Report

Commissioning module study

report

Report No. 19822/02

April 2007

Prepared for: Lars Fabricius

SAV UK Ltd
Scandia House
131 Armfield Close
West Molesey
Surrey
KT8 2JR

Compiled by: Glenn Hawkins

No. of pages: 21 of text

©BSRIA
SAV UK Ltd Commissioning module study

CONTENTS
1 Introduction .................................................................................................................................... 2

2 Executive Summary....................................................................................................................... 3

3 Flushing, cleaning and balancing of water systems .................................................................. 4

3.1 The purpose of flushing, cleaning and balancing of chilled water (CHW) and low
temperature hot water (LTHW) systems .................................................................................. 4
3.2 Fittings and equipment required for the flushing, cleaning and balancing of CHW or LTHW
systems ..................................................................................................................................... 4
3.3 The typical stages of a flushing and cleaning process for CHW or LTHW systems................ 5
3.4 Balancing CHW or LTHW systems ......................................................................................... 5

4 Design for CHW and LTHW system commissioning .............................................................. 6

4.1 The design of traditional CHW or LTHW systems using fan coil units................................... 6
4.2 The design of CHW or LTHW systems using fan coil units and commissioning modules ..... 7

5 About the study project ............................................................................................................... 10

6 Installation time benefits produced by a system using commissioning modules, when

compared to a traditional fan coil unit installation .................................................................. 11
6.1 BSRIA studies of traditional fan coil unit installations .......................................................... 11
6.2 The BSRIA study of fan coil unit system installation employing commissioning modules .. 11
6.3 A comparative analysis of a traditional fan coil unit installation and the installation of a fan
coil unit system using commissioning modules ..................................................................... 11

7 Flushing time benefits produced by a system using commissioning modules, when

compared to a traditional fan coil unit installation .................................................................. 13
7.1 The BSRIA study of flushing activities on a fan coil unit system employing commissioning
modules................................................................................................................................... 13
7.2 A comparative analysis of flushing activities on a traditional fan coil unit system & a fan coil
unit system using commissioning modules ............................................................................ 13
7.3 Flushing of horizontal mains pipework .................................................................................. 14
7.4 Flushing of fan coil unit circuits............................................................................................. 16

8 Balancing time benefits produced by a system using commissioning modules, when compared to
a traditional fan coil unit installation.............................................................................................. 19
8.1 The BSRIA study of balancing activities on a fan coil unit system employing commissioning
modules................................................................................................................................... 19
8.2 A comparative analysis of balancing activities on a traditional fan coil unit system & a fan
coil unit system using commissioning modules ..................................................................... 19

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1 INTRODUCTION
BSRIA was asked by SAV UK Ltd to conduct an independent study of installation and
commissioning activities on a project that utilised its commissioning modules. The objective of
the study was to collect sufficient information to enable a comparative analysis to be undertaken
between a traditionally configured fan coil unit system and a fan coil unit system that had been
configured to include commissioning modules.
This report has been generated following a study of installation, flushing and flow balancing
activities on an office development in central London. The variable volume, low temperature
hot water and chilled water systems on this project were based on an approach that employed 4-
pipe fan coil units and commissioning modules.
The comparative information employed in this report has been collected by BSRIA over the last
10 years during studies of traditional fan coil unit installations.

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2 EXECUTIVE SUMMARY

System installation

A traditionally designed fan coil unit installation on an office floor takes 28% more man-hours
to install than a fan coil unit system that has been designed to incorporate commissioning
modules.

For the study project, which had an air conditioning system containing 611 fan coil units and
265 commissioning modules, the overall installation time saving was 696 man-hours, or 17.4
man-weeks of effort. At an employment cost of £22 1 per hour, this equates to an installation
labour cost saving of £15,312.

Flushing of horizontal mains pipework

The flushing of the horizontal mains pipework in an office layout that incorporates
commissioning modules can be undertaken in 43% of the time it would take to flush in a
traditionally configured fan coil unit system
For the study project, which had an air conditioning system containing 611 fan coil units and
265 commissioning modules, the time saving for horizontal mains pipework flushing was 127
man-hours. At an employment cost of £22 per hour, this equates to a commissioning labour
cost saving of £2,790.

