Basic Tools, Instrumentation, and

Equipment
Many of the functional tests in the CTPL contain a list of the tools, instruments, and
equipment necessary to perform the test. In addition, the Functional Testing Field Tips table
in each chapter of the Functional Test Guide lists the instruments and tools typically required
to perform the tests associated with the topic of discussion in the chapter. The tools in the
following list are basic tools that you will probably need in the course of commissioning a
project, regardless of the testing to be performed. They are broken into two categories:
essential and desirable. The tools in the essential list are strongly recommended for any basic
tool set for commissioning work. The tools listed as desirable would make good additions to
the essential tool set as funding becomes available.

These lists are just starting points and are by no means comprehensive. The longer you work
as a commissioning provider, the more you will find that your tool and equipment set grows
and adjusts to accommodate your personal needs and preferences. In any case, having your
own tools and equipment offers advantages over borrowing the things that you need from
others working on the project site.

1 You can make sure that you have what you need when you need it.

2 You will have direct knowledge of the accuracy, capabilities, and limitations of your
instruments. This knowledge can be important in evaluating the information you gather.

3 You will have with you what you consider to be the right tools for the job.

Essential Tools, Instrumentation, and Equipment

Hand tools: A good set of hand tools includes an assortment of wrenches, screwdrivers,
pliers, wire cutters, wire strippers, channel locks, punches, hammers and other common hand
tools. These tools are especially useful in a retro-commissioning environment where it is
unlikely that there will be tradesmen available with the tools that you need.

Figure 4: Storage type clipboard

Flashlights: Having both a large flashlight and a mini flashlight is essential. The mini
flashlight will serve for most purposes, but the larger light can be useful for inspections above
ceiling spaces or other areas.
 Clipboard: Having a clipboard is important to provide a portable writing surface as well
as a way to hold on to notes and test procedures. For a little extra money, you can get one
with a storage compartment that provides a convenient way to carry some of your other
equipment around on the site with you (Figure 4).

Safety Equipment: Hard hats, safety glasses, ear protectors, and steel-toe shoes are
generally good ideas on construction sites and around machinery and may be mandatory at
some locations.

Calculator or Slide Rule: Having a small pocket calculator available makes quick field
estimates easy to accomplish. Having a slide rule means you can do the same thing without
batteries.

Psychrometric Chart, Tables, and Other References: Access to a psychrometric

chart makes analyzing an HVAC process easier to accomplish in the field. Having some
pocket hand books and frequently used tables can also be useful for helping you solve
problems in the field as they occur. Useful references might include:

The ASHRAE Pocket Handbook and similar handbooks by other professional

organizations

Steam tables

Refrigerant tables

A list with frequently used equations, formulas and units conversion factors

Tables of pressure loss factors for common duct and pipe fittings

Small scale floor plans of the building you are working in

Laminating these papers will make them more durable in the field and will also allow you to
draw and erase using a wax pen or crayon.

Multi Tool: A folding multiple tool device, like a Leatherman or a Gerber Tool, can come
in handy in the field. Just remember to take it off your belt and put it in your checked luggage
before going through airport security on your way home.

Camera: Documenting existing conditions and problems with a camera can be a real
time saver and memory jogger. Digital cameras have the advantage of providing an
instantaneous picture that can inserted in reports and e-mail. Some commissioning providers
use a digital camera plugged into a laptop logged into the Internet to witness pressure tests or
observe operating conditions from a remote location.

Indelible Markers:Several write on anything markers in different colors can be

useful for marking sensor locations on pipes and ducts. Soap stones and white grease pencils
are useful for making sensing port locations on black iron pipe.
 Jewelers Screw Drivers:A set of small screw drivers with different blade styles and
sizes can be useful for working on control system components for calibration and other
adjustments as well as working with small terminal strips.

Figure 5: Duct Test Port

(Image courtesy of the Vent Fabrics web site)

Drill and Drill Bits, Hole Plugs: A rechargeable, portable electric drill is useful in the
field to make holes in ducts for measuring air flows and temperatures. Hole plugs in the form
of rubber stoppers or sheet metal caps seal your test ports when you are done. (Figure 5)

Duct Tape and Silicon Sealant: Both of these products can be handy for temporarily
sealing test openings created in a duct system or for repairing the vapor barrier on insulation
when it is broken by a test port penetration. They need to be used with caution in some
process environments however. The off-gassing from the silicon sealant can create quality
control problems for some clean room processes.

