Intelligent Building Systems Inc., Examples of Commissioning

Proper commissioning and functional testing sniffs out those items that are "invisible" and easily missed by conventional acceptance procedures. These items often involve programming, installation methods, calibrations, and other lackluster issues that do not make for interesting reading. While this is the primary focus of commissioning, it is the physical realm that provides us with graphic (sometimes entertaining) examples of what happens during the translation from blueprint to real world. We have provided below some examples of what we find every day on every job. Names have been withheld.

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Shown is a power cord and float switch for a submersible pump located in a cooling tower pit. During operation of the tower, the water in this pit becomes very turbulent and all surfaces within become wet with water spray. The pump cord was specified to be pulled (without break or splices) to a disconnect switch located outside this wet location. As seen, the wiring length was more than adequate to extend to a dry location but was instead spooled inside the pit.

Note the use of a common indoor / dry location outlet and the standard plug connectors that will corrode over time. Note the unused and open top half of the outlet. Since these electrical connections are not sealed, this also poses a shock hazard whenever the tower is active and water spray wets the outlet.

The wire tie used on the pump float will not hold an accurate vertical position over time and will alter the float activation point. There is nothing to prevent the tie from rotating on the pipe, possibly tangling the float in the cords or the nearby valve handle.

Even with the manhole cover removed, this arrangement was well hidden from view. It was well on its way to causing injury or death for an unsuspecting worker. This was found after inspections by local authorities were complete.

The piping supports shown were first reported as needing to be bolted to the concrete decking. The method shown on the inset photo (glue) was found after the contractor had responded to the punch list report item as "complete".

None of the hangars or saddles
holding up the large piping have
the specified smooth radius saddle
blocks under the piping. These are
needed to match the pipe diameter
to the support hangar and prevent a
single point of contact to minimize
wear.

The contractor has instead placed
interior grade 2x4 blocking under the
piping for support (as seen to the right).

Water treatment system for a cooling tower (new construction).

The permanent line voltage to the panel should be hardwired, not cord connected. All electrical connections were specified to be made inside the panel, but external plug connections are seen.

The center drum was found empty with the feed pump running non-stop. The blow down valve was inoperative. Scale from improper treatment was already accumulating in the brand new tower.

The left drum of this water treatment system was labeled as a floor finishing wax with Super High Gloss Finish. It is unknown what was actually being pumped into the cooling tower but the drum was promptly changed after this was reported.

Material Safety Data Sheets and labels identifying the actual products in use on all of the drums are missing. This presents a safety hazard to personnel and is an OSHA violation.

The three feed pumps and intake tubing were not labeled. Service personnel cannot identify what lines are intended for what drum during routine chemical refills.

This cable was found above plenum ceilings. Note the CL2 rating instead of CL2P. This was found after the above ceiling electrical inspections by the local authority were complete.

This non-plenum rated cable that was installed in ceiling plenums used for environmental air, is a direct violation of electrical codes, fire codes, and project specification. All of the cable had to be replaced throughout the site.

The correct CL2P cable was submitted and approved, but this alternate material ended up at the site. Again, the transition from paper to real world faltered.

Duct smoke detector improperly installed. This was found after fire inspections by civil authorities were complete and approved.

Airflow is from right to left.

The detector is entirely inoperative as installed. The detector sampling tubes must be installed with tubes perpendicular to the air stream, not aligned with it as shown.

The mounting bracket shown is fabricated from common metal stud allowing vibration and movement during fan operation. This will eventually lead to a failure of the mounting.

The black box shown is a heat trace thermostat being used to control heat trace and thus protect outdoor cooling tower piping from freezing.

The thermostat is specified to enable the self regulating heat trace, (that is underneath the insulation) below 40°F outside ambient. The heat trace will regulate itself over the many feet of piping, thus keeping the pipe temperature above freezing.

Notice the sensing bulb capillary element that proceeds from the black thermostat housing to under the piping insulation cover instead of being in the outside air.

This will result in the heat trace power being cycled based on pipe temperature, not continuously powered in cold weather as intended. The thermostat may turn off a large length (50 feet) of heat trace when only a few feet of piping (at the thermostat bulb) is above freezing. The remaining piping may be much colder that what is sensed by the thermostat in this single location. This is a freeze hazard with the potential to cause thousands of dollars of damage.