Flushing of terminal unit circuits

The flushing of fan coil unit circuits in an office layout that incorporates commissioning
modules can be undertaken in 23% of the time it would take to flush fan coil units in a
traditionally configured pipework system.
For the study project, which had an air conditioning system containing 611 fan coil units and
265 commissioning modules, the time saving for fan coil unit flushing was 678 man-hours, or
17 man-weeks of effort. At an employment cost of £22 per hour, this equates to a
commissioning labour saving of £14,920.

Balancing of flow to terminal units

The balancing of fan coil unit terminal circuits in an office layout that incorporates
commissioning modules can be undertaken in 44% of the time it would take to balance fan coil
terminal circuits in a traditionally configured pipework system.
For the study project, which had an air conditioning system containing 611 fan coil units and
265 commissioning modules, the time saving for fan coil unit circuit balancing was 251 man-
hours. At an employment cost of £22 per hour, this equates to a commissioning labour saving
of £5,520.

1
The figure of £22 per hour has been derived from discussions with the site workforce and site management on a series of
London office developments. It is based on an average hourly rate for London of £16.25, which has been derived from an
average weekly wage of £650. This weekly wage includes bonus payments, overtime uplift and travel allowance. An additional
35% has then been added to cover national insurance, pension, statutory holiday & bank holiday costs and an overheads
allocation.

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3 FLUSHING, CLEANING AND BALANCING OF WATER SYSTEMS

3.1 THE PURPOSE OF FLUSHING, CLEANING AND BALANCING OF CHILLED WATER

(CHW) AND LOW TEMPERATURE HOT WATER (LTHW) SYSTEMS

System contaminants such as millscale, jointing compound and building debris will inevitably
be found in newly fabricated heating and cooling pipework systems. If allowed to remain in
any system, these contaminants will make the system prone to blockage at strainers, control
valves and small-bore heat exchangers. These contaminants may also initiate further corrosion
and encourage the growth of micro-organisms.
Pipework systems therefore need to be flushed and cleaned to remove these contaminants and
therefore reduce the risk of operating problems. At the conclusion of the flushing and cleaning
process, a system full of water is said to have achieved “static completion”.
System balancing is a key part of the commissioning process that advances a system from static
completion to full working order in accordance with specified requirements. The balancing
process ensures that every terminal unit receives the correct volume flowrate of water in relation to
all other units and that the total volume flowrate generated by a pump matches the design flowrate.

3.2 FITTINGS AND EQUIPMENT REQUIRED FOR THE FLUSHING, CLEANING AND
BALANCING OF CHW OR LTHW SYSTEMS

To facilitate the flushing, cleaning and balancing processes in a CHW or LTHW system, the
system design should incorporate the following basic fittings and equipment, in easily
accessible locations:

1. Regulating valves: These items should be sized in accordance with CIBSE

commissioning code W so that the valve is not less than 25% open. If valves are closed
beyond this point they may be prone to blockage. Achieving flushing velocities through
some high resistance, typically small diameter, regulating valves may be impractical.
In this case, they should be bypassed during the flushing and cleaning process.
2. Strainers: Strainers should have a basket capable of standing the maximum pump head
without distortion. Pressure test points should be provided on both sides of a strainer.
Drain valves are recommended on the flanges and/or end caps of Y strainers to allow
local draining of the strainer body and local pipework prior to basket removal and
back-flushing of the strainer.
3. Drain valves: All systems should be divided into self-draining sections that incorporate
drain valves.
4. Pressure test points and measuring devices: These items should be located on the side of
pipework lengths, not at the top or bottom where they can become air-locked or act as
dirt pockets.
5. Air vents: Air vents should be provided on flow and return pipework at the end of each
horizontal run and at the tops of each self draining section.
6. Isolation valves: Every system should be designed to enable the isolation and bypassing
of plant and equipment such as primary plant, terminal units, control valves and
regulating valves during the flushing and cleaning process.