Figure 6: Lab grade thermometers

Note the 2/10 degree scaling marks. (Image courtesy of the Fisher Scientific web site)

Tape Measure and 6 Foot Folding Ruler: Having at least one of these measuring tools
is nearly mandatory. Having one of each can be handy for taking measurements in different
situations.

Electrical Meters: Having a small portable multimeter and an amprobe available can
allow valuable troubleshooting information to be readily obtained. In inexpensive pocket
multimeter has the advantage of portability. However, a larger, higher precision meter can be
useful for cross checking calibration and input signals on control systems.

Lab Grade Thermometers: Electronic thermometers win the contest in terms of ease of
use, durability, and cost, but its hard to argue with a lab grade fluid in glass thermometer.
There are no batteries to fail and no calibration adjustments to make. Thermometers for
several common temperature ranges can be useful for providing a baseline for a relative
calibration test or troubleshooting. Pairs of thermometers in common ranges can provide a
good way to document temperature changes across heat transfer elements. Mercury
thermometers were the original instruments of choice in this category, but with the growing
concern over hazardous waste, thermometers using other liquids are becoming popular
because if they break, they do not pose a contamination problem. If you purchase these
devices, its a good idea to make some carrying cases for them out of PVC pipe large
enough to accommodate the thermometer encased in a layer of bubble wrap.

Sling Psychrometer: While somewhat harder to use than an electronic hygrometer, a

sling psychrometer will provide a reliable measure of wet bulb temperature. The instrument
uses mercury thermometers so there is never a need to change batteries or calibrate. Be
careful not to swing it into a wall or equipment housing. For tight quarters, units are available
with a battery-powered fan.

Inclined Manometers: A set of inclined manometers and several different sized pitot
tubes allow a variety of pressure and flow readings to be taken for a relatively low first cost.
At least two meters should be obtained, one in the 0 to 1/4 inch water column range for low
pressure readings and another in the 0 to 10 water column range for higher pressures. This
is one instance where the advantages of the electronic versions of these instruments might
outweigh the advantage of the inclined manometer measurement with no power supply
required. However, the inclined manometers will usually cost significantly less than the
electronic meter and offer a good compromise between price, flexibility, ease of use, and
accuracy. The meter set should be supplemented with several static and pitot static probes.
The probes come in a variety of lengths to allow ducts of all sizes to be traversed. The typical
diameter is 1/4, but short, flexible, smaller diameter probes are also available. These probes
are useful where pressure relationships must be verified by sliding the probe under a door
threshold or through the crack between the door and the jamb.

Precision Pressure Gauges: A set of high accuracy pressure gauges will be useful for
measuring coil and valve pressure drops as well as performing pump tests. This is another
area where the electronic version may provide better accuracy and flexibility, but at a cost
premium. A set of two or three precision gauges may be more viable as an initial investment.

Backpack: A backpack is a convenient way to carry all of this equipment around. It

allows you to keep both hands free yet have everything you need close at hand.

Pocket Tape Recorder: A small portable dictation type tape recorder can be a
convenient way to gather nameplate data in the field or record observations. It also is a
convenient way to take meeting minutes (be sure to tell everyone you are doing it first). A
voice activated feature is especially convenient since it allows you to simply clip the mike to
your shirt collar, slip the recorder in your pocket and make comments or document data as
needed.

Figure 7: Portable anemometers

(Images courtesy of the PG&E Energy Center)

Anemometer: A rotating vane anemometer can be a convenient way to estimate low

velocity air flows. Rough estimates of unit flow rates and minimum outdoor air flow rates can
be obtained by taking velocity readings across filter banks or intake louvers with this device.
The readings may not be exact, but they will be better than a guess. (Figure 7).

