Functional Testing Basics

1. Introduction. 2

2. Understanding the Fundamentals. 2

3. The Commissioning Process. 3

4. The System Concept6

4.1 The System Diagram.. 6

4.2 Detailed Sequence of Operations. 8

5. Testing Hierarchy. 9

5.1 Documentation. 10

5.2 As Built Submittals and Shop Drawings. 10

5.3 Installation Inspection Report Forms. 11

5.4 Performance Sheets. 11

5.5 Installation and O&M Manuals. 11

5.6 Balance Information. 12

5.7 Operating Sequence. 12

5.8 As Found and As Left Conditions. 13

6. Training. 13

6.1 When to Start13

6.2 Supplemental Information. 14

6.3 Control System Training. 15

6.4 Factory Training. 16

7. Verification Checks. 16

7.1 Verification Checks Development17

7.2 Verification Checks Checklist17

7.3 Factory Inspections and Tests. 17

7.4 Factory Supervision, Assembly, and Start-up. 18

7.5 System Readiness. 20

8. Warranties. 24

9. Temporary Operation. 26

10. Elements of a Functional Test28

11. Basic Tools, Instrumentation, and Equipment28

12. General Precautions and Preparations. 36

13. Observing Tests. 39

14. Returning To Normal40

15. Getting To Team-based Solutions. 40

16. Trend Analysis as a Functional Testing Tool41

16.1 Laying the Groundwork. 42

16.2 Defining the Data Set43

16.3 Using the Data Set44

17. Supplemental Information. 45

 

Figures

Figure 1: The Commissioning Process. 5

Figure 2: System schematic from the mechanical drawings. 7

Figure 3: Full system diagram for the air handler in Figure 2. 8

Figure 4: Storage type clipboard. 29

Figure 5: Duct Test Port 30

Figure 6: Lab grade thermometers. 31

Figure 7: Portable anemometers. 32

Figure 8 Tachometers. 32

Figure 9: Data loggers. 33

Figure 10: Portable Datalogger Guide. 33

Figure 11: Air Data Multimeter 34

Figure 12: Electronic Hygrometer and Electronic Pressure Gauge. 35

Figure 13: Field Calibration Equipment 36

Figure 15: Data Logging Advances over the Years. 42

Figure 16: Different Ways to View the Same Data Set 45