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3.3 THE TYPICAL STAGES OF A FLUSHING AND CLEANING PROCESS FOR CHW OR
LTHW SYSTEMS

The BSRIA guide AG 1/2001.1: pre-commission cleaning of pipework systems, gives the
following stages of a typical flushing and cleaning programme for a CHW or LTHW installation:

1. Static flushing (The static flush usually takes place after pressure testing)
2. Dynamic flushing
3. Degreasing
4. Biocide wash (for systems at risk from bacteria)
5. Removal of surface oxides (for systems with mild steel components)
6. Effluent disposal/final flushing
7. Neutralisation (for inhibited acid cleans only)
8. Passivation
9. Corrosion inhibitor and biocide dosing

3.4 BALANCING CHW OR LTHW SYSTEMS

The BSRIA guide AG 2/89.3: Commissioning water systems – application principles, identifies
proportional balancing as the most appropriate method of effectively regulating CHW of LTHW
systems. This technique involves adjusting regulating valves so that terminal units share the flow
in the correct proportions.
Successful application of this technique is entirely dependent on the inclusion of sufficient,
easily accessible, flow measurement devices and regulating valves, correctly positioned in the
pipework installation.

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4 DESIGN FOR CHW AND LTHW SYSTEM COMMISSIONING

4.1 THE DESIGN OF TRADITIONAL CHW OR LTHW SYSTEMS USING FAN COIL
UNITS

A traditional fan coil unit installation, as shown below in the schematic diagram from CIBSE
Guide KS7: Variable Flow Pipework Systems, and in the four site images on the following page, is
typically based upon the principle that each fan coil unit has its own flushing bypass loop, isolation
valves, flow regulating valve, flow measurement device, drain cock, and pressure test points.
If the system is variable flow and. is fitted with a pump which is controlled to vary its speed in
response to demand, then it is likely that differential pressure control valves (DPCVs) will need
to be incorporated in the system somewhere upstream of the fan coil units. These DPCVs will
also be surrounded by isolating valves, strainers, flow measurement devices and pressure test
points to facilitate flushing and flow balancing.
It can be seen that for a typical office development, this methodology means that lots of
separate components are required with lots of joints. Furthermore, this approach requires good
access in every fan coil unit and DPCV location for installation, flushing, cleaning, balancing,
maintenance and refurbishment activities.

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4.2 THE DESIGN OF CHW OR LTHW SYSTEMS USING FAN COIL UNITS AND
COMMISSIONING MODULES

A fan coil unit installation that employs commissioning modules, as shown in the site images below,
is based upon the principle that a group of 2 to 6 fan coil units have centralized flushing, back-
flushing, air venting, flow balancing, isolation, differential pressure control valve and strainer devices

In a typical office development, for example, this methodology means that fewer components and
fewer joints are required, when compared to a traditional fan coil unit installation. In addition, this
approach reduces the number of access locations required to perform installation, flushing,
cleaning, balancing and maintenance activities, when compared to a traditionally designed system.
An image of a commissioning module is shown below. The box is insulated and vapour-sealed
and has a hinged bottom plate for access. The commissioning module can be located up to 15
metres from a fan coil unit.

Supply manifold Flexible, multi-

with isolation layer pipe
valves
Return manifold
with regulating
valves &
Strainer and measurement
drain point points

Differential pressure
control valve

Flushing by-pass
and air vent
Isolation valves

The main features of commissioning modules are shown in the photograph above. The schematic
diagram below illustrates how the modules group together the various components and features.

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BOX

For comparative purposes, the following schematic diagram shows the configuration of a typical,
traditional rigid pipework arrangement for a fan coil unit installation.

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5 ABOUT THE STUDY PROJECT

The study project is located in central London. It involved the construction of an office
building that acts as a strategic global headquarters for a multi-national consumer goods
company.
The building is composed in the following manner
• Basement & sub basement – parking, plantroom and back of house facilities
• Ground floor – Reception and back of house facilities
• Floors 1,2 and 3 – Category A rentable floor space
• Floors 4,5,6 and 7 – Office space for the client
• Floor 8 – Restaurant and other business support facilities
• Roof – plant
There are 611 fan coil units and 265 commissioning modules on the project:

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6 INSTALLATION TIME BENEFITS PRODUCED BY A SYSTEM

USING COMMISSIONING MODULES, WHEN COMPARED TO A
TRADITIONAL FAN COIL UNIT INSTALLATION

6.1 BSRIA STUDIES OF TRADITIONAL FAN COIL UNIT INSTALLATIONS

During the last 10 years BSRIA has undertaken detailed studies of traditional fan coil unit
installation on site.
The images below show two examples of the type of traditional installations that have been
studied. They clearly show how improvised the pipework configurations typically are, and
illustrate the large quantity of marking, measuring, cutting and assembly that is required on site
to undertake each installation.

