Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)

June 2017

Method Statement for Testing, Adjusting & Balancing of

Chilled Water (CHW) Systems

Page 1 of 10
Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)
June 2017

Table of Contents
1. SCOPE OF WORKS ......................................................................................................................... 3

2. PURPOSE........................................................................................................................................ 3

3. REFERENCES & RELATED DOCUMENTS ........................................................................................ 3

4. ABBREVIATIONS ............................................................................................................................. 4

5. HEALTH SAFETY & ENVIRONMENT ................................................................................................ 4

6. INSTRUMENTS, EQUIPMENTS AND TOOLS .................................................................................... 5

7. RESPONSIBILITIES ......................................................................................................................... 6

8. GENERAL REQUIREMENTS............................................................................................................. 8

9. COMMISSIONING WORK SEQUENCE ............................................................................................. 8

10. ATTACHMENTS: ............................................................................................................................10

Page 2 of 10
Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)
June 2017

1. SCOPE OF WORKS
This Method Statement is to cover the Testing, Adjusting & Balancing of CHW Systems installed
in the project.
The tests includes checks on completion, preliminary completion and pre-commissioning and
commissioning checks after completion as per the commissioning phases described in volume 4
of the contractor’s general requirements for commissioning.

2. PURPOSE

This method statement has been prepared to define the step by step method to implement the
correct practices for Testing, Adjusting & Balancing of CHW Systems through the guidelines
contain herein so as to ensure that the job execution complies with the project requirements and
in accordance with the approved site test procedures to verify conformance with specification,
design and standards.

3. REFERENCES & RELATED DOCUMENTS

3.1 Project commissioning plan and specifications

 Commissioning Plan reference number

 --list all applicable project specifications here--

3.2 Relevant Standards & Codes:

 ASHRAE - American Society of Heating, Refrigerating & Air-Conditioning

Engineers.
 CIBSE - Chartered Institution of Building Services Engineers
 ASHRAE 111 - Practice for Measurement, Testing, Adjusting & Balancing of
Building Heating, Ventilation, Air-Conditioning & Refrigeration Systems.
 NEBB - Procedural Standard for Testing, Adjusting & Balancing of
Environmental Systems.
 CIBSE Commissioning Code W- Water distribution systems
 --list any other related standards and codes here—

3.3 Approved shop drawings and material submittals

 --list all applicable shop drawings and MAR here--

Page 3 of 10
Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)
June 2017

4. ABBREVIATIONS

Cx : Commissioning
CxM : Commissioning Manager
CxA : Commissioning Authority
Cx Team : Commissioning Team
BACS : Building Automation & Control System
ITP : Inspection and test Plan
RA : Risk Assessment
FCU : Fan Coil Units
DX : Direct Expansion
CHW : Chilled water
HVAC : Heating, Ventilating & Air-Conditioning
DRV : Double Regulating Valve
PICV : Pressure Independent Control Valve
VAV : Variable Air Volume
FAHU : Fresh air handling unit
AHU : Air Handling Unit

-----Insert list of all abbreviations and terms used in above list------

5. HEALTH SAFETY & ENVIRONMENT

Health and Safety procedures by the Main Contractor will be implemented for this job. The
responsible safety officer as per procedure will conduct a routine safety inspection in conjunction
with the relevant test Engineer.

5.1 Safety Rules During Testing

In order to ensure safe conditions during testing the following rules have to be followed:

 Persons engaged with the Testing, Adjusting & Balancing of CHW systems are
experienced commissioning engineers and have received proper and
adequate training related to procedures and test equipment utilized for the
particular testing activity.
 Test instruments and test equipment should be maintained in a safe condition
and the test methods not to create danger either for the operator or for other
persons.

Page 4 of 10
Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)
June 2017

 Where tests are required to circuits which are live for amp readings then the
tightness of the cable terminations will be checked without power prior to live
amp readings.
 Ensure that warning labels are installed on panels and plant.
 Ensure that all plant drives have been pre-commissioned by the BACS
contractor and the drive supplier prior to commissioning.
 When readings are being taken for amperage and running speeds a support
engineer will be in attendance for safety reasons.
 Ensure that the test area is adequately cordoned off to prevent unauthorized
access

5.2 Safety Lighting

 Safety lights will be used in case of power failure ensuring the good
illumination of the working area to aid evacuation if necessary.
 Adequate lighting shall be provided to ensure the good illumination on the
working area.

5.3 Safety & Task Lighting

Adequate lighting shall be provided to ensure the good illumination on the working
area.

