Z--Bldg. 503 HVAC Repair, NAS-JRB, New Orleans, LA
Department of the Navy, Naval Facilities Engineering Command | Published January 6, 2017
HVAC SYSTEM COMMISSIONING, OPTIMIZATION AND REPAIRS TO DLA BLDG 503
1. Contractor shall demolish the following:
a. Two 10 ton condensing units (save units for use elsewhere on base)
i. Copper line set connecting CUs to the FCU-1
ii. Two 10 ton thermal expansion valves at the FCU-1
b. Outside air duct current serving both FCU-1 and FCU-2
i. Including ductwork, insulation, and OA balancing dampers/actuators in duct work
c. VAV-6 and all associated ductwork in the bypass line
i. Contractor shall also demo the duct transition where they bypass line is connected, a new piece of duct work will be installed to replace it
d. Contractor must verify FCU-1 fan motor and determine if it is inverter duty rated
i. If not, motor must be removed and disposed of
e. Contractor shall demolish and remove the existing FCU-2 and HP-2, associated line sets, and existing air handling unit
2. Contractor shall install the following:
a. A new sheet metal duct transition in the supply line where the bypass duct and VAV-6 once was.
i. New insulation shall be install to match existing on supply lines
b. Contractor shall install a new outside air duct from existing louver, dedicated to FCU-1
i. Duct shall incorporate an opposed blade damper and actuator for OA control
ii. Duct shall be insulated
iii. Ducted shall be sized for appropriate OA total
c. Contractor shall install a new outside air duct from existing louver, dedicated to FCU-2
i. Duct shall incorporate an opposed blade damper and actuator for OA control
ii. Duct shall be insulated
iii. Ducted shall be sized for appropriate OA total
d. If FCU-1 supply motor was replaced due to line item 1.D.i, contractor shall furnish and install a new inverter duty rated motor
e. Contractor shall furnish and install a VFD equipped with disconnect and bypass for control over FCU-1 supply fan motor
i. VFD shall replace existing supply motor disconnect and motor starter
f. Contractor shall furnish and install two new condensing units,
i. Trane model TTA120J4HS** or approved equals
ii. Condensing unit shall be cooling only
iii. Equipped with two manifold compressors per condensing unit
iv. Equipped with unit isolators
g. Contractor shall run new copper line set of appropriate size for R-410a refrigerant from new condensing units to FCU-1
i. Contractor shall fire caulk and seal all wall penetrations
ii. Contractor shall furnish and install new thermal expansion valves for each circuit
h. Contractor shall furnish and install a new FCU-2 and HP-2 system including new condensing unit, air handler, and appropriate line sets
ii. Equivalent to Addison model RCA101004F or approved equal
3. Upon unit installation, contractor shall perform full system Test and Balance (T.A.B.) services
a. Contract shall balance all air system components back to design engineering set points and air flow rates, or as close to design performance as possible
i. Contractor shall utilize existing balancing dampers in the air distribution system, as the air distribution system is to be reused
b. Contractor shall be responsible for adjusting any unusual readings back to engineering design performance, or as close as possible.
c. The T and B Contractor shall be certified by the Association of Energy Engineers (AEE) or the National Environmental Balancing Bureau (NEBB) or Association of Air Balance Council (AABC) and provide a final report in hard and digital copy.
Air Distribution System Cleaning
4. Upon unit installation, contractor shall perform a full system cleaning as follows:
a. The contractor shall follow NADCA ACR 2006, IICRC S520, and EPA Guidelines to thoroughly clean all air handling units, variable air volume boxes, and supply and return duct work.
i. Service openings, as required for proper cleaning, at various points of the HVAC system for physical and mechanical entry and inspection will be utilized.
ii. Existing service openings already installed in the HVAC system will be used where possible. Other openings will be created where needed, and created so they can be sealed in accordance with industry codes and standards.
iii. Closures will be properly insulated and sealed to prevent air loss/gain or condensation on surfaces within the system.