6.2 THE BSRIA STUDY OF FAN COIL UNIT SYSTEM INSTALLATION EMPLOYING
COMMISSIONING MODULES

BSRIA undertook a detailed study of the installation of commissioning modules and pipework
during the construction of an office development in London. The two images below illustrate
the type of work that was observed.

6.3 A COMPARATIVE ANALYSIS OF A TRADITIONAL FAN COIL UNIT INSTALLATION

AND THE INSTALLATION OF A FAN COIL UNIT SYSTEM USING COMMISSIONING
MODULES

For the purpose of this comparative analysis between the traditional and innovative system
designs, the 4th floor of the study project in London has been employed. This floor contained
73 fan coil units and 33 commissioning modules.

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In order to collect installation time data for the site installation work involving the
commissioning modules, direct observation of the installation of these items and associated
pipework systems was undertaken.
In order to provide comparative installation time data for a traditionally designed fan coil unit
system, a hypothetical calculation was then made to determine how long it would have taken to
install this traditionally configured system. The BSRIA database of installation task times,
which has been compiled over the last 10 years, was used in this calculation.
For the comparative analysis, the following assumptions have been made:
1. The time taken to install the 73 fan coil units on the 4th floor of the building is the same
for both the traditional and the innovative system layout
2. The layout, and therefore the time taken, to install the primary horizontal distribution
pipework on the 4th floor of the building, is the same for both the traditional and the
innovative system layout

6.3.1 The time taken to undertake the fan coil unit system installation employing
commissioning modules, on the 4th floor of the study building
The following analysis employs the task times collected during the observation of installation
activities on the study project.

1. Connect 33 commissioning modules to the underside of 33 commissioning units x 20.5 minutes for 2
the ceiling slab (Includes measurement, marking, people = 1,353 minutes
making-up and installation of supports, elevation into
position and fixing in place)

2. Connect a pair of flow and return pipework runs from the 33 commissioning units X 142 minutes = 4,686
33 commissioning modules to the primary horizontal minutes
branch pipework (Includes measurement, marking,
making-up and installation of supports)

3. Measure, mark, make-up and install supports for the 73 fan coil units x 6 supports per unit x 8 minutes
pipework connecting the commissioning module to a fan per support = 3,504 minutes
coil unit . (On the study project, an average of 3 pairs of
supports was used on each of the LTHW & CHW flow
and return pipework runs connecting a fan coil unit to a
commissioning module)

4. Run a pair of LTHW flow and return pipes and a pair of 73 fan coil units x 2 pairs of pipes x 28 minutes
CHW flow and return pipes between the 73 fan coil units for 2 people per pair of pipes = 8,176 minutes
and the 33 commissioning modules

Total time taken 17, 719 minutes or 295.3 man-hours

6.3.2 The time taken to undertake a hypothetical traditional fan coil unit system installation on
the 4th floor of the study building
During the detailed observations undertaken by BSRIA over the last 10 years, the average time
taken to connect a 4-pipe fan coil unit to the primary horizontal pipework has been 311 minutes
per unit. This time includes the installation of pipework supports and the installation of
features such as individual bypass loops, isolation valves, drain points and regulating devices,
as illustrated earlier in this document.
The hypothetical time taken to undertake a traditional version of the fan coil unit installation on
the 4th floor of the study building would therefore be as follows:
1. Install the pipework connecting 73 fan coil units to the 73 fan coil units x 311 minutes per fan coil unit =
primary horizontal branch pipework 22, 703 minutes or 378.5 man-hours

Total time taken 22, 703 minutes or 378.5 man-hours

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7 FLUSHING TIME BENEFITS PRODUCED BY A SYSTEM USING

COMMISSIONING MODULES, WHEN COMPARED TO A TRADITIONAL
FAN COIL UNIT INSTALLATION

7.1 THE BSRIA STUDY OF FLUSHING ACTIVITIES ON A FAN COIL UNIT SYSTEM
EMPLOYING COMMISSIONING MODULES

BSRIA undertook a study of flushing activities on a fan coil unit system incorporating
commissioning modules during the construction of an office development in London. The two
images below illustrate the type of work that was observed.

