TESTING AND COMMISSIONING PROCEDURE

FOR

AIR CONDITIONING, REFRIGERATION AND

MECHANICAL VENTILATION INSTALLATION

IN

GOVERNMENT BUILDINGS

OF

THE HONG KONG SPECIAL ADMINISTRATIVE REGION

2022 EDITION

ARCHITECTURAL SERVICES DEPARTMENT

THE GOVERNMENT OF THE HONG KONG SPECIAL ADMINISTRATIVE REGION
 PREFACE

This Testing and Commissioning (T&C) Procedure aims to lay down the minimum testing and
commissioning requirements to be carried out on Air Conditioning, Refrigeration and Mechanical
Ventilation Installation in Government Buildings of the Hong Kong Special Administrative Region
(HKSAR). Such requirements are applicable to both new installations upon completion and existing
ones after major alteration.

The present edition was developed from the General Specification for Building Services
Installation in Government Buildings of the Hong Kong Special Administrative Region 2022 Edition
that was established by the Architectural Services Department (ArchSD).

Electronic version of this T&C Procedure is to be viewed on and free for download from the
ArchSD Internet homepage. As part of the Government’s efforts to limit paper consumption, hard copies
will not be put up for sale.

The ArchSD welcomes comments on this T&C Procedure at any time since the updating of this
T&C Procedure is a continuous process to tie in with technological advances.
 DISCLAIMER

This T&C Procedure is solely compiled for Air Conditioning, Refrigeration and Mechanical
Ventilation Installation carried out for or on behalf of the ArchSD in Government premises of the
HKSAR.

There are no representations, either expressed or implied, as to the suitability of this T&C
Procedure for purposes other than that stated above. Users who choose to adopt this T&C Procedure for
their works are responsible for making their own assessments and judgement of all information contained
here. The ArchSD does not accept any liability and responsibility for any special, indirect or
consequential loss or damages whatsoever arising out of or in connection with the use of this T&C
Procedure or reliance placed on it.

The materials contained in this document may not be pertinent or fully cover the extent of the
installation in non-government buildings and there is no intimated or implied endorsement of the sales,
supply and installation of the materials and equipment specified in this T&C Procedure within the
territory of the HKSAR.
 TABLE OF CONTENTS
Page

1. Introduction 1

2. Objectives of the Testing and Commissioning Works 1

3. Scope of the Testing and Commissioning Works 2

3.1 Tests and Inspections during Construction

3.2 Functional Performance Tests
3.3 Commissioning, Statutory Tests and Inspections
3.4 Documentation and Deliverables
3.5 General Commissioning Requirements
3.6 General Testing Requirements

4. Testing and Commissioning Procedures 8

4.1 General Test and Inspection Requirements

4.2 Water, Air and Refrigeration Systems
4.3 Other Relevant Tests and Inspections

Annex

Annex I Testing and Commissioning Progress Chart for Air Conditioning, Refrigeration and
Mechanical Ventilation Installation

Annex II Testing and Commissioning Certificate for Air Conditioning, Refrigeration and
Mechanical Ventilation Installation

Annex III List of Calibrated Equipment/Instruments Necessary for the Testing and
Commissioning Works

Annex IV Flow Charts

Annex V Reference for Testing and Commissioning Procedures

Table of Contents T&C Procedure for Air Conditioning, Refrigeration and

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 Testing & Commissioning Procedure for
Air Conditioning, Refrigeration and Mechanical Ventilation Installation

1. Introduction
The procedures stated in this Testing and Commissioning (T&C) Procedure cover the activities in
preliminary tests and inspections, functional performance tests and the commissioning of newly
completed Installations and existing ones after major alteration. They are so compiled to facilitate
the work of Project Building Services Engineer (PBSE) and Project Building Services Inspector
(PBSI) / Project Electrical and Mechanical Inspector (PEMI), who are appointed as the Supervising
Officer’s Representatives, in the following aspects with respect to testing and commissioning:

(a) to vet and approve the T&C procedures for Air Conditioning, Refrigeration and Mechanical
Ventilation Installation;

(b) to witness those T&C procedures as specified; and

(c) to accept the T&C certificates and other supporting data.

T&C works shall be carried out as detailed in this T&C Procedure. Supplementary T&C plans may
be proposed as appropriate and agreed by PBSE.

The administrative requirements for T&C works are in general as specified in the General
Specification for Building Services Installation 2022 Edition and all current corrigenda/amendments
thereto published before the date of first tender invitation for the Contract issued by the ArchSD (the
General Specification).

All words and expressions shall have the meaning as assigned to them under the General Specification
unless otherwise specified herein.

2. Objectives of the Testing and Commissioning Works

The objectives of the T&C works are:

(a) to verify proper functioning of the equipment/system after installation;

(b) to verify that the performance of the installed equipment/systems meet with the specified design
intent, statutory requirements and energy performance, if any, through a series of tests and
adjustments; and

(c) to capture and record performance data of the whole installation as the baseline for future
operation and maintenance.

For the avoidance of doubt, depending on the specific demands of individual installation, the PBSE
may require additional or substitute T&C works in regard to any elements in the Installations other
than those indicated in this T&C Procedure.

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3. Scope of the Testing and Commissioning Works

3.1 Tests and Inspections during Construction

The purpose of these tests is to ensure that all components and systems are in a satisfactory and
safe condition before start up. Preliminary adjustment and setting of equipment at this stage
shall also be carried out at the same time to pave way for the coming functional performance
tests.

Before carrying out any test, it shall ensure that the Installations comply with all relevant
statutory requirements and regulations. The T&C works shall also comply with all site safety
regulatory requirements currently in force. In particular, the Contractor shall note the statutory
requirements listed in the General Specification in carrying out the works.

3.2 Functional Performance Tests

The purpose of functional performance tests is to demonstrate that the Installations can meet
the functional and performance requirements as specified in the Contract. Functional
performance tests should proceed from the testing of individual components to the testing of
different systems in the Installations.

Temporary modifications may be made as the tests proceed. The specific tests required and the
order of tests will vary depending on the type and size of systems, number of systems, sequence
of construction, interface with other installations, relationship with the building elements and
other specific requirements as indicated in the Contract. The testing of systems may have to be
carried out in stages depending on the progress of work or as proposed.

Part of the tests may be required to be carried out in suppliers’ premises in accordance with the
provisions in the Contract.

Any performance deficiencies revealed during the functional performance tests must be
evaluated to determine the cause. After completion of the necessary corrective measures, the
tests shall be repeated as appropriate.

If any test cannot be completed because of circumstances that are beyond the control, it shall
be properly documented and reported to the PBSE, who shall then liaise with the relevant
parties to resolve the situation. The testing shall be resumed immediately upon the attainment
of a suitable testing environment.

3.3 Commissioning, Statutory Tests and Inspections

Commissioning is the advancement of the Installations from the stage of static completion to
full working conditions and to meet the performance requirements as specified in the Contract.
This will include setting into operation and regulation of the Installations. Fine-tuning of the
commissioned system shall be carried out to match system performance to the actual needs of
the building occupier more closely.

Tests to meet statutory requirements shall be carried out. After the proper testing and
commissioning of the Installations, the relevant authorities shall be notified through the PBSE

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 on the completion of the Installations and its readiness for statutory inspection and testing.
Necessary inspections and tests as required by the Authorities shall be arranged.

3.4 Documentation and Deliverables

Proposed T&C procedures together with the Testing and Commissioning Progress Chart shown
in Annex I shall be submitted to PBSE for approval.

All inspection and T&C results shall be recorded in the appropriate test record forms. A
complete set of these forms can be found in Annex II.

Data recorded in other formats may also be accepted subject to prior approval of the PBSE.
Upon completion of all the required T&C works, a testing and commissioning certificate shown
in Annex II shall be completed and signed to ensure that the agreed T&C works have been
duly carried out.

A functional performance test report covering all measured data, datasheets, and a
comprehensive summary describing the operation of the system at the time of the functional
performance tests shall be prepared and submitted to the PBSE. Deviations in performance as
specified in the Contract or the design intent should be recorded, with a description and analysis
included.

A final performance evaluation of the Installations, where required in the Contract, shall be
included in the commissioning report.

3.5 General Commissioning Requirements

3.5.1 General Checking Procedure

Systems shall be properly commissioned to demonstrate that all the equipment delivers
the designed capacities and that air and water flow rates are balanced in accordance with
the design.

Since the air systems are usually completed ahead of the hydraulic systems,
commissioning of the air systems will commence earlier than the water systems.

Prior to any commissioning works, the completion of the associated builder’s work and
the building services installations of the air-conditioning and ventilation system shall be
checked to ensure that commissioning can proceed without obstruction.

(a) Checking Procedures on builder’s work:

(i) Plantrooms are completed and free of construction debris;

(ii) All plant room doors are fitted and lockable;

(iii) Permanent power supply of sufficient capacity is available and a security

access mechanism to all plant areas is in place to prevent unauthorised plant
switching;

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 (The normal security access system is one of "Permit to Work" arrangement
and procedure should be proposed in accordance with the guidelines on
"Permit to Work" issued by the Labour Department.);

(iv) All builder’s work and building services installations in association with air-
conditioning systems are satisfactorily completed;

(v) All glazing works are completed and all windows closed;

(vi) All curtain walls and the building fabric are completed and reasonably water-
tight;

(vii) All external doors, all stairs and lobbies, and toilet doors are completed and
securable;

(viii) All ceiling works are completed, unless specifically agreed, with the
exception of those access areas required to be left open for final adjustment
and testing of high level building services equipment during the
commissioning period.
All dust generating activities by other trades are finished and all areas are
thoroughly cleaned and sealed to prevent ingress dust from getting into the
ventilation and air-conditioning systems during operation; and

(ix) All builder’s work in association with pressurised and depressurised areas
are completed.

