Commissioning Existing Equipment and Systems

Overview
Commissioning existing equipment or systems can provide impressive benefits towards
improving building operations, tenant comfort, energy use reduction and increased equipment
life. Generally, the primary objective of commissioning existing equipment is to bring the
system or equipment back to its original intended operation, subject to any legitimate changes
made since installation. In addition, adjusting the way systems are operated to improve
performance is also an objective.

The cost-effectiveness of commissioning existing equipment can be relatively high, when the
effort focuses on equipment that uses the most energy and/or larger pieces of equipment. When
the more numerous and small zone-level equipment is included in commissioning, however,
commissioning can easily become quite expensive. For this reason, most commissioning efforts
include only those systems and equipment that have the most opportunity for improvement
without large capital outlays. This toolkit is primarily focused on commissioning new
installations, but the following provides some guidance on commissioning existing equipment.
The first section provides a list of the parts of the Model Commissioning Plan and Guide
Specifications that can be used when commissioning existing equipment. The second section
provides an overview of actual site procedures to follow when commissioning or tuning up
existing equipment.

I. Applying the Model Commissioning Plan and Guide

Specifications to Existing Equipment
The Model Commissioning Plan and Guide Specifications was intended for new construction or
larger building renovations. However, there is material contained in that document that can be
used in commissioning existing equipment and systems. This material includes the following
items:

Solicitation for Commissioning Services

Commissioning Firm Experience and Commissioning Project Experience Listing (Exhibits 4, and
5, under Part I, Commissioning Requirements—Design Phase) can be used when obtaining the
services of a commissioning firm.
Design Narrative
Design Documentation Format, (Appendix I, under Part II, Model Commissioning Plan—
Design Phase) can be used to provide format to the development or recreation of the original
design intent of existing equipment or systems.

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 Prefunctional Checklists
Commissioning or tuning existing equipment and systems entails evaluating their current
condition. The prefunctional checklists (found in Specification Section 15998 of Part III) for
various equipment types can be used for this purpose.
Testing Requirements
Specific test requirements that may apply to the equipment in your building can be found in
Specification Section 15997 for mechanical systems and Section 16997 for electrical systems (in
Part III, Guide Specifications). These can be used when developing the scope of work for the
commissioning and for the development of the detailed commissioning plan.
Sample Functional Tests
Though only samples, the tests provided in Sections 15999 and 16999 of Part III can be used by
the commissioning agent for reference for developing formats, content and rigor for the actual
functional tests of existing equipment.
Functional Performance Testing
Guidance regarding the development of test procedures and acceptable test methods found in
Part III, Section 17100, 3.6, applies to both new and existing equipment.
Forms
Many of the forms found in Appendix 1 of Part IV, Commissioning Plan—Construction Phase,
can be used for existing equipment commissioning. These forms include a Commissioning
Issues Log, Request for Documentation, Commissioning Memorandum, Commissioning Request
for Information, Commissioning Progress Report, Staff Training Plans, Detailed Commissioning
Schedule, Facility Staff Participation in Commissioning, Functional Testing Scope Outline.

II. Procedures for Commissioning Existing Building

Equipment and Systems
This section outlines suggested steps for commissioning existing equipment. It assumes that a
building has been selected and a commissioning agent is hired. It also assumes that an objective
of commissioning is to reduce energy waste and therefore outlines the site activities specific to
obtaining energy savings. This section does not cover the initial building selection process.

Planning Phase

1. Identify and Communicate the Primary Objectives for Commissioning the Building or
Systems
It is important to understand exactly what the objectives are for putting a building or building
system through the commissioning process and to clearly communicate those objectives to the
commissioning agent. It also may be important to have measurable objectives in order to
demonstrate the effectiveness of commissioning. The commissioning process may focus on one
or several of the following objectives:

• Reduce comfort calls

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• Increase equipment life
• Obtain energy savings
• Improve indoor air quality
• Reduce staff time spent on emergencies
• Increase the asset value of the building
• Retain tenants

2. Obtain a General Overview of the Building and Systems

The commissioning agent performs a walk-through of the building to obtain a general
understanding of what system types exist, how the systems are controlled and what the building
is used for. It is also important to identify which systems, equipment, and groups of smaller
equipment controlled together are the largest energy users. To expedite this activity, compile a
building documentation package for the commissioning agent to study prior to the walk-through.
This packet may include the following:

• Drawings relevant to the systems scheduled for commissioning

• O&M manuals
• TAB report
• Equipment list with nameplate information
• PM logs
• Sequences of operation
• Energy efficient operating strategies
• Energy bill (electric and gas) information for at least 12 months along with a rate schedule

3. Develop the Building-Specific Commissioning Plan

Once the commissioning agent and building staff have clearly defined the objective for
commissioning and have reviewed the documentation, the commissioning agent develops the
commissioning plan. The plan includes the following information:

• Commissioning objectives
• Scope of commissioning
• Commissioning team members and their roles and responsibilities
• Schedule of commissioning events
• Scope of testing
• Description of diagnostic monitoring and use of energy management control system trending
• List of products resulting from the commissioning effort

Investigation Phase

4. Perform an Operation and Maintenance (O&M) Site Assessment

The goal of the O&M site assessment is to gain an in depth understanding of how and why the
building systems and equipment are currently operated and maintained. For large and complex
buildings and systems the commissioning agent generally develops a formal assessment
document that includes a detailed building staff interview and an in-depth site survey of
equipment condition. To expedite the assessment process, assign a building operator to work
with the commissioning agent. The designated operator should be someone who is quite

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knowledgeable in operating and maintaining the systems designated for commissioning. The
assessment should identify some of the following issues:

• Current design and operational intent and actual control sequences

• Equipment condition issues (broken dampers, dirty coils, sensor calibration, etc.)
• Current schedules
• The most severe control and operational problems
• Where the most comfort or trouble spots are in the building

It may be cost effective to have the assigned building operator make minor adjustments and
repairs as the site assessment progresses.

