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• What are the full capabilities of the current system? Are those capabilities being
used appropriately?
• Is the current system technologically obsolete? If not, can the current system be
upgraded, or is it an “orphan” system?
• Are problems with the system due to lack of maintenance or service?
• Have the software, firmware, and hardware revisions been kept current? If not,
what is the extent of the upgrades required?
• Is the controlled equipment in need of replacement or upgrade?
• Are there an excessive number of trouble or comfort calls for which the EMS is
the cause rather than the cure?
Valves and Actuators - Specifying the right valve and actuator is important to ensure
optimal system control without unnecessary modulation or hunting. Valves must be sized
correctly; in some cases, a pair of valves in series may be necessary to provide the
proper turndown ratio for tight control. Valves must also be able to provide tight close-off
against worst-case system- head pressures.
Dampers - Specify the tightness and leakage rate of dampers appropriate for the
application, as well as blade and edge seals for most applications and special support
shafts for large dampers, if necessary. Be specific.
Gages - Ensure that gages are provided in the following locations, even if a sensor is
included as a point in the control system: 1) pressure gages on both sides of all pumps
greater than 1 hp; 2) mercury thermometers in the return and supply of all primary
thermal plant equipment (chillers, cooling towers, boilers, converters, etc.). Gages are
often provided by the mechanical contractor, but retrofits may require the controls
vendor to supply them.
Offsite Communications - Specify who will have modem access to the site terminal
and what the level of access will be. It is generally advisable to give the vendor access
to the system to simplify service and troubleshooting. Clearly state any software setup
that the contractor should perform at any other sites. Specify what alarms and warnings
will occur offsite and specify auto-dial/auto-answer features and setup. Specify clearly
any tie-in requirements to other facilities’ EMS via modem, dedicated line, or the
Internet.
Vendor and Staff Qualifications - The success of a controls project depends more on
the individuals hired to design and install the system than on the hardware and software
chosen. In the project specifications, it is important to require approval of the
qualifications of the company, the lead programmer, and the lead installing technician.
Even if a designated company is to be used, the staff qualification requirements are
important.
Most companies have a range of skill on staff and, without a written request or
specification, there is no guarantee that higher-level staff will be assigned to your project
rather than someone marginal or even incompetent.
Sequences of Operation - One of the keys to a successful EMS installation is the
clarity and completeness of the written operation sequences. Ideally, the full operation
sequences for each piece of equipment should be in the original job specifications. If the
designer’s specification are not detailed and explicit enough, significant interpretation is
required of the controls programmer, who may not have the expertise and certainly will
not know the designer’s full intent for each control loop. To prevent this, encourage the
designer to provide extra-detailed sequences and have the facility technical staff review
them for clarity. Involving a commissioning consultant during design will also ensure that
the sequences are sufficiently detailed.
Completion Milestones - After substantial completion of a project (when the owner can
take useful occupancy of the system) the contractor may lose interest in the full
completion of his tasks. To avoid frustrating delays, add a milestone to the
specifications: functional completion (the point when all remaining test, adjust and
balance (TAB) and commissioning responsibilities of the contractor are complete, except
for seasonal or deferred testing.)
For example, functional completion could be specified as 60 days after substantial
completion, with a monetary penalty for default.
Warranty - Consider specifying a warranty of three years for all control equipment,
analog sensors, and I/O modules, and a warranty of one year from acceptance for all
other materials, installation, and workmanship. Be clear in the warranty about electrical
components that are related to or part of the controls installation, which may otherwise
not be included in the warranty.
Support - If a maintenance contract or onsite assistance during the first few months or
year will be part of the original job specifications, make sure all details are clear. Include
the response time for emergency service calls and specify whether after-hours visits and
regular phone support are provided. State that the supplier shall have an in-place
support facility within 150 miles of the site with technical staff, spare parts inventory, and
all necessary test and diagnostic equipment.
The commissioning process for control systems includes the following activities:
Scheduling
Exception Scheduling. If there is an exception to the regular schedule (e.g., a half day
or longer hours than normal), this feature allows you to program the exception for that
day only rather than changing the regular schedule. Once the exception period is
passed, the program returns to the original schedule.