b. The HVAC system will be cleaned using Source Removal mechanical cleaning methods designed to extract contaminants from within the HVAC system and safely remove contaminants from the facility.
i. Source Removal methods will be selected that will render the HVAC system visibly clean and capable of passing cleaning verification methods and other specified tests, in accordance with all general requirements.
ii. No cleaning method, or combination of methods, will be used which could potentially damage components of the HVAC system or negatively alter the integrity of the system.
c. All methods used will incorporate the use of vacuum collection devices that are operated continuously during cleaning.
i. A vacuum device will be connected to the downstream end of the section being cleaned through a predetermined opening.
ii. The vacuum collection device will be of sufficient power to render all areas being cleaned under negative pressure, such that containment of debris and the protection of the indoor environment are assured.
d. All registers, grills, and diffusers will be disassembled, contact cleaned and reassembled.
i. All vacuum devices exhausting air inside the building will be equipped with HEPA filters (minimum efficiency), including hand-held vacuums.
ii. Mechanical agitation devices are used to dislodge debris adhered to interior HVAC system surfaces, such that debris may be safely conveyed to vacuum collection devices.
e. Methods will include those, which will not potentially damage the integrity of the ductwork, nor damage porous materials such as liners inside the ductwork or system components.
DDC HVAC Optimization
5. As part of the HVAC System Optimization and Energy Efficiency Efforts, the contractor shall repair, modify and install new as required to provide for a DDC Control System supporting the total HVAC system of Bldg 503 including all air handling units, condensing units, variable air volume boxes.
The focus of this new DDC system shall achieve the following:
a. Maintain positive building pressure
b. Maintain a negative relationship between the fuel lab and adjacent building spaces
c. Maintain appropriate space temperature and humidity in each zone via new zone sensors and system detection
d. Maintain Appropriate level of mechanical cooling and dehumidification through modulation of 4 stages of cooling in the new condensing units
e. Provide consistent supply air temperature and humidity off of the FCU-1 cooling coil to ensure air is being conditioned
f. Provide tight control of FCU-1 system supply air volume based on VAV box demand and appropriate control over FCU-1 supply fan motor speed
i. Utilize newly installed system static pressure control based on existing VAV damper position and associated demand
g. Provide individual zone control of cooling or heating
i. Individual VAV control utilizing existing electric heat
ii. Individual Zone control without compromising system level conditioning or dehumidification
h. All for modulation of Outside Air being introduced to the building via FCU-1 based on building occupancy or building pressure
i. Allow system scheduling capabilities with setbacks based on building utilization and occupancy schedules
Additional DDC Control requirements:
1. Develop and install, replace or upgrade existing Direct Digital Control (DDC) system for the Bldg 503 which provides the required temperature of 78 ± 2°F and a relative humidity of 50 ± 5% which will reside on a contractor provided standalone DDC Controller / Monitor to be located within the Bldg’s Mechanical Room.
The New Direct Digital Control (DDC) system shall monitor outside air flow, along with building pressurization to increase/decrease outside air to maintain a positively pressurized building.
a. The Contractor shall provide and install a new Direct Digital Control (DDC) system to control the HVAC systems serving the above facility areas. Note: the new DDC system shall be equal or similar to a Trane Tracer Version 16 (or later) system as is currently approved to reside on the NMCI network per DADMS ID # of 47893 and/or 85176 .
b. The Contractor shall provide DDC Control System Software to be loaded on a contractor provided Center monitoring station with all Graphical User Interfaces required for full operation of the HVAC system.
c. The new Control system shall include a Building/ System Control Unit (SC) panel to reside in the mechanical room and ready for NMCI system connection at a later date or by Telephone network.
d. A “touch-pad” interface shall be provided on the DDC building/system control unit (SC) with scheduling, over-ride, setpoint control and alarm monitoring functions for the Base Facility/ies Identified per each requirement.
e. Each piece of HVAC equipment shall be provided with a standalone Application Specific or Custom Application control module.