7.2 A COMPARATIVE ANALYSIS OF FLUSHING ACTIVITIES ON A TRADITIONAL FAN COIL

UNIT SYSTEM & A FAN COIL UNIT SYSTEM USING COMMISSIONING MODULES

For the purpose of this comparative analysis between the traditional and innovative system
designs, the 4th floor of the study project in London has been employed. This floor contained
73 fan coil units and 33 commissioning modules.
In order to collect data for the work involving the flushing of the CHW and LTHW pipework
systems, direct observation of the flushing activities was undertaken.
In order to provide comparative installation time data for a traditionally designed fan coil unit
system, a hypothetical calculation was then made to determine how long it would have taken to
undertake flushing activities on traditionally configured system. The BSRIA database of task
times, which has been compiled over the last 10 years, was used in this calculation.
For the comparative analysis of the flushing process, the following assumptions have been
made:
1. The time taken within the central plantroom for activities such as the activation of
circulation pumps and opening and closing of valves is the same for both the traditional
and the innovative system layout
2. The time taken for the flushing of plantroom and riser pipework is the same for both the
traditional and the innovative system layout
3. The drainage connection points located in the core area of each floor, are the same for
both the traditional and the innovative system layout
4. In practice, the flushing of the CHW and LTHW systems is undertaken separately.
However, for the purpose of simplifying the explanations and calculations used in the
comparative analysis, the 4th floor pipework installation has been considered as a single
system.

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7.3 FLUSHING OF HORIZONTAL MAINS PIPEWORK

With reference to BSRIA guide AG 1/2001.1: pre-commission cleaning of pipework systems,

water should not be passed through terminal units such as fan coil units at this stage of the
commissioning process. This means that all fan coil units need to be isolated from the flow of
water. This is shown in the schematic diagram below, which illustrates the traditional flushing
of horizontal mains pipework using the bypasses on each fan coil unit.

Commissioning modules achieve the same result but with a single flushing by-pass for each group of
fan coil units. This is shown in the schematic diagram below, which illustrates the flushing of
horizontal mains pipework using the inbuilt flushing bypasses in each commissioning module.

7.3.1 The time taken to the flush the horizontal mains pipework on the 4th floor of the study
building
The process employed to flush the CHW and LTHW horizontal mains pipework on the 4th floor
of the study project was as follows:

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1. Move working platform or step ladder to a

commissioning unit location
The adjacent image shows a
commissioning engineer on a step ladder
and clearly illustrates the access problems
that many commissioning specialists
typically encounter on site
This task took an average of 3.5 minutes
for 2 people

2. Isolate the fan coil unit circuits served by

the commissioning module and open the
pair of valves that isolate the
commissioning unit.
This adjacent image shows a
commissioning engineer opening the
isolation valves of a commissioning
module
This task took an average of 2 minutes for
2 people
2. Closing of commissioning module isolation
valves. Removal, cleaning and
replacement of strainer basket.
The adjacent image shows a strainer
basket that had been removed from a
commissioning module.
This task took an average of 5 minutes for
2 people

The total time taken to isolate the 73 fan coil units and flush the horizontal mains pipework on
the 4th floor of the study project by using the above methodology was as follows.

1. Isolate the 73 fan coil units by closing isolation valves 33 commissioning units x 10.5 minutes for 2
contained in the 33 commissioning modules, and flush people = 693 minutes
horizontal mains pipework and commissioning module
bypass loops, as outlined in the process description above

Total time taken 693 minutes or 11.6 man-hours

7.3.2 The hypothetical time taken to the flush the horizontal mains pipework on the 4th floor of
the study building
If the 4th floor of the study project contained a traditionally configured fan coil unit installation,
the above process, with the exception of the strainer removal, cleaning and re-installation 2 ,
would have to be undertaken for each of the 73 fan coil units on the floor. It would need to be
undertaken for both the CHW and LTHW pipework system in separate work programmes.
The hypothetical time taken to flush a traditional fan coil unit installation on the 4th floor of the
study building would therefore be as follows.

