Hermatic and Semi Hermatic Compressor .

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41 Points to remember Chiller Operation Never run the compressor motor under vacum and in the absence of refrigerant gas ( for Hermatic and Semi Hermatic Compressor )

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42 Points to remember Drain Valves Always ensure that drain valves are provided at the header of Air Handling unit coils. SPPR Use of Single Phase Preventer Phase Reversal is recommended to be installed in the control circuits.

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43 Points to remember Current Imbalance Never forget to measure the current imbalance for inductive loads like motors etc. Current imbalance can be calculated by the following formula:

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44 Training Session: COMMISSIONG OF HVAC SYSTEM COMMISSIONING OF HVAC SYSTEM THANK YOU FOR YOUR PARTICIPATION

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