5. Develop a List of O&M Deficiencies/Opportunities

Concurrent with the O&M site assessment, the commissioning agent begins to develop a master
list of O&M deficiencies or improvements for possible implementation. This list will ultimately
become an important decision making tool for the operating staff and is a primary product of the
commissioning effort. Every finding from the assessment and from the diagnostic monitoring
activity (see #6 below) is placed on this “master list” including those adjustments and repairs
made during the assessment process. The list includes the name of the system or piece of
equipment involved, a description of the deficiency or problem, and a suggested solution.

6. Develop and Implement a Diagnostic Monitoring Plan

Using the information gained from the O&M site assessment, it may be necessary to obtain more
complete and exact data on when and how systems are actually operating since the assessment
may only identify suspected areas for improvement. The commissioning agent develops and
implements a diagnostic plan for using either the building’s energy management control system
trending capability (this is acceptable as long as the system’s sensors have been recently
calibrated) and/or portable data loggers. It is generally recommended that data be gathered for a
minimum of one week including a typical weekend. Once the data is gathered, the
commissioning agent analyzes the findings and checks it against the O&M assessment
information for discrepancies. Any deficiencies are added to the “master list” described above
in #5.

7. Functionally Test Systems and Equipment

It may be necessary to manually test the system or equipment in question during the
investigation process. Functional testing may be done as a part of diagnostic monitoring or in
lieu of diagnostic monitoring. When data loggers are not available or the energy management
control system is inadequate for trending, functionally testing the system manually is the only
option. Manual testing involves putting the system or piece of equipment through a series of
tests that checks its operation under various modes and conditions. Spot measurements are taken
to verify correct operation and equipment efficiencies.

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Selection / Implementation Phase

8. Determine Which O&M Opportunities are Most Cost Effective to Implement

Once the investigation process is complete, the master list of O&M opportunities is used to
decide which improvements are most important to implement. As part of the selection
processes, it may be necessary to do some engineering analysis to determine which opportunities
will save the most energy and cost the least to implement. It is not unusual to expect a simple
pay back of 18 months or less for the selected improvements.

9. Implement O&M Improvements

The overarching goal for commissioning existing building systems is to implement cost effective
improvements. Unless improvements are actually put in place, the commissioning process
remains incomplete. Depending on staff time and expertise, the implementation process may be
carried out by in-house O&M staff. In some cases implementation may need to be outsourced.
For example, hiring a controls contractor may be necessary if in-house staff lacks the expertise
or access required to make control strategy changes at the program level.

10. Supervise the Implementation Process and Retest as Needed

It is often important to retain the commissioning agent through the implementation process
whether implementation is done in-house or outsourced. The commissioning agent may
supervise those tasked with installing the improvements depending on the level of complexity.
Also, it is often necessary (and highly recommended) to retest some of the equipment and
systems, either manually or through diagnostic monitoring, to ensure that the improvements are
working as expected and that they positively effect other systems and equipment as well as the
building occupants.

Project Hand-Off Phase

11. Identify Possible Energy-Efficient Capital Improvements.

During the normal course of commissioning , review current equipment and system efficiency,
condition and age not only for O&M improvements but also for future energy-efficient capital
improvements. Although the existing building commissioning does not involve implementing
expensive energy-efficient capital improvements, it is often the first step toward obtaining these
improvements. It is therefore important for the commissioning agent to recommend a list of
relevant energy-efficient capital improvements as part of the project hand-off. This list may
include the following:

• Energy-efficient lighting retrofit (interior and exterior lighting, exit lighting, etc.)
• Addition of lighting sweep controls
• Daylight harvesting
• Variable frequency drives
• CO2 based ventilation control

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12. Commissioning Final Report
The commissioning agent prepares a comprehensive final report that generally includes the
following information along with an executive summary:

• Project background
• Building / systems description
• Scope of the commissioning project
• The “master list” of improvements
• A description of which improvements were implemented and a cost/savings analysis
• List of recommended capital improvements
• The original and corrected commissioning plan
• The EMCS trending plan and logger diagnostic / monitoring plan and results
• All completed functional tests and results

Acceptance of the final report by the building staff or owner’s representative concludes the
project hand-off phase

Other Commissioning Tasks for Contract Consideration:

1. Finalize an O&M plan outline, including examining and enhancing the current
maintenance service contract procedures.

2. Develop a list of required O&M documentation and methods for the building or
systems. Include full written sequences of operation for all equipment.

3. Develop an energy efficiency plan and policy, including strategies for obtaining
management buy-in.

4. Develop guidelines for implementing a preventative maintenance plan.

5. Develop a comprehensive training plan. Or, develop recommendations for appropriate

building staff to attend training in general O&M concepts and for specific equipment
and systems. This will include both building operators and facility managers or
owners.

6. Develop guidelines and recommendations for incorporating an energy accounting and

tracking system.

7. Develop a list of operational strategies for the owner to incorporate in the future.

8. Develop an operations assessment program and systems tune-up and recommissioning

schedule.

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 Reference Documents
An excellent book that details the process of tuning up existing equipment for energy efficiency
is, Energy-Efficient Operation of Commercial Buildings: Redefining the Energy Manager’s Job,
Peter Herzog, McGraw-Hill, 1996.

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