Tachometer: The speed at which shafts rotate can be a key indicator of performance.
There are a variety of tachometer options available such as mechanical tachometers, digital
tachometers, and strobes that allow the shaft speed to be measured without actually being in
contact with the shaft. The strobe tachometer is generally the most expensive option, but it
also is the most flexible and safest approach. When working with a strobe tachometer, it is
important to remember that the strobe will freeze the shaft motion at the fundamental speed
(the speed that you want to measure) as well as at its harmonics (even multiples of the speed
you want to measure).

Figure 8 Tachometers

The instrument on the left must be in contact with the rotating shaft to measure rpm. The
strobe on the right can be used for non-contact measurement by freezing the motion of
the rotating element.

Taking shaft speed measurements will involve working in close proximity to rotating
machinery and extreme caution should be exercised when taking these readings. Make sure
that you do not have any items which could become entangled with the shaft and pull you
into the machine. If possible, take shaft speed readings through the openings provided with
the belt and shaft guards in place. If the motor and shaft are mounted internal to the fan
casing, you need to be aware that if someone opens the access door to the unit while it is
operating, there can be considerable wind pressure generated which can throw you off
balance.

Dataloggers: Even though most current technology buildings are equipped with DDC
systems that allow trending of the data required to commission the system, having several
data loggers available with a variety of input sensors to supplement this capability can often
be useful for the following reasons:

1 Proper commissioning or troubleshooting of some systems may require a sensing point

that was not included with the DDC package. Using a datalogger available to pick up this
information is often the quickest, least costly way to obtain the data.
2 Retro-commissioning applications in older buildings may involve working with non-DDC
controlled systems. For these situations, portable dataloggers provide an economically
feasible approach to obtaining trend data.

3 Most commercial DDC systems are restricted to a trending rate of 1 sample per minute or
more. This is suitable for many applications, but can be a limitation for a identifying
problems in some processes. Many dataloggers are capable of sampling at frequencies of
once per second or more.

Figure 9: Data loggers

A wide variety of data logging equipment is available in the current market at modest cost.
Capabilities range from small, dedicated purpose units like the loggers pictured to the left to
multiple channel, programmable loggers like the unit pictured on the right.

Figure 10: Portable Datalogger Guide

This guide on portable dataloggers, along with other manuals outlining O&M best practices
can be downloaded free of charge from www.peci.org/om.

The capability to log four temperatures, one or two amperages, and status of motors and
lighting will allow a commissioning provider to address most of the common problems
encountered in the field when the need exists to supplement existing DDC equipment or
troubleshoot an isolated problem. Humidity and low and high range pressure logging
capability can also be useful. In situations where multiple systems and parameters must be
monitored, significantly more datalogging capacity will be required if there is not a DDC
system available. If the commissioning provider does not have the datalogging capacity
necessary, they can lease dataloggers and input sensors or purchase the additional
dataloggers.

Most investments in current technology data logging will pay for themselves quickly in
improved diagnostic capability, reduced trouble shooting labor, and more accurate energy
savings projections.

Desirable Tools, Instrumentation, and Equipment

Shortridge or Other Electronic Air Data Multimeter: An electronic pressure

measurement meter like the meters used by most balancing firms is an expensive but highly
useful tool. Most meters of this type can measure pressures in the thousandths of an inch
water column range accurately, and thus can detect and measure low velocity pressures and
air flow rates. Typically, they have a variety of ranges and often will perform the calculation
to convert a velocity pressure to velocity, allowing direct readings of velocity to be taken.
They also can be purchased with a memory feature that allows multiple readings to be taken,
stored and averaged allowing a pitot tube traverse to be made easily by one person.

Figure 11: Air Data Multimeter

(Image courtesy of the Shortridge Company)

Radios: For large projects or for tests requiring coordinating multiple parties at different
locations, a set or even several sets of radios are invaluable. Generally, the more expensive
radios are worth the extra money in terms of range and flexibility, especially inside buildings
and on large projects where numerous people are using radios to communicate.

Personal Organizers: Personal organizers, like the Palm Pilot, can be quite useful for
commissioning providers and others working out in the field. At a minimum, having a ready
reference for schedules, appointments and contacts can be useful. There are also numerous
engineering applications available that can make life easier including units conversion
programs and psychrometric programs.