(b) Checking procedures:

(i) Air intake screens and louvres are unobstructed and clean;

(ii) Fan and other equipment chambers are clean and free of construction debris;

(iii) Floor gulleys and drainage traps are clear;

(iv) Fans are checked for impeller housing clearance and free of foreign objects;

(v) Heater batteries and cooler batteries are clean and fins are combed;

(vi) Condensate drain trays for cooling coil and drains for humidifier are
unblocked;

(vii) Dampers are clean;

(viii) Ducting and other airways are clean;

(ix) All electrical wiring circuits (power, lighting and controls) are completed, or
will be completed at the correct stage during the commissioning period;

(x) All electrical panels are commissioned and clean;

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(xi) Lighting systems are installed;

(xii) Permanent power supply is available at the electrical panels, and all the
connected equipment can be switched on;

(xiii) All equipment are checked for:

- Equipment rotation (fan kicked only);
- Lubrication;
- Belt tension;
- Motor fixings;
- Duct flexible connector correctly aligned;
- Keyway and setscrew tightness;
- Clean condition;
- Vibration isolation adjustment;
- Correct operation of VAV control gear;
- Correct overloads and amperages;
- Investigate and locate all stop-start, disconnect and circuit interruption
devices; and
- Inspect fan inlet and outlet to ensure satisfactory performance conditions
are provided.

(xiv) All outside air, return air and spill air dampers are operative;

(xv) All fire and volume control dampers are fitted and left in the fully open
position;

(xvi) The supply air systems are blown through;

(xvii) All VAV and CAV terminals are installed, together with grilles and diffusers;

(xviii) All manual control valves are open or pre-set, as required;

(xix) All strainers are cleaned;

(xx) All water systems are flushed, vented and filled and chemical cleaning
process is completed;

(xxi) Water treatment is completed;

(xxii) All filter media are installed;

(xxiii) Plant room access is restricted to authorised personnel only; and

(xxiv) All functional and safety devices are installed and operational.

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 3.5.2 Codes for Commissioning Procedure

All aspects of the commissioning procedure shall follow the recommendations in the
relevant Commissioning Codes or Guides published by the CIBSE, ASHRAE or the
relevant Code of Practices issued by the Government. It shall include, but not limited to:-

(a) Preliminary checks to ensure that all systems and system components are in a
satisfactory and safe condition before start-up;

(b) Preliminary adjustment and setting of all plant and equipment consistent with
eventual design performance;

(c) Energising and setting to work on all plants; and

(d) Final regulation and demonstration that the installation delivers the correct flow
rate of fluids and air at the conditions specified in the Contract Documents.

3.5.3 Progressive Commissioning

Progressive commissioning programme shall be arranged to suit the Contract completion

date or any other agreed date.

3.5.4 Specialist Commissioning

Any specialist plant or equipment such as Central Control and Monitoring System
(CCMS) shall be commissioned and tested by the skilled commissioning engineer and/or
technician of the specialist equipment manufacturer.

3.6 General Testing Requirements

3.6.1 Cleaning

Equipment or installation shall be kept clean internally and externally before testing and
commissioning.

(a) Water System

(i) The system (new or old) shall be flushed using an appropriate chemical
dispersant of a type and strength recommended by a reputable chemical
water treatment manufacturer and guaranteed in writing by that company as
suitable for the application in question.

(ii) The quality of cleaning water discharged shall comply with EPD
requirements or be treated if needed as stated in Sub-section 6 of the General
Specification.

(iii) The chemicals shall remain in the system for 48 hours, including a minimum
of 12 hours with the pumped circulation in operation, unless otherwise
recommended by the supplier with substantiated technical support accepted
by the Supervising Officer.

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 (iv) After chemical cleaning, the system shall be flushed and drained immediately.
The chemical water treatment specialist shall continue to take water samples
at all system low points until the water samples indicate iron and chemical
residues below the level of 1 ppm.

(v) The success or failure of the above operation will depend on a high-speed
rate of draining down which is entirely related to the size of the drain points
and the ability of air to enter the system from the top.

(vi) For high-speed draining down purposes, temporary 50 mm valved drain

outlets shall be provided on all points where the main pipework is 50 mm dia.
or over.

(vii) Adequate drainage nearby to discharge by large hose shall be ascertained in

order to ensure flooding of low level areas will not occur.

(viii) Subsequent to the flushing operations, the large drain down points shall be
reduced to 15 mm valves or cocks or the sizes as indicated in the Contract
Drawings.

(b) Air System

(i) Ductwork systems shall be cleaned by purging using the supply air fan, or
robot duct cleaning as recommended by the ductwork system cleaning
specialist. No fan shall be started until cleaning is commenced.

(ii) All submitted proposals for arrangements to ensure cleanliness of air and
water systems shall follow the recommendations in the relevant
Commissioning Codes or Guides published by the CIBSE, ASHRAE or the
relevant Code of Practice issued by the Government.

(c) Refrigerant system

The piping system shall be welded by flow of dry nitrogen through the tube or
welding method recommended by the Manufacturer’s before pressure test and
evacuation test.

The refrigerant pipework when completed shall be pressure tested by nitrogen gas
in two or more steps up to manufacturer recommendation.

3.6.2 Tests under Operating Conditions

Hydraulic and functional performance tests shall be included under operating conditions,
on the Installations to the entire satisfaction of the Supervising Officer.

3.6.3 Calibrated Equipment/ Instruments

3.6.3.1 The proposed list of testing equipment/ instruments to be used for T&C (Annex
III) must be agreed with the PBSE prior to commissioning the work.

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 3.6.3.2 The suggested items of equipment/ instruments & accessories necessary to
comply with the T&C objectives are not limited to the following:

(a) sound level meter to BS EN 61672-1 [2013] with built-in octave filter and
sound level calibrator, Microphone Sensitivity: 2dB, Resolution: 0.1dB;

(b) electronic manometer;

(c) a tachometer, which should be the high quality, direct contact, self-timing
type;

(d) multi-tester;

(e) digital vane type anemometer;

(f) digital hot wire anemometer;

(g) refrigerant leakage tester;

(h) digital thermometers/humidity meter; and

(i) dial gauges.

4. Testing and Commissioning Procedures

4.1 General Test and Inspection Requirements

4.1.1 Work Tests

(a) Work tests shall be carried out in accordance with the type normally associated
with the specified item of equipment and to the standards as laid down in the
Contract.

(b) Static pressure tests shall be carried out on items such as pressure vessels, water
coils, plate type heat exchangers, radiator and convector elements, and all items of
plant or equipment, as laid down in the Specification and Drawings.

(c) Dynamic rotation tests shall be carried out on items such as fan impellers and drives,
compressor, pump impellers and drives. Tests shall be conducted through the
entire rotational speed range up to a maximum of 150% design operating speed if
such provisions have been made in the Contract. When items of plant are
purchased ex-stock, manufacturer’s test certificate will suffice.

(d) Rotational test on electric motors will not be carried out if the equipment is
constructed to the related content of IEC standard, or any other approved standards.

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4.1.2 Weld in Piped Services

(a) An accredited laboratory shall be engaged to perform welding inspection, non-

destructive tests and result analysis following the sample size stated below:

Welded joints with pipe diameter Sample size

≤ 300 mm 5%
≥ 350 mm 100%

Attention shall be drawn to the magnitude of this task, the constraints of the water
mains, and the time frame within which testing must be carried out.

(b) PBSE reserves the right, at an early construction stage, to carry out destructive
inspection for a randomly selected sample of up to 2% of the total welded joints.
Should any of the above welds prove faulty in materials or workmanship, a further
2% of the welded joints may be ordered for destructive inspection. If any of the
additional welds inspected still found unsatisfactory, PBSE may order any number
of welds to be removed. The works shall include the removal and repair of the
unsatisfactory welds.

(c) The PBSE may conduct visual inspection for at least 2 welds done by each welder.
The welds for inspection shall be randomly selected by the PBSE. Each welder
shall be allocated an identification number. Each weld shall be stamped or marked
with the appropriate identification number to identify the welder. Repair of welds
if any defects are found.

(d) The following test standards, or any standards as deemed appropriate by the PBSE,
shall be followed:-

Visual Inspection BS EN ISO 17637:2016 or equivalent

Magnetic Particle Testing BS EN ISO 17638:2016 or equivalent
Ultrasonic Testing BS EN ISO 17640:2018 or equivalent

4.1.3 Pressure Testing of Refrigerant Piped Services

4.1.3.1 Before carrying out pressure test, spotted open-up inspection for joints shall be
required to inspect the internal finishing after brazing to ensure the quality of
the workmanship.