5.4 Emergency Arrangements

 General: Site general safety procedures will be followed. In case of emergency

the Safety Officer or the most senior employee present will stop the work,
and make the necessary emergency arrangements and report to the assembly
points as described during Site Induction Course.
 Communication from site areas to Site Office via mobile phones

5.5 Risk and Controls

 Risk assessments checklist (please attached)

6. INSTRUMENTS, EQUIPMENTS AND TOOLS

The following is the list of calibrated instruments and tools that will be used during
commissioning process:

Page 5 of 10
Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)
June 2017

 U-Tube Water Manometer

 Ultra Sound meter
 Pressure Gauges
 Tachometer
 Sling Hygrometer
 Miscellaneous hand tools

7. RESPONSIBILITIES

7.1 Commissioning Manager (CxM)

 CxM will have the overall responsibility of the Project for execution, quality
and safety. The Project Commissioning Manager will maintain the planning
progress and coordination of works with Main Contractor.
 Manage the entire commissioning activities as well as the commissioning
personnel (Engineers, 3rd party commissioning team hired, etc.)
 Will inform in advance all related internal Sub Contractors and organize a
meeting to prevent future difficulties during the Testing and Commissioning
of the particular system.
 Monitor that the progressing works are carried out according to the planned
program and all the equipment required to execute the full commissioning
works are available as per the project planning and are in good condition
 Plans, schedules and coordinates the Commissioning team to implement the
procedure for Testing, Adjusting & Balancing of CHW systems
 Report overall commissioning progress to the Main Contractor.

7.2 Commissioning Engineer

 Responsible for the day to day activities on site, for test, design information
approval and for the onsite Testing & Commissioning ensuring that quality
standards are maintained throughout the commissioning process.
 Verify that applicable equipment and systems are installed according to the
manufacturer’s recommendations and to industry accepted standards.
 Verify that all commissioning works are to be carried out according to
specification and approved drawings.
 To ensure in consultation with the Commissioning Manager that the
manpower involved in the Commissioning process are moved as agreed and
planned.
 Coordinate with the Lead Engineer, Commissioning Team, and Specialist Sub
Contractor and plan the work in advance as per the work sequence.

Page 6 of 10
Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)
June 2017

 Coordinate with the Main Contractor and ensure implementation of any

comments raised by the consultant.
 Monitor and update Testing and Commissioning progress and report to the
Commissioning Manager.

7.3 Commissioning Contractor

 Verify test and document proper performance of equipment and system.

 Maintain proper coordination with the Engineer on the daily basis regarding
the commissioning status of the particular equipment/system being
undertaken.
 To provide the Engineer daily progress report indicating the works achieved
and discuss with him the planned activities for the next day.
 To inform the Engineer of the areas/system ready for inspection.
 Ensure full coordination with the Safety Officer to maintain safe working and
proper housekeeping of the site.

7.4 Manufacturer/Supplier

 Initial system/equipment start up

 Shall co-operate with the Commissioning Manager & Engineer, as far as may
be necessary,
 Shall provide equipment specific test sheets
 Shall attend the site as per the commissioning schedule to lead the equipment
testing as per project requirements
 Shall provide calibrated test instruments as required to carry out the
commissioning process
 Shall provide their own specialist equipment which is not generally on site and
this should be agreed before commencement.
 In case of failure in any test, the supplier will rectify, and the commissioning
engineer to re-offer the test to CxM & the Consultant for re-witnessing and
approval.

7.5 HSE Officer

 Ensure site specific safety plan is implemented and followed for each activity.
 Provide required training.
 Regularly pay site visits to ensure that safety is being exercised at site as per
requirement.
 Advise the Construction Manager/Commissioning Manager for any infraction
for safety procedures.
 Stop all unsafe work activities

Page 7 of 10
Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)
June 2017

8. GENERAL REQUIREMENTS

 All the instruments used for the commissioning shall have a valid Calibration
Test Certificates and must be made available.
 All commissioning results shall be prepared, obtained and maintained by the
commissioning team as given in this procedure.