Electronic Thermometer: Electronic thermometers are a rugged and easy approach to

field temperature measurements. The accuracy will probably not be as good as a good lab
grade thermometer, and this reduced accuracy should be kept in mind when taking readings.
Many of these devices use thermocouples for inputs and the accuracy can easily be 2 or
more degrees. Accuracy will not matter for differential readings taken with the same meter or
relative calibration work, but it may be significant in instances where absolute accuracy is
important.

Figure 12: Electronic Hygrometer and Electronic Pressure Gauge

(Images courtesy of Omega Engineering and the PG&E Pacific) Energy Center)

Electronic Hygrometer: Electronic hygrometers offer a more rugged, faster way to take
humidity measurements compared to a sling psychrometer. However, these devices may not
offer the accuracy of a good sling psychrometer with matched liquid filled thermometers.
Special equipment is often required to perform accurate calibrations of electronic
hygrometers.

Electronic Pressure Gauge: Electronic pressure gauges often offer a more versatile
approach to multiple range pressure measurements, but usually at a cost premium compared
to precision bourdon tube type gauges. The electronic version most likely offers better
accuracy than the mechanical version.

Dataloggers: As indicated previously, expanding your stock of dataloggers is desirable.

Adding datalogging capacity or the ability to log different data sources will improve your
ability to diagnose and correct problems in a timely fashion.

Signal generators, and Field Calibrators: In most instances, the calibration of sensors
will be the responsibility of other parties. However, in a retro-commissioning or
troubleshooting environment and in situations where calibrations need to be crosschecked,
field calibrators can be a useful tool. In addition, having this type of calibration equipment
will allow a true, multipoint calibration to be performed in the field.

Multi-function units frequently allow one instrument to simulate a variety of fairly standard
functions, as shown in the upper left in Figure 13. Dedicated instruments, like the RTD
calibrator shown in the upper right in Figure 13 may offer better precision or the ability to
simulate many different variations of a particular device.

When using field calibrators and simulators, there is one important point to remember. Unless
the simulator is simulating the measured parameter in a manner that subjects the entire
sensing system to the simulation, then calibration to the simulated signal is only calibrating a
portion of the system. For example, if a 4-20 ma field calibrator is installed in place of a duct
mounted RTD with transmitter and the readings at the controller are adjusted based on the
signals from the calibrator, then the calibration assumes that the information provided by the
transmitter/RTD assembly is accurate. To improve upon this situation, an RTD simulator
could be installed on the transmitter in place of the RTD. Now, adjustments made include any
inaccuracies placed in the input by the transmitter. But, the process still assumes that the
RTD is providing accurate information to the transmitter. Immersing the transmitter in a bath
that subjects it to the required calibration temperatures (Figure 13 right picture) calibrates the
entire system. Of course, the calibration will only be as good as the reference standard used to
determine the bath temperature.

Figure 13: Field Calibration Equipment

A multiple function calibrator is shown in the upper left, a RTD calibrator in upper right, and
a constant temperature dry bath at the bottom. (Images courtesy of Omega Engineering and
the PG&E Pacific Energy Center)

Portable Folding Ladder: Having your own ladder will usually pay for itself in the long
run because it can take a surprising amount of time to locate, borrow, and return a ladder on a
construction site or in an existing facility.

Portable Folding Table And Chair: As a commissioning provider, you will find that
you are working with manuals, drawings, binders, laptop computers, and other equipment on
a frequent basis. Having a portable folding table and chair will allow you to quickly set up a
temporary work area on a project site and get organized.

All tools should be used safely and with consideration for the labor practices at the job site.
Work rules and trade practices can vary by location. You probably have found that at some
sites there is a lot more latitude regarding how hands on you can be. These rules can also
change when the project transitions from being owned by the contractor to being owned by
the Owner. Finally, corporate safety plans and practices may restrict the amount of hands-on
work that can be accomplished by someone who is not an employee of the company. For
your own sake and the sake of safety and labor relations, always check on the rules and
practices that are in effect on a site before diving into working on a machine with your tools.