4.1.3.2 Pressure Testing of Refrigerant Piped Services

Refrigerant systems and circuits shall be pressure tested with nitrogen gas to test
pressures as indicated below: -

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 High Side Low Side
Refrigerant Test Pressure Test Pressure
kPa kPa

R 134a (Air-cooled) 2080 1190

R 134a (Water-cooled) 1270 880
Others * *

* In performing pressure tests for refrigerant systems and circuits containing

blend refrigerants (e.g. R407C or R410a etc.), manufacturer’s recommended
procedures and test pressures shall be followed.

4.1.3.3 Pressure Testing of Chilled Water Piped Services

The method of recording the pressure tests shall be all as indicated in Clauses
4.1.6.6.5 and 4.1.6.6.6.

(a) Prior to application of insulation and painting to the welded pipe joints
and cleaned pipe surfaces, all water pipework shall be hydraulically
pressure tested to 1.5 times the maximum working pressure of the system
for not less than 2 hours or otherwise specified, without leakage or loss of
pressure. The maximum working pressure shall be deemed to be the static
head plus the total pump head. The minimum test pressure for water pipe
is 1,000 kPa.

(b) The pressure test shall be carried out in different sections of the hydraulic
systems in such zoning approved by the PBSE.

(c) Where any plant cannot withstand the maximum pipework test pressure,
it shall be isolated during the pipework tests, and then the isolated plant
shall be tested at its test pressure.

(d) All plugs, caps, tees and drain fittings shall be provided to enable the
pressure tests to be carried out.

(e) Before hydraulic pressure tests are carried out, all safety valves, gauges,
etc., shall be effectively isolated or removed. For all safety equipment,
these shall be effectively tested at their design working pressure during
commissioning of the Installations.

(f) Tests on lengths of pipe or portions of systems shall be applied by filling

the section to be tested with water up to its testing pressure.

(g) The pressurised section shall then be left fully isolated without further
strokes of the pump and all joints must remain watertight for a period of
at least 2 hours. As to whether or not the section is sound shall be
governed by the rate at which the pressure falls. The PBSE acceptable
percentage of pressure falls shall be agreed with the SOR.

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 (h) Any fault discovered during such tests shall be at once remedied and the
test reapplied until the section under test is considered sound. Remedial
work shall conform to all the requirements of the Specification for
material and standards of workmanship.

(i) Upon completion of the test, the water shall be released and drained away
as rapidly as possible, the section being then thoroughly sluiced through
to ensure the removal of as much dirt and dross as possible before being
refilled and put into service.

4.1.4 Air Leakage Test for Ductwork

4.1.4.1 All ductwork shall be tested for air leakage in accordance with Clause 6.1.2 of
the General Specification.

4.1.4.2 The joints on ductwork shall be tested for air leakage. All openings such as fan
outlets, grilles, access panels, test holes, etc. shall be sealed before test:

(a) Prior to application of insulation and painting, all installed ductwork,

including exhaust, smoke extraction, air-conditioning, ventilation, etc.,
shall be tested to the requirements of the General Specification. The
method of air leakage test shall follow the HVCA standard DW/series or
the “Low Pressure Duct Construction Standards” and “High Pressure
Duct Construction Standards” issued by the SMACNA of U.S.A. as
directed by the PBSE. Air ducts shall be leakage tested and any defects
shall be rectified before applying insulation and commissioning.

(b) For preliminary and visual test, the method will include using chemical
“white” smoke generator. All openings in the ductwork shall be properly
sealed followed by the introduction of smoke.

4.1.5 General Electrical Checks

Prior to the initial running of any electrically driven pump, fan, valve, electric heater or
automatically advancing filter, the following procedures should be adopted.

4.1.5.1 With all electrical supplies isolated, check:

(a) the local isolation of motor and control circuits;

(b) that there are no unshrouded live components within the panels;

(c) that the panels and switchgears and heaters are clean;

(d) that the motor and surrounding areas are clean and dry;

(e) that the transit packing has been removed from contactors and other
equipment;

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 (f) that there is no mechanical damage to switchgears and heaters and that
thermostats are of a suitable range to operate at ambient temperature;

(g) that all mechanical checks on the pump, fan, motor, valve or automatic
filter, where appropriate, are completed;

(h) that all connections are tight on busbars and wirings;

(i) that the internal links on the starter are correct;

(j) that all power and control wirings have been completed in detail to the
circuit diagram, paying special attention to circuit for star-delta connected
or specially wound motors;

(k) that the fuse and circuit breaker ratings are correct;

(l) that the starter overloads are set correctly in relation to the motor name-
plate full load current;

(m) that the dashpots are charged with the correct fluid and the time
adjustments and levels are identical;

(n) that insulation tests on the motor have been performed satisfactorily;

(o) that the adjustable thermal cut-outs are set correctly (check manufacturers’
test certificates);

(p) that all cover plates are fitted;

(q) The power metering and monitoring devices are installed correctly, if any;
and

(r) The energy metering and monitoring devices are installed correctly, if any.

4.1.5.2 With the electrical supply available, check:

(a) check that the declared voltage range is available on all supply phases;

(b) where motor powers are substantial or reduced voltage starting or

complex interlocks are involved:

- the control circuit logic and the starter operation shall be tested before
the motor is rotated;

- the supply should first be isolated; then by the withdrawal of 2 power

fuses or disconnection of cables followed by reinstatement of supply
to the control circuit alone, the control circuit shall be activated and
starter operation observed; and

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 - adjust the timer, check for proper operation of all contactors, relays and
interlocks. Finally open the isolators, reinstate power connections and
close the isolators, where appropriate.

(c) where small motors have direct-on-line starting and simple control
circuits, the starter operation, etc., should be checked when first starting
the motor; and

(d) never energise electronic valve motors until the checks specified have
been completed.

4.1.6 Pre-commissioning Checks of Water Distribution System

4.1.6.1 System Cleanliness

Irrespective of the precautions taken during the construction stage to keep the
internal surfaces of pipework clean, the following procedures shall be used to
clean the system.

4.1.6.1.1 Flushing

(a) divide the pipework system into self-draining sections so that

the maximum possible flushing rate is achieved;

(b) isolate or bypass items which are particularly sensitive to dirt

such as pumps, chillers, small bore coils and tubes, including
induction and other room unit coils and spray nozzles. Washers,
cooling tower basins, feed and other tanks which may have
accumulated with deposits during manufacturing or installation
should also be isolated and flushed independently; and

(c) where make-up or feed tanks are used for flushing, ensure that
the maximum possible pressure is sustained on the system
during the flushing process. This may necessitate the provision
of a temporary parallel feed of mains water into the tank where
the ball valve has limited capacity. This T&C Procedure
assumes that the connection of the section from the tank is at a
high point in the section being flushed. The flushing water
wherever appropriate, shall be recirculated with suitable
filtration to reduce the water demand and wastewater discharge.

(d) Ensure:

(i) that flushing is carried out from the upper to the lower
sections of a multi-section system, flushing with the
lowest point; initial flushing should always be from small
bore to large bore pipe. Particular care is required on
reverse return systems and systems with roof-top chiller or
boiler plant;

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 (ii) that the large bore outlet is not opened until the section
being flushed is fully primed;

(iii) that the maximum possible flow rates are used; and

(iv) that flushing continues until the outflow runs clear.

4.1.6.1.2 Cleaning by Forced Circulation

Where facilities exist, cleaning of systems can be achieved by

circulation of the medium in order to collect dirt at filters or other
selected points in the system. Where circulation is achieved by the
use of a pump, this action shall be deferred until the pump has been
set to work in accordance with Clause 4.2.1.4. The circulating
velocity shall be 1.5 times of normal water velocity in pipe.

4.1.6.1.3 Chemical Cleaning & Corrosion Inhibiting

Chemical Cleaning, if required, shall be carried out as specified by

the specialist. Corrosion inhibiting, where specified, should be
carried out after flushing.

4.1.6.2 State of System

Check:

(a) that where special valve packing is required, e.g. grease in medium or high
temperature system, this shall be in accordance with manufacturer’s
instructions;

(b) that pressure tests have been completed throughout;

(c) that the system has been cleaned in accordance with Clause 4.1.6.1.1;

(d) that permanent water connections have been made; and

(e) that water treatment is available if specified.

4.1.6.3 Check of System before Filling

Check:

(a) that probes, pockets, pressure gauges, siphons, orifice plates and taps, and
air vents are installed;

(b) that drains and overflows are connected and free from blockage;

(c) that connections to heating and cooling coils and all other heat exchangers
are correct in relation to the design water flow direction;

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 (d) that control and non-return valves are installed the right way round;

(e) that relief valves are installed as specified and are free to operate;

(f) that relief valve outlets are piped away to suitable drain points;

(g) the expansion devices for alignment and freedom from obstruction;

(h) the presence of special pump priming devices where specified;

(i) that the strainer meshes are of the correct grade and material;

(j) that the changeover devices for duplex strainers are operative and that
there are means of isolation for single strainers;

(k) that washers, tanks, nozzles and filters are clean;

(l) that tank covers are provided where specified;

(m) that drain cocks are closed and other valves are left open or closed
according to the plan for filling;

(n) that the feed connection is in its correct location; and

(o) that all pipework and fittings are adequately supported, guided and/or
anchored where applicable.