Note the access doors that are not, themselves, accessible.

How did the local authority ever inspect the fire dampers that reside inside these ducts?

Lack of coordination between trades is a common source of problems, and should be closely watched by the construction manager.

Where this round, high pressure duct makes a 30° bend, a four inch gap between the ducts was noted. The duct is joined not with sheet metal, but duct tape and grey duct sealing compound (to hide the tape). In the center of the photo you can see the sealer has flaked off, exposing the tape.

The standards for sheet metal installation as written by SMACNA, were not followed as clearly specified in the project contract.

Where's Waldo?

Did you see the creatively placed air conditioning unit condensate drain over the sink? If not, you might notice it dripping on your head while washing your hands.

Due to inadequate mounting height of an AC unit, the pipe fitter quickly ran out of the needed slope and distance for the drain and opted to go for the nearest point of drain, rather than stop work and seek direction from the construction manager.

The blue labels on the chilled water lines are actually the proper color to represent pressurized gas, not water, as defined by the specified ANSI safety code.

The project contract calls for 360° pipe markers to encircle the pipe for view from any angle and disallows the strap fasteners that were used.

The pipe insulation has a bare paper face. It should have a protective canvas jacket covering in exposed mechanical spaces, as per specification.

The pipe insulation is resting directly on the stationary support and does not have the specified saddles and rollers to protect the insulation and allow for pipe expansion and movement.

The piping support is to be painted per contract.

All electrical conduits and junction boxes are to be color coded with paint, per contract.

Here we see a chipped fan blade on a 30hp fan of some four feet in diameter. On equipment this large, these kinds of damages are often an indication that mishandling occurred during shipping or crane rigging.

On this aluminum blade, this chip has the potential to become a crack and the blade may eventually break, thus sending a foot long section of blade hurtling about in the fan compartment.

The flexible pipe couplings shown (the blue fittings with braided stainless steel covers) are improperly installed. These couplings have a thick rubber accordion bellows under the outer covering.

As seen in the photo, the outer covering of the vertical couplings are crumpled. This indicates vertical compression of the coupling from the weight of the piping above. The coupling is designed to absorb lateral movement, not bear weight.

The contractor needs to support the overhead piping so that the coupling returns to its documented dimensions for length.

The couplings are also missing safety retainer bolts that are required by the manufacturer to prevent overextension of the coupling (the opposite of what is happening here) and possible catastrophic breakage.

Domestic cold water lines are not insulated as specified and will sweat.

The Fan Coil Unit (seen overhead) is completely inaccessible for maintenance of the filter, fan, and controls.

The round duct on the right is the Fan Coil Unit discharge duct, attached to the horizontal outlet of the Fan Coil Unit. The use of smooth transitions as per specified SMACNA standards was ignored. The unit should be relocated to facilitate proper ductwork.

The discharge duct insulation does not continue over the round duct as it should. Why insulate just part of a cold AC duct?

The duct on the right edge of the photo is built from bits and pieces of spliced sheet metal without fitted joints or seams, then generously covered in duct seal. The specified internal duct liner and external insulation are missing.

The ceiling support bar is hung from conduit and ductwork, not directly anchored to structural members. This is another violation of specification, and in some cases, code.

The photos to the left show heat trace cable being applied to piping just before being covered with insulation. Because this cable provides heat to prevent freeze of exterior piping, its installation is critical to prevent costly damage.

The trace is not applied per manufacturer's instructions as shown in the product installation literature samples (copyright Raychem Inc.). The contractor has short-cut the installation to save time and material at the owners expense (of possible ruptured piping).

The trace is incorrectly routed on the short side of most elbows.

The trace is incorrectly routed on the bottom of the horizontal pipe. The instructions say it should be at the 4-5 o-clock position (to avoid collected moisture).

The trace does not wrap around Tee's to provide additional heat where the piping mass is greater.

The trace does not wrap around Valves to provide additional heat where metal handles will protrude from the insulation covering.

The flow switch fitting neck to the left of the valves needs to be wrapped as well.