9. COMMISSIONING WORK SEQUENCE

9.1 Pre – Start/Pre – Commissioning Checks

1. Safe access and egress at all times to the location of the FAHU/AHU & FCU's the
areas the system serves and above ceilings as required is to be provided. All
termination correctly done.
2. Approved installation drawing / Schematic
3. Approved Chilled water flushing report
4. DRV Schedule / Technical Chart
5. Access to all areas should be free from obstruction
6. Controls specialist Engineers should be available
7. Check if motors and pump bearings are lubricated
8. Verify pump rotation is correct
9. Monitor motor start-up and running currents
10. The CHW system consists of DRVs across all the risers to different levels in the
building. In the equipment (AHUs, FCUs) 2-way regulating valves are regulating
the flow
11. At least 100mm clearance from pressure test points is maintained to enable
manometer tubes to be connected without kinking. Ensure proper access to
double regulating valves, PICVs are maintained.
12. Mark-up schematic drawing validating all test point locations
13. Before measuring the ΔP, generally checks will be made to ensure
- Open all the regulating valves, control valves, gate valves etc fully
- The system having been cleaned and flushed is filled and fully vented, all air
venting is to be validated by the commissioning engineer to ensure they are
satisfied adequate venting has been provided and will not affect readings
and measurements
- All strainers (FCUs, AHUs) are clean
- All control valves function correctly (fully open manually or automatic).

9.2 Checks before pump start

Page 8 of 10
Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)
June 2017

1. All normally open valves are fully open

2. All by pass and normally closed valves are fully closed
3. The pump suction and discharge valves are fully open on the selected pump.
4. The delivery valve of the stand by pumps are closed unless NRV’s are there. The
suction valve should be kept open
5. The pump casing is vented of air

9.3 Flow Measurement and Water Balancing of DRV’s

1. Water balancing will be carried out as prescribed by CIBSE commissioning code

‘W’, and the final position of all regulating valves will be recorded on test sheet.
2. With the fully open of control valves and DRVs as full load condition, the ∆P of
each main DRVs can be measured at the test ports and the flow rate can be
obtained based on below equation. The main DRVs will be balanced to ensure the
system flow is satisfactory for balancing to commence

𝐾𝑣𝑠 √∆𝑃
𝑄=
36
Where Q = Flow rate (L/s)
∆P = Differential pressure at test ports (kPa)
Kvs = Flow Coefficient provided by supplier (m3/hr)
3. Reading of P, the calculated flow rate and DRV setting will be recorded on the
test sheet

9.4 Proportional balancing of DRV’s

1. The responsible commissioning engineer shall identify the least favored (index)
and most favored circuits before commencing. The most favored circuit will be
the one that received the highest flow rate as a percentage of the design flow
when all control valves are fully opened. The least favored circuit will be the one
receiving the lowest flow as a percentage of the design flow rate. Reference shall
be made to CIBSE Commissioning Code W.
2. Proportional balancing shall be used to ensure all risers receive the correct
amount of flow
3. For each riser, calculate the flow ratio λ, where λ – measured flow / design flow
4. Identify the riser with the lowest flow ratio (λmin). This is referred to as the index.
It the risers have the same pressure loss for design flow, the farthest one from
the incoming flow will normally have the lowest flow as it receives the smallest
differential pressure. If the risers do not have the same pressure loss, then any
may have the lowest flow rate.
5. Use the DRV (a) of the index unit as the reference valve

Page 9 of 10
Method Statement for Testing, Adjusting & Balancing of CHW Systems (sample)
June 2017

6. Adjust the reference valve so that (a) λ=λmin. Lock the reference valve to this
setting. Connect flow measuring instruments for continues flow
7. Set the next upstream riser balancing valve so that (b) λ = λ(a) + (5% to 10%). The
plus 5% to 10% proportional regulation is to ensure that the system is not over
regulated as it is only necessary to balance the system to the specified tolerances.
This will have the effect of changing the flow ratio λ (a).
8. If the setting at DRV (b) changes the flow in the reference valve (a) by more than
5%, the valve (a) shall be readjusted so that λ (b) becomes proportionally equal
to the new value of λ(a), within 5% to 10%. Lock valve (b) to this setting.
9. Proceed to adjust the flow in all upstream risers on the branch (c)... (d)... (e) etc.
Work towards the pump as described in the points above using the same
reference terminal for comparison of λ until all terminals on the branch are
balanced within the specified tolerances
10. Note; when the final (closest) DRV(x) is adjusted, the flow ratio on λ (a) changes,
but λa...b...c etc remain proportionally equal to λ(a). Terminals (c) (b) and (a) for
example, therefore remain proportionally balanced relative to each other, hence
why the index is used as a reference.
11. Upon final balancing, lock all DRV’s and valve positions mentioned in the test
sheet.

10. ATTACHMENTS: (Please attach)

10.1 Risk Assessment Checklist

10.2 System/equipment Schedule
10.3 Approved IRE
10.4 Approved MAR
10.5 Related approved shop drawings
10.6 Testing & Commissioning Test Sheets

Page 10 of 10