4.1.6.4 Mechanical Checks

4.1.6.4.1 Pumps

Check:

(a) the external cleanliness of the pumps, remove and clean and
replace all strainers;

(b) that the flow direction is correct;

(c) that all components, bolts, fixings, tie bars etc., are secured;

(d) that the impellers are free to rotate;

(e) the level and plumb of pump and motor shaft and slide rails;
(direct drive pumps require particular attention in this respect);

(f) the anti-vibration mountings for correct deflection;

(g) that the correct drivers are fitted;

(h) that the pipework imposes no strain at the pump connections;

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 (i) the securing and alignment of pulleys and couplings;

(j) the belt tension and match;

(k) the cleanliness of the bearings;

(l) that the lubricant is fresh and of the correct grade;

(m) that the coolant is available at the bearings when specified.

(n) that glands are correctly packed and the gland nuts are finger-
tight only, pending adjustment to correct drip rate after start-up;
and

(o) that drive guards are fitted and the access for speed
measurement is provided.

4.1.6.4.2 Motorised Valves and Float Switches

Check:

(a) that the valves are installed the correct way round;

(b) that the valve spindles are free to move;

(c) for freedom from excessive looseness;

(d) the fit of pins;

(e) the rigidity of the mountings;

(f) the stiffness of the linkage members;

(g) the tightness of locking devices; and

(h) the bearing lubrication.

4.1.6.4.3 Cooling Towers

Check:

(a) that the water-circulating system serving the tower is

thoroughly cleaned of all direct and foreign matters;

(b) that interior filling of cooling tower is clean and free of foreign
materials such as scale, algae, or tar;

(c) that the cooling tower fans are free to rotate and the tower basin
is clean; and

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 (d) that the water-circulating pumps are ready for test.

4.1.6.5 System Filling

4.1.6.5.1 All water tanks shall, after erection, be filled with water and shall
remain filled for at least 24 hours during which all joints shall be
carefully examined. Any defect shall be rectified immediately and
the test repeated.

4.1.6.5.2 Before finally charging, the water systems shall be thoroughly

flushed and all strainers, filters, etc. cleaned or replaced.

4.1.6.5.3 Charge the system with water by filling from the bottom upwards
forcing the air to high points – for venting to atmosphere. Careful
consideration should be given to the stage of valves and automatic
air vents before and during filling to avoid air-locks and excessive
spillage. Take care not to exceed the working pressure of the
system when filling from a high pressure source. When the whole
system is filled, disconnect the filling source, open the permanent
supply and adjust the tank levels.

4.1.6.6 Hydraulic testing for water distribution pipe work systems

4.1.6.6.1 General

All water distribution pipework systems shall be hydraulically

tested in sections as installation work progresses.

4.1.6.6.2 Test Pressure

The hydraulic test pressure shall be 1.5 times the maximum

working pressure of the system. The maximum working pressure
shall be deemed to be the status head plus the total pump head. The
minimum test pressure for water pipe is 1,000 kPa.

4.1.6.6.3 Precautions

Before hydraulic tests are carried out, all safety valves, gauges, etc.
shall be effectively isolated or removed. These safety equipment
shall be effectively tested at their design working pressure during
commissioning of the Installations.

4.1.6.6.4 Method of Testing

For a satisfactory and acceptable test, the pressure shall be

maintained for a period of 2 hours or as otherwise stated in the
Particular Specification, without loss of pressure after all weak
joints, defective fittings and pipes disclosed by the initial
application of the test are rectified. During the final testing period

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 the Supervising Officer or his Representative shall be invited to
witness the tests. All sections of the work under test shall be
accessible for inspection and selected welds shall be hammer tested.

4.1.6.6.5 Hydraulic Test Certificates

Certificates of all hydraulic tests made on the Site shall be

forwarded to the Supervising Officer for approval and such
approval shall be obtained before any thermal insulation is applied.
A separate and duplicated set of the installation/shop drawings shall
be provided for the purpose of keeping accurate records of site tests.
One copy will be kept by the Supervising Officer or his
Representative on the Site and the other retained.

4.1.6.6.6 Details on Test Certificate

All test certificates shall be signed by the contractor varying out the
T&C and by the Supervising Officer or his Representative who has
witnessed the test. All test certificates shall contain the following
particulars: -

- Date of test
- Apparatus or section under test
- Makers number (if any)
- Nature, duration and conditions of test
- Result of test
- Name of contractor’s representative (in block letter) in charge
of test
- Name of Supervising Officer or his Representative at witness
the test

A blank form of test certificate shall be submitted for SOR’s

approval prior to carrying out the actual test on the Site.

4.1.7 Pre-commissioning Checks of Air Distribution System

4.1.7.1 System Cleanliness

4.1.7.1.1 During Construction

Dust and debris should be prevented from entering the duct system
as far as possible and the system inspected and cleaned as part of
pre-commissioning steps.

4.1.7.1.2 During T&C, the following procedures should be adopted:-

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 (a) ductwork systems shall be cleaned by purging using the supply
air fan, or robot duct cleaning as recommended by the ductwork
system cleaning specialist if employed;

(b) temporary filter media shall be used where building work is still
in progress during T&C, and replaced with clean filters for final
measurements of flow rates;

(c) computer room plants, in particular where under floor air

distribution systems are used, should not be run before the
rooms have been properly cleaned;

(d) extraction systems should not be run whilst building work is in

progress and dirt is present; and

(e) where a specialist ductwork cleaning company is employed,

system commissioning should not commence until cleanliness
has been inspected and certified.

4.1.7.1.3 Prior to the fitting of air cleaning equipment, ensure that the
environment is clean and then proceed to check the following for
cleanliness:

(a) air intake screens and louvres;

(b) fan and other equipment chambers;

(c) f1oor galley and all drainage traps;

(d) fan internals;

(e) heater and cooler batteries;

(f) cooling coil condensate trays;

(g) washer tanks;

(h) humidifiers;

(i) eliminators;

(j) dampers and linkages;

(k) ducting and other airways;

(l) sensing elements; and

(m) terminal units.

4.1.7.2 Air Regulating Devices and Other Components within Airways

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 Check:

(a) that turning vanes, thermal insulation, acoustic linings, heating/cooling

battery fins and sensing elements have been fitted without damage;

(b) that heater and cooler batteries, humidifiers, filters, silencers, fire dampers,
sail switches, volume control dampers etc., are installed correctly in relation
to air flow;

(c) the damper free-movement, clearances seating pinning to damper spindles,

position of blades with respect to quadrant indication, relative positions of
blades in multi-leaf dampers;

(d) the control linkages on motorised dampers for alignment, rigidity,

lubrication and free movement without slackness;

(e) that dampers throughout the system are secured in open/close position, as
desired, with damper actuators locked;

(f) the free movement of fire dampers together with the location of, access to
fit the of fusible link assembly and the correct rating of fusible link; all fire
dampers are finally secured in open position;

(g) that all adjustable louvers are set without deflection, i.e. normal to face of
grille. Adjustable cones on diffusers are set either all in the fully up or all in
the fully down position; and

(h) that test holes are provided at strategic points for the measurement of branch
and total air volume flow.

4.1.7.3 Visual Checks for Air Tightness

Check:

(a) the builder's work for ducts and shafts are completed with air sealed;

(b) access doors to plant equipment are sealed around the whole periphery;

(c) ductwork joints, including flexible couplings are air tight;

(d) inspection covers are fitted;

(e) drainage water seals are intact; and

(f) plugs or covers for test holes are fitted.

4.1.7.4 Mechanical Checks

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4.1.7.4.1 Fans

The following should be checked:

(a) internal and external cleanliness of fans;

(b) all components, bolts, fixing, etc. are secured;

(c) impeller secured, free to rotate, of correct handing and correct

clearances;

(d) axial-flow-type fans installed for correct air flow direction and,
where compounded, in correct order;

(e) level and plumb of fan and motor shaft and slide rails;

(f) anti-vibration mountings for correct deflection and the removal

of transit bolts and packing materials;

(g) the static balance;

(h) correct drive is fitted;

(i) securing and alignment of pulleys and couplings;

(j) belt tension and match;

(k) cleanliness of the bearings;

(l) lubricant is fresh and of the correct grade;

(m) coolant is available at bearings when specified;

(n) drive guards fitted and access for speed measurement provided;

(o) satisfactory operation of inlet guide vanes over full range of

movement; and

(p) fan casings to be earthed are correctly and soundly bonded.

4.1.7.4.2 Automatic Fabric Roll Filter

(a) Check level mounting;

(b) Check alignment, clearances and free movement of spools,

drives and limit switches; and

(c) Check lubrication of spool drive motor, gearbox and spool

bearings.

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4.1.7.5 Automatic Recleanable High Voltage Electrostatic Filter

4.1.7.5.1 Before approaching the filter, establish:

(a) what isolators must be opened and fuses withdrawn to

completely disconnect the filter plant from the low voltage
supply. Beware of interlocking circuits which are energised
from elsewhere and cannot be isolated locally to the filter;

(b) the arrangements for preventing access to any high voltage

component until it is earthed; and

(c) adequate labels for instructions /precautions /warnings to be

displayed at the entrance access to the filter.

4.1.7.5.2 With all low voltage supplies isolated, check:

(a) the local isolation of all low voltage circuits;

(b) that switchgears are clean and undamaged;

(c) that the transit packing has been removed from contactors and
other equipment;

(d) that all wiring connections are tight;

(e) that all wirings have been completed according to circuit

diagram; and

(f) that all cover plates are fitted.