2. The new DDC Operator Interface shall be as follows:
a. The workstations shall be able to access all information in the system.
b. Workstation information access shall use the BACnet Protocol.
Communication shall use Annex J of ASHRAE Standard 135-95. Local connections of the workstation shall be on ISO 8802-3 (Ethernet). Remote communications shall use either the BACnet Point to Point Physical/Data Link Layer Protocol or IP over Point to point (PTP).
c. System Graphics. The Operator Workstation software shall be graphically oriented. Provide a method for the operator to easily move between graphic displays and change the size and location of graphic displays on the screen. The system graphics shall be able to be modified while on line. An operator with the proper password level shall be able to add, delete, or change dynamic points on a graphic. Dynamic points shall include analog and binary values, dynamic text, static text, and animation files.
Graphics shall have the ability to show animation of equipment. Graphics shall be capable of launching other PC applications.
d. Custom Graphics. Custom graphic files shall be created with the use of commonly available graphics packages such as PC Paint. The graphics generation package shall create and modify graphics that are saved in industry standard formats such as PCX, BMP, GIF and JPEG. The graphics generation package shall also provide the capability of capturing or converting graphics from other programs such as Designer, or AutoCAD.
e. Graphics Library. Furnish a complete library of standard HVAC equipment such as chillers, boilers, air handlers, terminals, fan coils, and unit ventilators.
This library shall also include standard symbols for other equipment including fans, pumps, coils, valves, piping, dampers, and ductwork. The library shall be furnished in a file format compatible with the graphics generation package program.
f. Engineering Units. Allow for selection of the desired engineering units (i.e. Inch pound or SI) in the system. Unit selection shall be able to be customized by locality to select the desired units for each measurement.
g. System Applications. Each workstation shall provide operator interface and off-line storage of system information. Provide the following applications at each workstation.
h. Automatic System Database Save and Restore. Each workstation shall store on the hard disk a copy of the current database of each building controller.
This database shall be updated whenever a change is made in any panel in the system. The storage of this data shall be automatic and not require operator intervention. In the event of a database loss in a building management panel, the first workstation to detect the loss shall automatically restore the database for that panel.
i. Manual Database Save and Restore. A system operator with the proper password clearance shall be able to archive the database from any system panel and store on magnetic media. The operator shall also be able to clear a panel database and manually initiate a download of a specified database to any panel in the system.
j. System Configuration. The workstation software shall provide a graphical method of configuring the system.
The user with proper security shall be able to add new devices, and assign modems to devices. This shall allow for future system changes or additions.
k. On-Line Help and Training. Provide a context sensitive, on line help system to assist the operator in operation and editing of the system. On-line help shall be available for all applications and shall provide the relevant data for that particular screen. Additional help information shall be available through the use of hypertext. Provide an interactive tutorial CD, which will act as on-line training/help for the systems operator.
l. Security. Each operator shall be required to log on to the system with a user name and password in order to view, edit, add, or delete data.
System security shall be selectable for each operator. The system supervisor shall have the ability to set passwords and security levels for all other operators. Each operator password shall be able to restrict the operator’s access for viewing and/or changing each system application, full screen editor, and object. Each operator shall automatically be logged off of the system if no keyboard or mouse activity is detected. This auto logoff time shall be set per operator password. All system security data shall be stored in an encrypted format.
m. System Diagnostics. The system shall automatically monitor the operation of all workstations, printers, modems, network connections, building management panels, and controllers.
The failure of any device shall be annunciated to the operator.
n. Alarm Processing. Any object in the system shall be configurable to alarm in and out of normal state. The operator shall be able to configure the alarm limits, warning limits, states, and reactions for each object in the system.
o. Alarm Reactions. The operator shall be able to determine what actions, if any, are to be taken, by object (or point), during an alarm. Actions shall include logging, printing, starting programs, displaying messages, dialing out to remote stations, paging, forwarding to an e-mail address, providing audible annunciation or displaying specific system graphics. Each of these actions shall be configurable by workstation and time of day.