1. Flush the horizontal mains pipework and the bypass 73 fan coil units x 5.5 minutes for 2 people x 2
loops of 73 fan coil units configured in a traditional pipework systems (CHW & LTHW) = 1,606
manner using the process outlined in BSRIA guide AG minutes
1/2001.1: pre-commission cleaning of pipework systems

Total time taken 1, 606 minutes or 26.8 man-hours

2
This would be done during the flushing of the terminal unit circuit

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7.4 FLUSHING OF FAN COIL UNIT CIRCUITS

Once the primary distribution pipework has

been correctly flushed, each fan coil unit
should be flushed through.
A two-stage, back-flush and forward-flush
process is recommended. Figure 20 on page
46 of BSRIA guide AG 1/2001.1: pre-
commission cleaning of pipework systems,
illustrates this process.
This diagram is shown on the right of this
text.

The purpose of the back-flushing process is to remove the small amounts of loose debris, which
may have collected in the terminal units and associated small-bore pipework.
An equivalent approach for flushing fan coil units using commissioning modules is illustrated
in the schematic diagram below. The diagram shows forward and back flushing through an
individual fan coil unit using a commissioning module.

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7.4.1 The time taken to undertake the flushing of fan coil unit circuits through the
commissioning modules on the 4th floor of the study building

The observed process for flushing of fan coil unit circuits on the study project involved the
connection of a long length of hose between the pumping receptacle and a drainage point
located in a riser core, as shown in the two images below.

This was followed by a repeated process for each commissioning unit, as outlined in the five
images shown below and on the following page.

1. Move working platform and pumping

receptacle to a commissioning unit
location and connect to power to a power
distribution point.
The adjacent image shows a pumping
receptacle. The submersible pump is
located within the vessel.
This task took an average of 3.5 minutes
for 2 people

2. Connect the drainage hose to the

commissioning unit using a working
platform.
This adjacent image shows how a
threaded connection is used to connect
the hose to the strainer/drain point
element of the unit
This task took an average of 1.5 minutes
for 2 people

3. Back flushing of multiple fan coil units

simultaneously through the commissioning
unit
The adjacent image shows the discoloured
water that has been transferred to the
pumping receptacle during the flushing
process.
This task took an average of 6.5 minutes
for 2 people

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4. Forward flushing of length of pipe between

the flow isolation valve and the
commissioning unit.
The adjacent image shows a
commissioning engineer isolating fan coil
unit circuits
This task took an average of 5 minutes for
2 people

5. Disconnection of drainage hose. Removal,

cleaning and replacement of strainer
basket.
This task took an average of 5 minutes for
2 people

The total time taken to flush the fan coil unit circuits on the 4th floor of the study project was as
follows.

1. Flush the CHW and LTHW circuits of 73 fan coil units 33 commissioning units x 21.5 minutes for 2
using the 33 commissioning modules, as outlined in the people = 1,419 minutes
process description above

Total time taken 1, 419 minutes or 23.6 man-hours

7.4.2 The hypothetical time taken to undertake the flushing of traditionally installed fan coil
unit circuits on the 4th floor of the study building

If the 4th floor of the study project contained a traditionally configured fan coil unit installation,
the above 6-stage process would have to be undertaken for each of the 73 fan coil units on the
floor. It would need to be undertaken for both the CHW and LTHW pipework system in
separate work programmes.
The hypothetical time taken to flush traditionally installed fan coil unit circuits on the 4th floor
of the study building would therefore be as follows.

1. Flush the CHW & LTHW circuits of 73 fan coil units 73 fan coil units x 21.5 minutes for 2 people x 2
configured in a traditional manner, using the process pipework systems (CHW & LTHW) = 6,278
outlined in BSRIA guide AG 1/2001.1: pre-commission minutes
cleaning of pipework systems

Total time taken 6, 278 minutes or 104.6 man-hours

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8 BALANCING TIME BENEFITS PRODUCED BY A SYSTEM

USING COMMISSIONING MODULES, WHEN COMPARED TO A
TRADITIONAL FAN COIL UNIT INSTALLATION

8.1 THE BSRIA STUDY OF BALANCING ACTIVITIES ON A FAN COIL UNIT SYSTEM
EMPLOYING COMMISSIONING MODULES

BSRIA undertook a study of balancing activities on a fan coil unit system incorporating
commissioning modules during the construction of an office development in London. The two
images below illustrate the type of work that was observed.