4.1.7.5.3 High Voltage Electrical System

Only Registered Electrical Worker(s) with recognised training from

the filter supplier on maintenance of high tension portion of the
equipment should be allowed to enter the filter casing; the
responsible person/team should have the interlock key which
controls the opening of the access door to the section of filter which
he is entering or a fuse link or other item to prevent the filter being
energised; a second person should be stationed outside the door as
an observer and he will normally also be in control of the operation
of the power pack from this position. Before working on any filter
system, any residual High Tension (H.T.) charge must be
discharged using an earthing tool with insulated handle. Where the
power pack is remote from the filter, a shorting bar should be
securely fixed between earth and each H.T. feed to the filter.

The inbuilt features which prevent access to high voltage

components shall, without fail, shall be checked as follows:

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 (a) no access to filter section via inlet or outlet ductwork
connections. Where equipment is being used as a barrier,
beware of items which are demountable without tools such as
pre-filter cells. Such items should always be supplemented by
safety screens as should dampers with blade width exceeding
100 mm;

(b) any mechanical interlock correctly links H.T. circuits to earth

before access door can be opened and simultaneously de-
energises the H.T. primary circuit to prevent overload caused
by the earth link;

(c) no duplicate keys on the Site for the mechanical interlock

system;

(d) any safety switches fitted to access doors break the Low
Tension (L.T.) interlock circuit and destroy.

(e) H.T. potential before the door is open wide enough to allow an
arm or leg to reach a H.T. component within the filter casing;
also check that switches are held positively open to prevent
manual closure or closure by spring failure whilst access door
is open;

(f) check that H.T. potentials are reduced to a safe level within the
time it takes to open the door and reaches any H.T. component.
This will be of particular importance when door safety switches
do not merely augment a mechanical interlock earthing system
but are also the sole safety interlock, the value of bleed resistors
connected across each capacitor holding H.T. charge will be
critical; and

(g) a solid copper or aluminium bond connects the H.T. power

pack and filter frame to the building’s main earthing system.

4.1.7.5.4 Cleanliness and Mechanical Condition

With all electrical supplies isolated, H.T. circuits earthed and

precautions for staff adopted in accordance with Clause.4.1.7.5.3.
Check:

(a) for unsafe ladders, walkways or dangerous projections;

(b) the internal cleanliness of casing, components, including

insulators and ductwork connections;

(c) that all components are in place and correctly connected; no

damage or distortion to ioniser and collector sections; no
obvious foreign items in the filter cells; ioniser wires of the
correct diameter and type to be provided and to be correctly

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 tensioned; displacement of these wires from the centres
between neutral electrodes should not exceed 5% of the
distance between the neutral electrodes; no distortion of
collector plates and gaps between plates shall not vary by more
than 10%;

(d) that the wash water and f1uid coating systems are completed;
reservoir is charged with correct f1uid and drainage systems are
completed and free from blockage; connection is provided for
manual wash; and

(e) that fabric alter sections are loaded with media; if automatic
advancing then checks listed in Clause.4.1.7.4.2 shall be
carried out.

4.1.7.5.5 Interlock Sequence and Alarm Systems

With electrical supply available check:

(a) that the filter interlock sequence is correct; and

(b) that all safety and failure alarm systems and function correctly.

4.2 Water, Air and Refrigeration Systems

4.2.1 Water Distribution System

4.2.1.1 General

The system as detailed in Annex V Fig.V includes only those plant items
necessary for clarification of the regulation method described. The procedure
given here may have to be adapted to suit the particular arrangement.

The method of manual regulation detailed below is applicable to the following

systems:

(a) constant volume, variable temperature primary circuits;

(b) constant volume, variable temperature secondary circuits; and

(c) the maximum flow situation in a variable volume system designed

without diversity.

4.2.1.2 Procedures

This section defines the procedures to be carried out in order to achieve a water
distribution system, which works satisfactorily and is regulated appropriately.
These works should normally be carried out with the medium at ambient
temperature and therefore there is no need for heated or chilled water to be

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 available. It is unwise, in any event, to conduct the commissioning of heating
or refrigeration plant (particular if of low thermal capacity) before design
primary circulation flow rates have been established and any likelihood of
primary flow rate variations due to modulation of unbalanced secondary
systems have been eliminated.

4.2.1.3 Checks Prior to Pump Start-Up

(a) check that all normally open isolating and regulating valves are fully open
and that all normally close valves are closed. In the case of thermostatic
valves it is essential that provision for fully opening of the valves is
available. Most electric motorised valves have either provision for
manual override of normal control using a switch on the main control box
or a facility to position the valves seat mechanically;

(b) check that the direction signs of all valves are the same as the water flow
direction;

(c) check that the horizontal or vertical alignment of all flexible joints is
within the tolerances recommended by manufacturers’ installation
guideline;

(d) open all control valves to full flow to heat exchangers of branch circuits;
and

(e) fully open the return and close the flow valve on the pump, close valves
on standby pump. Closing the flow valve on the duty pump will limit the
initial starting current, which is usually excessive at the first time a pump
is running due to bearing stiffness.

4.2.1.4 Initial Running of Electrically Driven Centrifugal Pump Set

4.2.1.4.1 Initial start

On activating the motor starter at initial start, check that:

(a) the direction and speed of rotation of the motor shaft are correct;

(b) the motor, pump and drive are free from vibration and undue
noise;

(c) the sequence timing adjustment of star-delta starters, auto-

transformer starters, etc. is set in accordance to motor starting
current;

(d) the motor running current on all phases are balanced and do not
exceed motor nameplate rating The flow valve can be opened
at this point to raise the running current to say 50 per cent of the
name-plate full load current;

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 (e) there is no sparking at the commutator or slip rings for d.c. or
slip ring motors;

(f) there is no overheating of the motor (see BS EN 60947-4-

1:2019 and BS EN 60034-3:2020);

(g) there is no seepage of lubricant from the housing;

(h) the water flow to water-cooled bearings is sufficient;

(i) the ventilation systems of air-cooled motors are operating

correctly; and

(j) the motor running current are correctly matching with the speed
as specified by manufacturer’s pump data sheet on multi-speed
motors.

4.2.1.4.2 Initial run

(a) ensure that a light load should be sustained until the

commissioning engineer is satisfied from the checks listed in
Clause 4.2.1.4.1 and from motor insulation test readings that
further load may be applied. Repetitive starting of the motor
should be avoided to prevent over-stressing of the fuses,
switchgear and motor;

(b) gradually open the discharge valve from closed position until
the motor current reaches either the design value or the motor
full load current, whichever is the lower;

(c) check the pump pressure developed by means of the pump

altitude gauges against the design pressure. If excessive
pressure is developed at this stage, the cause should be
investigated and rectified; and

(d) adjust the discharge valve so that the flow as determined

roughly from the pump characteristic is between 100 and 110
per cent of the design value.

Note that the motor full load current is not exceeded.

4.2.1.4.3 Running-in period

(a) the pump should be run in accordance with the manufacturer’s

recommendations and should be under fairly continuous
observation. It should not be left running outside normal
working hours unless attended;

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 (b) ensure that a means of temporarily bypassing the terminal units
liable to choking be completed in advance as a parallel circuit
of each coil for AHUs/Chillers;

(c) check that the bearings and motor temperature remain steady,
that no noise or vibration develops and that no bolts or fixing
works is loose;

(d) close the valves to the AHUs/Chillers and other vulnerable

units to avoid blockage at the coils of terminal units;

(e) vent all high points from time to time. When possible the
medium should be heated to maximum permissible levels to
assist in removing air from the heating system;

(f) adjust the gland nuts of the pump glands to give the correct drip
rate; (not applicable to mechanical seals.) and

(g) after 8 hours of running, check all strainers. If these are clean,
regulation can commence. Otherwise, clean the strainers and
run again for at least 8 hours and then re-check.

(Remark: Observations afterwards may then become less

frequent, but it is advisable, while commissioning other parts of
the system later, to check the pump from time to time.)

4.2.1.4.4 Standby Pump

(a) on installations with a standby pump, the standby pump should

also be commissioned;

(b) this pump can be checked against the other duty pump. In the
unlikely event of failure of the duty pump, commissioning can
continue using standby pump; and

(c) carry out a full diagnosis of the reasons for the failure of the
duty pump before energising the standby pump to ensure that
any contributory causes are remedied.

4.2.1.4.5 Secondary Pump

(a) in systems with primary and secondary pumps, starting

procedures for the primary pumps should be dealt with first;

(b) isolate the secondary system during this period to prevent any
accumulated deposits not removed during the flushing process
being carried over into the secondary services;

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 (c) after the final check of strainers referred to in Clause 4.2.1.4.3,
the secondary system can be opened up and the starting
procedure for the secondary pumps initiated; and

(d) only after a final check of both primary and secondary strainers
should actual regulation commence.