An object in alarm that has not been acknowledged within an operator specified time period shall be re-routed to an alternate operator specified alarm receipt device.
p. Binary Alarms. Each binary object shall be set to alarm based on the operator-specified state. Provide the capability to disable alarming when the associated equipment is turned off or is being serviced.
q. Analog Alarms. Each analog object shall have both high and low alarm limits and warning limits. Alarming must be able to be automatically and manually disabled.
r. Trend Logs. The operator shall be able to define a custom trend log for any data in the system. This definition shall include interval, start-time, and stop-time.
Trend intervals of 1, 5, 15, 30, and 60 minutes as well as once a shift (8 hours), once a day, once a week, and once a month shall be selectable. All trends shall start based on the hour. Each trend shall accommodate up to 64 system objects. The system operator with proper password shall be able to determine how many samples are stored in each trend. Trend data shall be sampled and stored on the Building Controller panel and be archived on the hard disk. Trend data shall be able to be viewed and printed from the operator interface software. Trends must be viewable in a text-based format or graphically. They shall also be storable in a tab delimited ASCII format for use by other industry standard word processing and spreadsheet packages.
s. Alarm and Event Log. The operator shall be able to view all logged system alarms and events from any location in the system. The operator shall be able to sort and filter alarms. Events shall be listed chronologically. An operator with the proper security level may acknowledge and clear alarms. All that have not been cleared by the operator shall be archived to the hard disk on the workstation.
t. Object and Property Status and Control. Provide a method for the operator with proper password protection to view, and edit if applicable, the status of any object and property in the system. These statuses shall be available by menu, on graphics, or through custom programs.
u. Clock Synchronization.
The real time clocks in all building control panels and workstations shall be synchronized on command of an operator. The system shall also be able to automatically synchronize all system clocks; daily from any operator designated device in the system. The system shall automatically adjust for daylight savings and standard time if applicable.
v. Reports and Logs. Provide a reporting package that allows the operator to select, modify, or create reports. Each report shall be definable as to data content, format, interval, and date. Report data shall be archived on the hard disk for historical reporting. Provide the ability for the operator to obtain real time logs of designated lists of objects.
Reports and logs shall be stored on the PC hard disk in a format that is readily accessible by other standard software applications including spreadsheets and word processing. Reports and logs shall be readily printed to the system printer. The operator shall be able to designate reports that shall be printed or stored to disk at selectable intervals.
w. Custom Reports: Provide the capability for the operator to easily define any system data into a daily, weekly, monthly, or annual report. These reports shall be time and date stamped and shall contain a report title and the name of the facility.
x. Standard Reports. The following standard system reports shall be provided for this project.
These reports shall be readily customized to the project by the owner.
1. All Points in Alarm Report: Provide an on demand report showing all current alarms.
2. All Points in Override Report: Provide an on demand report showing all overrides in effect.
3. Schedule Report: Provide a summary of all schedules including Holiday and Exception schedules.
4. Commissioning Report: Provide a one-time report that lists all equipment with the unit configuration and present operation.
y. Controller. Provide a full screen editor for each type controller and application that shall allow the operator with proper password to view and change the configuration, name, control parameters, and system set-points.
An editor for the scheduling application shall be provided at each workstation. Provide a monthly calendar for each schedule. Exception schedules and holidays shall be shown clearly on the calendar. Provide a method for allowing several related objects to follow a schedule. The advance and delay time for each object shall be adjustable from this master schedule.
aa. An operator with proper password level shall be able to modify the schedule. Schedules shall be able to be easily copied between objects and/or dates.
bb. Air System Equipment Coordination. Provide a full screen editor that allows equipment to be grouped for proper operation as specified in the sequence of operations. This shall include the coordination of VAV boxes.
etc with their associated Air Handling Equipment.
cc. Custom Application Programming. Provide the tools to create, modify, and debug custom application programming. The operator shall be able to create, edit, and download custom programs at the same time that all other system applications are operating. The system shall be fully operable while custom routines are edited, compiled, and downloaded.