Setpoints
Setpoints range from those inside equipment logic, which are rarely changed, to
space temperature setpoints, which seem to need constant adjustment. Some setpoints
are defined by the operator and associated with a schedule; others may be adjusted by
internal calculations of the program (e.g., reset temperatures or pressures).
Space Temperature Setpoints. The building manager’s job, among other things, is to
maintain occupant comfort while identifying ways to reduce energy consumption.
Controlling the space temperature may be the single most time time-consuming and
problematic task a building operator deals with. Often, the possibilities for reducing
energy use by altering space temperature setpoints are not investigated for fear of
adversely affecting comfort. This may be the case at times, but large multi-zone
buildings with DDC can present opportunities to move beyond a traditional building-wide
setpoint. The following information should be reviewed when considering space
temperature setpoint changes:
• Time of day
• Number and fluctuation of occupants in zone
• Humidity conditions
• Size of zone
• Location of zone
• Zone exposure (perimeter or core, south or north, etc.)
• Impact on reheat or simultaneous heating and cooling
• Impact on pumping, fan, or plant efficiency
• Equipment in zone (e.g., computers or laboratory equipment).
Dual Setpoint Control (Deadband). The most common strategy for optimizing space
temperature setpoints is to have separate heating and cooling setpoints or one setpoint
with a wide deadband (greater than 4ºF). This lowers the potential for simultaneous or
overlapping heating and cooling, thereby reducing wasted energy and comfort
complaints.
Other Setpoints. The building operator should be familiar with a number of other basic
setpoints. It is critical to have an understanding of the purpose behind each setpoint and
the impact on energy and other systems when the setpoints are altered. An up-to-date
consolidated list of all primary setpoints as part of the system documentation is very
useful.
Basic Setpoints
• Supply air temperature
• Mixed air temperature
• Coil discharge air temperature (hot and cold deck)
• Heating water
• Boiler lockout
• Chiller lockout
• Chilled water supply temperature
• Entering condenser water temperature
• Duct static pressure
• Economizer changeover
• Space temperature (summer and winter)
• Space temperature deadband
• User thermostat adjustment range
• Pump or piping differential pressure
• Return air relative humidity
• Supply air relative humidity high limit
Alarms
Registering and recording alarms is a critical part of any EMS. In addition to
basic alarm functionality, an EMS provides options in specifying how alarms are
monitored, reported, routed, and ultimately dealt with. For any monitored or controlled
point, most systems’ basic alarm functions can be set up to register and display the
following:
• Equipment failures
• Sensor failures
• High parameter value (temperature, pressure, etc.)
• Low parameter value (temperature, pressure, etc.)
• Invalid temperatures (sensor is being tampered with)
• Manual override of machinery at remote locations
• Communications problems
Safeties
Safeties are sequences programmed into an EMS that are automatically initiated
to protect equipment, property, or life. The condition that initiates the safety sequence
may also generate an alarm (high duct static fan shut down, freeze condition fan shut
down, etc.). Using safeties can protect equipment and the building itself from damage
and may also reduce or eliminate the need for alarm reporting to remote sites to engage
an after hours emergency service call. For example, a high-water condition in the cooling
tower may indicate a clogged intake screen or faulty make-up valve. This condition is
serious enough to require immediate attention for a tower without a separate float
control. After hours, an alarm would be required to sound offsite for immediate service. A
safety sequence would simply close the make-up water valve and/or shut down the
chillers until the normal facility operators could deal with the issue the following morning.
Trending Points. Ideally, the EMS should be capable of providing the following types of
information:
• Temperature
• Pressure
• Damper and valve position commands, including variable frequency drive control
signals
• Virtual points (internal calculations such as enthalpy or changing setpoints and targets)
• (ON/OFF) status or stage
• Flow rate (water or air)
• Alarm state
• Current
• Power demand (kW)
• Energy consumption (kWh, therms, gallons, etc.)
• Revolutions per minute (RPM)
• Virtual points