4.2.1.5 Regulation of Water Flow

4.2.1.5.1 Principles of water flow rate measurement & registration

(a) the installation location of the devices shall follow the

manufacturers’ recommendation in order to obtain accurate
flow measurement results. The devices may be a venturi-meter,
an orifice plate, a control valve with known calibrated flow
characteristics, a calibrated regulation valve, electromagnetic
flow sensors or any device with a constant flow coefficient and
calibration chart;

(b) referring to Fig. 4.2.1.5.1, the pressure drop across the device is
proportional to the square of the water flow rate. Hence the
actual-to-design water flow is given by;

Q1 P1

Q2 P2
where P1 = Actual pressure drop in kPa
P2 = Design pressure drop in kPa
Q 1 = Actual water flow rate in m3/s
Q 2 = Design water flow rate in m3/s

Pi Po

ΔP = Pi - Po

DEVICE

Fig. 4.2.1.5.1 Pressure drop across a device

(c) water flow regulation is achieved by varying the water flow

across the device followed by measuring the pressure drop
across it until the actual-to-design flow rate is within the
tolerance acceptable by the PBSE; and

(d) recommended tolerances for flow rate balancing in chilled

water systems should not exceed 0% to (+)10% with the
exception of terminal units where flow rate is small (<0.1 l/s).
For small flow rates, the tolerances for index unit should be

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 within (-)7.5% to (+)15% and for other circuits, they should
preferably be within (-)5% to (+)5%. The pressure differential
signal of a suitable device should be between 1 kPa and 10 kPa.

4.2.1.5.2 Illustration of Balancing Procedures

For details, refer to Reference no. 3 of Annex V.

4.2.1.6 Automatic Water Balancing (AWB)

If so specified in the Particular Specification or the Contract Drawings, AWB

system shall be adopted. Balancing shall be carried out to meet specified water
flow with tolerance as recommended in Clause 4.2.1.5.1. All necessary
balancing valves with actuators and Direct Digital Controllers (DDCs), flow
measuring devices and all interface necessary equipment for CCMS connection
shall be provided in order to achieve automatic water balancing.

The AWB system shall perform 3 main functions, namely, (1) water balancing
for system commissioning, (2) monitoring of the flow rates and (3) re-balancing
of water due to change of load profile. The AWB shall be so designed to achieve
a fully automatic control in performing the water balancing. No on-field
adjustment, measurement and testing during the water balancing shall be
required. The only step is to input the design flow rates to the CCMS and
observe the change from the monitor and revise input data if any.

4.2.1.6.1 Method of Balancing

(a) A computer programme with a compact algorithm for water

system balancing shall be provided. Such algorithm completed
with water circuit diagram and location of balancing valves
shall be submitted within 3 months after the commencement of
the Contract for approval.

(b) The algorithm shall be designed to achieve the water balancing

using the logic of the procedure as outlined in the General
Specification and Clause. 4.2.1.5. After completion of the pre-
water balancing procedure as specified in Clause 4.1.6, the
AWB system shall balance all water circuits by operating the
motorised balancing valves through the CCMS.

4.2.1.6.2 Hardware and software

Any necessary hardware and software such as DDC controllers,

sensing devices, operating software and self-diagnostic devices of
the AWB are deemed to be included in the Contract. The AWB is
an integral part of the CCMS and any standards or requirement not
specified in this section shall refer to the relevant Sections and
Clauses or CCMS specified in the Contract. The communication
protocol shall comply with the ASHRAE’s BACnet standards, or

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 relevant international standards as stated in Clause 6.2.5.3 of the
General Specification.

4.2.1.6.3 Pre-commissioning Consideration

The motorised modulating control valve shall be appropriately

selected and design the algorithm in achieving a stable AWB
system. Any additional items and/or modification works required
for achieving a stable system shall be provided and installed at no
additional cost.

The AWB system shall balance all water circuit as specified in the
Particular Specification or the Contract Drawings to a steady
balanced state. The CCMS system shall coordinate with the control
of all other system such as chiller plant to complete the balancing.
The input design flow data and balancing point of each motorised
balancing valve shall be logged and password protected in the
CCMS. Power shall not be required to maintain motorised
modulating control valves at the balancing point.

Only the person with authority shall change the flow rates and re-
balance the water circuit. The password shall be at least 64-bit
encrypted and stored in the CCMS. The flow rate and temperature
at each motorised balancing valve shall be displayed with colour
graphic layout diagram on the computer monitor and updated at
intervals agreed by PBSE.

The colour graphic layout diagram shall show the location and
number of motorised balancing valves on the background of the
schematic water flow diagram with floor level and room name.
The CCMS shall generate and print out, if requested, tables showing
the actual flow rates, design flow rates and the corresponding
percentage difference of the water passing through motorised
modulating control valves against their location and floor level. The
difference between the input design flow rates and actual flow rates
shall be in accordance with Clause 4.2.1.5.1.

The algorithm and corresponding colour graphic layout diagram

shall be easily updated for any modification of water circuit.

4.2.1.6.4 Demonstration

Dummy testing shall be performed by inputting at least 20 sets of

water flow rates or as specified in the Particular Specification to test
the stability of the AWB system and the timing required for
adjusting. The values of the dummy testing water flow rates shall
be submitted for approval at least 2 weeks before T&C. Any
electronic measuring equipment for use with automatic water
balancing shall be provided and permanently installed at designated
location at no additional cost.

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 4.2.1.7 Balancing Water Circuits

4.2.1.7.1 Method of Balancing

All circuits shall be balanced by operating the regulation valves

provided. Fluid flow through the cooling and heating coils shall be
adjusted to provide the design air temperature drop or rise.

4.2.1.7.2 CIBSE Commissioning Code 'W'

In general, the system shall be balanced using the procedure as

outlined in the CIBSE Commissioning Code "W" - Water
Distribution Systems.

4.2.2 Air Distribution System

4.2.2.1 Precautions Against Airborne Dirt

The system should have been cleaned internally in accordance with Clause
4.1.7.1 but further precautions shall be taken before starting the fans for the first
time:

(a) disconnect final flexible connections to terminal units such as induction

units and blender boxes;

(b) preferably remove all high efficiency terminal filters;

(c) check that suitable temporary protection has been provided for anything
within the spaces served by the system which could be damaged by initial
discharge of dust from supply outlets at first starting;

(d) install main inlet filter cells, properly coated as necessary, to avoid
introducing additional dirt into the ductwork system after start-up;

(e) check seating of cells for air tightness; and

(f) commission automatic fabric and electrostatic filters in accordance with

Clauses 4.2.2.2 and 4.2.2.3.

4.2.2.2 Automatic Fabric Roll Filter

The scope of the test is to verify effective performance of the automatic fabric
roll filter in accordance with the manufacturer’s technical information and/or
the stated requirements in the Particular Specification. The general test
procedures for the unit is:

(a) preliminary checks in accordance with Clause 4.1.7.4.2 shall have been
completed;

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 (b) install filter media in accordance with manufacturer’s instructions;

(c) energise the filter without air flow;

(d) with the differential pressure control device looped out, close the isolator
controlling supply to filter and test operation by the manual advance switch;

(e) leave the filter on manual advance until the correct total air flow through
the filter is established;

(f) the correct total air flow through the filter shall be established as part of the
procedure for regulation of air flow (see Clause 4.2.2.5 below);

(g) commission the differential pressure controller after establishment of

correct air flow as described in (see Reference no. 4 of Annex V) for which
the clean filter condition will normally have been manually selected;

(h) an inclined manometer with pressure sampling points adjacent to the filter
fabric will be used to measure the prevailing static pressure drop across the
clean filter and this will be recorded;

(i) the filter may then be progressively blanked off (e.g. with cardboard) until
the manometer indicates the design ‘dirty filter’ pressure drop;

(j) the differential pressure control will be adjusted to start advancing the filter
at this ‘dirty filter’ pressure drop and to stop advancing the filter at the
design clean filter pressure drop; and

(k) Filter performance shall be tested according to ANSI/ASHRAE Standard

52.2-2017 – Method of Testing General Ventilation Air-Cleaning Devices
for Removal Efficiency by Particle Size.

4.2.2.3 Automatic Recleanable High Voltage Electrostatic Filter

The scope of the test is to verify effective performance of the automatic

recleanable high voltage electrostatic filter in accordance with the
manufacturer’s technical information and/or the stated requirements in the
Particular Specification. The general test procedures for the unit is:

(a) only Registered Electrical Worker(s) with recognised training from the
filter supplier on maintenance of high tension portion of the equipment
should be allowed to enter the filter casing;

(b) the responsible person/team should have the interlock key which controls
the opening of the access door to the section of filter which he is entering or
a fuse link or other item to prevent the filter being energised;

(c) a second person should be stationed outside the door as an observer and he
will normally also be in control of the operation of the power pack from this
position;

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(d) before working on any filter system, any residual H.T. charge must be
removed using an earthing tool with insulated handle; and

(e) where the power pack is remote from the filter a shorting bar should be
securely fixed between earth and each H.T. feed to the filter.

4.2.2.3.1 Preliminary Checks

Under no circumstance shall commissioning proceed until all

checks listed in Clause 4.1.7.5 have been completed.

4.2.2.3.2 Water Wash and Fluid Coating Systems

(a) commission the wash and coating systems in accordance with

Clauses 4.1.6 and 4.2.1;

(b) adjust sequence timers; and

(c) the filter should be washed prior to initial energising and if

specified coated with fluid, allowing correct drainage period to
elapse. (Note : This may be a matter of hours.)

4.2.2.3.3 Automatic Fabric Filter Sections

Commission any automatic fabric filter sections in accordance with

Clauses 4.1.7.4.2 and 4.2.2.2.