8.2 A COMPARATIVE ANALYSIS OF BALANCING ACTIVITIES ON A TRADITIONAL FAN

COIL UNIT SYSTEM & A FAN COIL UNIT SYSTEM USING COMMISSIONING MODULES

For the purpose of this comparative analysis between the traditional and innovative system
designs, the 4th floor of the study project in London has been employed. This floor contained
73 fan coil units and 33 commissioning modules.
In order to collect data for the work involving the flushing of the CHW and LTHW pipework
systems, direct observation of the balancing activities was undertaken.
In order to provide comparative installation time data for a traditionally designed fan coil unit
system, a hypothetical calculation was then made to determine how long it would have taken to
undertake balancing activities on traditionally configured system. The BSRIA database of task
times, which has been compiled over the last 10 years, was used in this calculation.
For the comparative analysis of the balancing process, the following assumption has been
made:
1. The time taken for the balancing of riser pipework and the principal horizontal pipework
on each office floor is the same for both the traditional and the innovative system layout
2. In practice, the balancing of the CHW and LTHW systems is undertaken separately.
However, for the purpose of simplifying the explanations and calculations used in the
comparative analysis, the 4th floor pipework installation has been considered as a single
system.

8.2.1 The time taken to undertake the balancing of fan coil unit circuits using the
commissioning modules on the 4th floor of the study building

The process employed to balance each fan coil unit circuit on the 4th floor of the study project
was as follows:

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1. Move working 6. Adjust the

platform & manometer double regulating
tube set to valve to obtain the
commissioning module correct flow through
location. the fan coil unit, as
The adjacent image indicated on the
shows an engineer and differential pressure
a manometer set on a reading of the
small mobile platform. manometer set.
This task took an This task took an
average of 2 minutes average of 2 minutes
for 2 people for 2 people

2. Note down the 7. Lock the

required performance regulating valve
criteria on the control with an allen key, as
sheet by extracting data shown in the
from the label on the adjacent image.
commissioning module
lid. This task took an
average of 1/2
The adjacent image minute for 2 people
shows this data on the
lid of a module.
This task took an
average of 1 minute for
2 people

3. Open the 8. Note actual test

commissioning module reading the on the
and undo the test point control sheet.
caps
A control sheet for
The adjacent image balancing works is
shows a commissioning shown in the
module with its lid open. adjacent image.
This task took an
average of 1 minute for This task took an
2 people average of 1/2
minute for 2 people

4. Purge the air from 9. Repeat steps 4-

the 1st circuit by 8 for the other fan
connecting the high- coil circuits
pressure hose and connected to the
venting into a container. commissioning
The adjacent image module.
shows this activity being The adjacent image
undertaken. shows this activity
This task took an being undertaken.
average of 2 minutes for This task took an
2 people average of 11
minutes for 2
people per module

5. Connect the low- 10. Close the lid on

pressure hose. the commissioning
module.
The adjacent image
shows a pair of hoses The adjacent image
connected to binder shows a
points. commissioning
module within a
ceiling void.
This task took an
average of 1/2 minute for This task took an
2 people average of 1 minute
for 2 people

© BSRIA Report Number 19822/02 20

SAV UK Ltd Commissioning module study

The total time taken to balance the fan coil unit circuits on the 4th floor of the study project was
as follows.

1. Balance the CHW and LTHW circuits of 73 fan coil units 33 commissioning units x 21.5 minutes for 2
using the 33 commissioning modules, as outlined in the people = 1,419 minutes
process description above

Total time taken 1, 419 minutes or 23.6 man-hours

8.2.2 The hypothetical time taken to undertake the balancing of traditionally installed fan coil
unit circuits on the 4th floor of the study building
During the observations undertaken by BSRIA over the last 10 years, the average time taken to
balance a traditionally installed fan coil unit circuit has been 11 minutes for 2 people.
The hypothetical time taken to balance a traditional fan coil unit installation on the 4th floor of
the study building would therefore be as follows.

1. Balance the CHW & LTHW circuits of 73 fan coil units 73 fan coil units x 11 minutes for 2 people x 2
configured in a traditional manner, using the process pipework systems (CHW & LTHW) = 3,212
outlined in BSRIA guide AG 2/89.3: commissioning minutes
water systems – application principles

Total time taken 3, 212 minutes or 53.5 man-hours

© BSRIA Report Number 19822/02 21