3. The Building Control Unit shall be as follows:
a. The DDC System shall be composed of one or more independent, stand-alone, microprocessor based Building Control Units to manage the global strategies described in System software section.
b. The Building Controller shall have sufficient memory to support its operating system, database, and programming requirements.
c. The controller shall provide a communications port for connection of the Portable Operators Terminal using Point to Point BACnet physical/data link layer protocol or a connection to the inter-network.
d. The operating system of the Controller shall manage the input and output communications signals to allow distributed controllers to share real and virtual point information and allow central monitoring and alarms.
e. Controllers that perform scheduling shall have a real time clock.
f. Data shall be shared between networked Building Controllers.
g. The Building Controller shall utilize industry recognized open standard protocols for communication to unit controllers.
h. The Building Controller shall continually check the status of its processor and memory circuits.
If an abnormal operation is detected, the controller shall:
1. Assume a predetermined failure mode.
2. Generate an alarm notification.
3. Create a retrievable file of the state of all applicable memory locations at the time of the failure.
4. Automatically reset the Building Controller to return to a normal operating mode.
i. BACnet. The Building Controller shall use the Read (Initiate) and Write (Execute) Services as defined in these BIBBS:
a. Communications. Local connections of the Building Controller shall be on ISO 8802-3 (Ethernet). Communications shall use Annex J of ASHRAE Standard 135-95. Each Building Controller shall also perform routing to a network of Custom Application and Application Specific Controllers.
As an Option, Each Building Controller shall perform communications to a network of Custom Application and Application Specific Controllers using BacNet or LonTalk FTT-10 and LonMark profiles.
b. Environment. Controller hardware shall be suitable for the anticipated ambient conditions. Controller used in conditioned ambient shall be mounted in an enclosure, and shall be rated for operation at 0 C to 50 C [32 F to 120 F].
c. Serviceability. Provide diagnostic LEDs for power, communications, and processor. All wiring connections shall be made to field removable, modular terminal strips or to a termination card connected by a ribbon cable. The primary logic board shall be removable without disconnecting field wiring.
The Building Controller shall maintain all BIOS and programming information in the event of a power loss for at least 72 hours.
e. Immunity to power and noise. Controller shall be able to operate at 90% to 110% of nominal voltage rating and shall perform an orderly shut-down below 80% nominal voltage.
f. The Building Controller shall have a seven segment LED display on the main board that indicates the current operating mode of the controller.
g. Building Controller Operator Display. The building controller shall include an operator display allowing the user to perform basic daily operations tasks on the building automation system. At a minimum this operator display shall:
1. Be installed on the building controller and require no additional power source.
2. Consist of a one-quarter VGA touch screen with 320 X 240-pixel resolution.
The brightness and the contrast of the backlit touch screen shall be adjustable to allow for easy reading of information on the screen.
3. Be capable of having unique user identification and passwords that can be programmed to limit access to the system and operator functions.
4. Display the current state of an input/output point and equipment controller connected to the system.
5. Give the operator the ability to override the current state of an output point or HVAC equipment controller connected to the building controller.
6. Allow the operator to modify the start and stop times of any time-of-day schedule within the system.
7. Provide a visual indication that a system alarm exists and allow for an optional audible alarm annunciation.
8. Provide the ability to view and acknowledge alarms that are annunciated at that building controller.
9. Allow the operator to view custom graphical displays with dynamic status information.
10. Automatically update displayed system information every 10 seconds.
4. The Contractor shall perform a commissioning of all new DDC controls and a test and balance (TAB) – as required above to ensure proper airflow, water flow, operation, and control within the limits of design capability.