4.2.2.3.4 Initial Energising of Filter Without Air Flow

(a) check that no one is inside filter casing, that access doors are
closed and that no entry can otherwise be made to the filter
interior;

(b) cancel and lock out any remote control system for filter;

(c) switch on filter;

(d) check that there is no flash-over problem and that indications

from meters and lamps on filter control panel are normal;

(e) all safety measures listed in Clause 4.1.7.5.3 must be

implemented before entry to the filter casing; and

(f) restore full automatic control sequence and make it ready for
the establishment of air flow through the filter.

4.2.2.3.5 Application of Air Flow to Filter

When air flow is established through the filter (see Clause 4.2.2.4.5):

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(a) check that there is no excessive flash-over (say, an average of
over 5 per minute per square metre of the face area);

(b) an inspection should be made on the de-energised filter after a

few hours operation with air flow established (see Clause
4.2.2.4.5);

(c) the H.T. voltage shall be checked at ioniser and collector

sections. Unless otherwise specified the H.T. voltage should
be within +3% of the nominal figure specified at the mean
declared L.T. voltage;

(d) polarity should normally be arranged with positive voltage on

the ioniser section to limit ozone generation;

(e) measurement of H.T. voltage shall be by means of an

instrument comprising high stability resistance chain with high
sensitivity millimetre in series, or electrostatic voltmeter across
1 section of the chain;

(f) only a skilled and experienced operator should attempt

measurement of H.T. voltage. Great care is necessary to avoid
contact with live parts of the meter and no part of the meter or
its connections should be touched when it is connected to H.T.
components; any such connections should normally be special
H.T. cables to avoid current leakage;

(g) readings should normally be made with the meter placed within
the filter casing and observed from the outside through the
observation window;

(h) the correct total air flow through the filter shall be established
as part of the procedure for regulation of total air flow (see
Reference no. 4 of Annex V);

(i) the uniformity of air velocity distribution across the face of the
de-energised filter bank should be checked using an
anemometer after the regulation of total air flow (see Reference
no. 4 of Annex V). To do this, it will be necessary to override
the interlock with the supply fan;

(j) single point measurements of indicated velocity should be

made at the centre of each 300 mm square of the face area, and
where appropriate instrument correction factors shall be
applied to each of the readings;

(k) the mean indicated velocity is then calculated and each of the
point readings is expressed as a percentage of this mean. The

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 percentage variations of velocity must be within the tolerances
specified; and

(l) upper limits will always be critical and a failure to meet the
specified tolerances must be rectified.

4.2.2.3.6 Filter Performance

Filter performance shall be tested according to ANSI/ASHRAE

Standard 52.2 – 2017 – Method of Testing General Ventilation Air-
Cleaning Devices for Removal Efficiency by Particle Size and
equipment shall be tested to meet Underwriters Laboratories UL
Standard 867 [2011] - Electrostatic Air Cleaners.

For kitchen application, oil mist and odour removal performance

shall be verified by recognised testing laboratory and equipment
shall be tested to meet Underwriters Laboratories UL Standard 710
[2012] - Exhaust Hoods for Commercial Cooking Equipment (for
Fire and Burnout Test only).

4.2.2.4 Initial Running of Electrically Driven Fan Set

4.2.2.4.1 Limit the Load

(a) wherever possible the first start of any motor should be on light
load;

(b) with centrifugal fan sets this will normally be achieved by

limiting the mass flow by operation of the main damper. The
fan characteristics must be available so that excessive suction
or delivery pressure is not applied to the ductwork system.

4.2.2.4.2 Initial Start

On activating the motor starter, check:

(a) that the direction and speed of rotation of motor shaft are
correct;

(b) that the motor, drive and fan are free from vibration or undue
noise;

(c) the motor starting current for sequence timing adjustment;

(d) the motor running current on all phases;

(e) that there is no sparking at commutator or slip rings;

(f) that there is no overheating of motor (see BS EN 60470 [2001]);

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 (g) that there is no seepage of lubricant from the housing;

(h) that there is no overheating of the bearings;

(i) that oil rings are running freely;

(j) note the reduced speed rev/s and the motor running current on
multi-speed motors;

(k) the rev/s of fan and motor; and

(l) visually / audibly check the performance of fan belts in case of

abnormal vibration.

4.2.2.4.3 Initial Run

(a) a light load run shall be sustained until the PBSE/PBSI is

satisfied from the checks listed in Clause 4.2.2.4.2 above; and

(b) repetitive starting of the motor should be avoided to prevent

over-stressing of fuses, switchgear and motor.

4.2.2.4.4 Start at Normal Load

(a) after the initial light load run, the machine shall be stopped and
restarted at normal starting load, and the checks listed in Clause
4.2.2.4.2 repeated; and

(b) avoid repetitive starting.

4.2.2.4.5 Running-in Period

(a) after a short run at normal load (a few minutes’ run will
normally suffice) flexible connections to terminal units, etc.,
and terminal filters (which were removed in Clause 4.2.2.1)
shall be restored to position;

(b) subsequently a running-in period shall be sustained until the fan

set is in a reliable continuous running condition; and

(c) the regulation of the air distribution system shall be delayed

until the running-in period (which may last for a few days) is
completed satisfactorily.

During the running-in period the following work shall be conducted:

(d) the dynamic balance of the fan and motor shall be investigated
and corrected if necessary; and

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 (e) the performance of electrostatic filter shall be checked (see
Clause 4.2.2.3).

4.2.2.5 Regulation of Airflow

4.2.2.5.1 State of the System and Building

Before starting the regulation of airflow, check that the following

conditions are fulfilled:

(a) relevant building features are completed and consistent with

their normal state. Windows and doors are opened or shut as
appropriate;

(b) should (a) be impractical, make appropriate provisions

(temporary blanking-off or opening etc.) to simulate the normal
state of the spaces under test;

(c) in exercising (a) & (b) above, maintain flexibility with

reference to requirements in (g) below;

(d) the duct system is completed and practically leakage-free and

in the case of a high velocity system, pressure testing is
satisfactory;

(e) the requirements of checks listed in Clause 4.1.7 have been met;

(f) the corresponding cooling and heating systems (including duct

heaters) shall normally be shut off, except for fresh air systems,
some cooling or heating may be applied to the main duct only
for air tempering purpose; and

(g) the associated air supply or extract system that has not been
regulated should normally be shut down and the duct system
under regulation shall be balanced against atmosphere i.e. with
doors or windows open (or purpose-made provisions) to
maintain the relevant spaces under atmospheric pressure.

4.2.2.5.2 Balancing Air Flow Circuits

(a) airflow tests shall commence as soon as a ducting system and

fan are installed and wired up. In some instances, temporary
electrical supplies to fans may be necessary in order to test
ductwork under working conditions;

(b) All air diffusers and grilles shall be balanced by regulating the
dampers provided. Each system of ductwork shall be balanced
so that every branch duct, diffuser, grille and pressure relief
valve shall carry the required quantity of air;

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 (c) Generally, the test procedure shall comply with that set out in
the CIBSE Commissioning Code "A" - Air Distribution
Systems; and

(d) after completion of the balancing, all dampers, grilles, diffusers,

etc. shall be locked in position with permanent marking and
shall be demonstrated to the Supervising Officer that the
Installations comply with the Particular Specification and that
the air distribution is balanced in accordance with the air flow
details shown in the original Contract Drawings or as later
instructed.

4.2.2.5.3 Principle of Proportional Air Balancing

For details, refer to Reference no. 4 of Annex V.

4.2.2.6 Variable Air Volume System

(a) the self-balancing system characteristic requires little actual air balancing
work. The exercise is targeting on verifying the performances of the VAV
boxes and fan airflow discharge in response to changes in controlling
parameters;

(b) check that the system is clean, to avoid damage to VAV box components.
Check that Site conditions in Clause 4.2.2.5.1 are met, unless otherwise
stipulated below;

(c) fully review the recommendation from supplier in the setting to work and
commissioning of both VAV box and variable airflow device. Adhere to
these recommendations to avoid damages due to improper handling;

(d) obtain fan curves and surge characteristics;

(e) for a variable speed drive operating on variable frequency control, obtain
data pertaining to the change of fan motor speed and corresponding airflow
with the change of frequency. For a vortex damper control, obtain similar
data against the change of damper setting. Determine the maximum and
minimum fan speed or damper settings;

(f) construct a theoretical system curve with approximate surge area. The
system curve initiates at the minimum inlet static of the boxes, plus system
loss at minimum flow and terminates at design maximum flow;

(g) for variable speed control, the operating range is between “the minimum
speed that can produce the necessary minimum box static at lowest flow
while still remaining in the fan’s stable range” and “the highest speed
necessary to obtain maximum design flow”;

(h) for inlet vane damper control, the operating range is between “the surge line
intersection with the system curve” and “the maximum design flow”;

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(i) set the fresh/exhaust/recirculation dampers in either full fresh air or full
recirculation positions;

(j) set the supply and extract fans systems to their minimum speed conditions.
Start the fans, and gradually increase the airflows. Motor running current
checks should be made at various increments, to prevent overloading.
Check that the fans are operating within the extreme conditions identified
from (e);

(k) check system static pressures at or close to the positions specified for the
pressure sensor for automatic regulation of fan speed, and at VAV boxes
near to the fan. This is to prevent over-pressurisation of system components;

(l) should abnormal excessive current or pressure are detected in (j) or (k)
above, check for any improper settings. Refer to the designer for unresolved
problem;

(m) with fan motor current and system pressure not being exceeded, increase
the airflow to the maximum design condition;

(n) verify the VAV box factory settings on maximum and minimum flows with
change in controlling parameter (e.g. actuator responses to voltage
fluctuation according to temperature change). Also check intermediate
settings. This must be done according to the VAV manufacturer’s
recommendations;

(o) in conducting the exercise in (n) for a particular box, it may be necessary to
throttle airflow to other boxes/branches in order to bring the one at test with
sufficient pressure and flow;

(p) in conducting (n), a sufficient number as agreed by PBSE/ PBSI of boxes

should be checked to be representative of the system. If a wide variation
occurs, it may be necessary to check all the boxes;

(q) check that the least favoured VAV box is also operating at the system’s
minimum design airflow;

(r) for VAV box delivering air to a number of secondary terminals, air
balancing of these terminals should be carried out according to Reference
no. 4 of Annex V;

(s) repeat (h) to (n) for different design conditions dictating the flows of fresh
air and recirculation;

(t) in the above processes, the fan drive mechanism will have to be repeatedly
adjusted. Do this in accordance with the fan drive manufacturer’s
recommendations;

(u) take readings of all above measurements and settings;

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 (v) review the data and work in conjunction with the control specialist to arrive
at the desired fan drive settings and VAV box settings; and

(w) it is important to ensure that pressure sensors for fan airflow control are so
located that they offer responsive, stable and reliable regulation across the
full range of fan operation. Should the pre-determined positions not be
appropriate, reflect this to the PBSE.

4.2.2.7 Pressure Differential Between Spaces

There are systems designed to achieve a pressure differential between spaces

served, for purpose of isolation or containment. Airflow in hospital from clean
area to less clean area is one of the applications. The following actions shall be
taken:

(a) check that Site conditions in Clause 4.2.2.5.1 are met, unless otherwise
stipulated below;

(b) check that suitable paths for make-up or spill air are provided. Open all
doors and hatches between the pressurised spaces;

(c) run the supply or extract fan;

(d) balance the air terminals in accordance with Reference no. 4 of Annex V;

(e) set the fan airflow rate to design requirement;

(f) close all doors and hatches so that the space is in its normal operating
condition;

(g) run the other extract or supply fan previously not in operation;

(h) balance the system previously not balanced;

(i) set up and commission pressure control devices in accordance with

manufacturer’s recommendations;

(j) set the fan airflow rate to design requirement;

(k) re-check airflow rates of previous system;

(l) if the flow rates are within specified tolerance, the balancing work is
completed;

(m) if the readings are not within tolerance, re-check the system balance
described in (d) & (e) above and, where necessary, make adjustments to
reinstate the balance of the previously set total volume flow rate. Reiterate
this step until no further adjustment is required;

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 (n) measure and record the pressure differentials between all adjacent spaces
and compare the measurements with the specified design requirements.

(o) verify that airflow indicator i.e. Inclined Tube Air Flow Indicator (ITAFI)
between spaces served are fixed and of correct size and type; and

(p) to check and record the flow pattern.

4.2.2.8 Dual Duct System

(a) dual duct system comprises a cold duct and a hot duct, respective air to be
mixed in a mixing box before discharging to air-conditioned space at the
appropriate dry and wet bulb temperatures. The cold duct usually can
handle 85% to 100% of system flow, and the hot duct 40% to 80% flow;

(b) check that Site conditions in Clause 4.2.2.5.1 are met, unless otherwise
stipulated below;

(c) start balancing by setting all room control thermostats for maximum cooling,
fully opening the cold air valves;

(d) proceed to the extreme end of the system (longest duct run) and check the
static pressure drop across the box. The reading should exceed or equal the
minimum static pressure recommended by the manufacturer of the box
(about 185 Pa static pressure is common for the mechanical regulator);

(e) for mixing boxes that are not factory preset, set the mechanical volume
regulator in accordance with manufacturer’s recommendation. Refer to
calibration curve wherever appropriate;

(f) measure airflow of all air terminals;

(g) for mixing box delivering air to a number of secondary terminals, air-
balance them according to Reference no. 4 of Annex V;

(h) air-balance the flow from boxes to Reference no. 4 of Annex V should
relevant dampers be available and the readings in (f) indicate unacceptable
tolerances. Make adjustment to box air valve if necessary in accordance
with manufacturer’s recommendation;

(i) change the control settings to full heating and make certain that the controls
and dual-duct boxes function properly; and

(j) measure airflow from all air terminals and check against design. For out-of
range mixing box, make adjustment to the air valve if necessary in
accordance with manufacturer’s recommendations.

4.2.2.9 Automatic Air Balancing (AAB)

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If so specified in the Particular Specification or the Contract Drawings, AAB
system shall be adopted. Balancing shall be carried out to meet the specified
airflow with tolerance level as recommended in Reference no. 4 of Annex V.
All necessary motorised volume control dampers, airflow measuring devices
and all interface equipment necessary shall be provided for CCMS connection
in order to achieve AAB.

The AAB system shall perform 3 main functions, namely, (1) air balancing for
system commissioning, (2) monitoring of the airflow rates and (3) re-balancing
of air due to change of load profile. The AAB shall be so designed to achieve a
fully automatic control in performing the air balancing. No on-field adjustment,
measurement and testing during the air balancing shall be required. The only
step is to input the design airflow rates to the CCMS and observe the change
from the monitor and revise input data if any.

4.2.2.9.1 Method of Balancing

Computer program with a compact algorithm for system balancing

shall be provided. Such algorithm completed with air side
schematic diagram and location of motorised volume control
dampers shall be submitted within 3 months after the
commencement of the Contract for approval.

The logic of the algorithm shall be designed to achieve the air

balancing using the procedure as outlined in the General
Specification and Clause 4.2.2. After the completion of the pre-air
balancing procedure as specified in Clauses 4.1.7 and 4.2.2.5, the
AAB system shall balance all air circuits by operating the motorised
volume control dampers through the CCMS.

4.2.2.9.2 Hardware and Software

Any necessary hardware and software such as DDC controllers,

sensing devices, operating software and self-diagnostic devices of
the AAB are deemed to be included in the Contract. The AAB is an
integral part of the CCMS, any standards or requirements not
specified in this section shall refer to relevant Sections and Clauses
or CCMS specified in the Contract.

4.2.2.9.3 Pre-commissioning Consideration

(a) Motorised volume control dampers shall be selected and the

algorithm shall be designed in achieving a stable AAB system.
Any additional items and/or modification works required for
achieving a stable system at no additional cost shall be supplied
and installed.

(b) The AAB system shall balance all air circuit as specified in the
Particular Specification or the Contract Drawings to a steady
balanced state. The CCMS system shall coordinate with the

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 control of all other systems such as AHUs and FCUs to
complete the balancing. The input design flow data and
balancing point of each motorised volume control damper shall
be logged and password protected in the CCMS. Only the
person with authority shall be able to change the flow rates and
re-balance the air circuit. The flow rate and temperature at each
motorised volume control damper shall be displayed with
colour graphic layout diagram on the computer monitor and
updated at intervals agreed by PBSE.

(c) The colour graphic layout diagram shall show the location and
number of each motorised volume control damper on the
background of the airflow schematic diagram with floor level
and room name. The CCMS shall generate and print out if
requested tables showing the actual flow rates and design flow
rates of the air passing through motorised volume control
dampers against their locations and floor level. Suitable
hardware and software such as flow meter, actuators, DDC and
the operating system shall be selected to achieve overall
performance of the AAB in accordance with Reference no. 4 of
Annex V.

(d) The algorithm and corresponding colour graphic layout

diagram shall be easily updated for any modification of air
circuit.

4.2.2.9.4 Demonstration

Dummy testing shall be performed by inputting at least 20 sets of

airflow rates or as specified in the Particular Specification to test the
stability of the AAB system and the timing required for adjusting.
The values of the dummy testing air flow rates shall be submitted
for approval and at least 2 weeks before T&C. Any electronic
measuring equipment for use with automatic air balancing shall be
provided and permanently installed at their location at no additional
cost.

4.2.2.9.5 Motorised Volume Control Dampers

Motorised volume control dampers shall be tested in accordance

with the recommendation of the manufacturer to assure automatic
air balancing. All dampers provided shall also comply with the
relevant Section of the General Specification.

4.2.2.10 Air Handling Units (AHUs)

The T&C of air handling units should be carried out in line with the General
Specification and the items as specified below.

4.2.2.10.1 Operation

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 (a) AHU systems must be in operation before the test and balance
procedures are started; and

(b) all controls must be installed, calibrated and fully operational.

4.2.2.10.2 Inspection

(a) inspect the system to determine if it is complete and operable,

check on the condensate drains, etc.;

(b) verify that the drives are installed properly and are of the correct
size and type. Verify that the inlet vanes are working;

(c) refer to the pre-requisites for balancing;

(d) verify that the fan wheels are on a single shaft. If they are on a
split shaft, then verify that the shafts are properly connected to
the drive end; and

(e) verify that the filters are clean and of correct size and type.

4.2.2.10.3 Procedures

(a) check the fan for proper operating condition and the fan motor
shall be below the full-load current rating;

(b) measure and proportionally balance the air distribution if the

total discrepancy is within 20% of design. If not, investigate
and make adjustments as required;

(c) locate a traverse position in a straight section of duct. Refer to

the ‘Pitot Tube Traverse’ procedures;

(d) traverse to determine fan airflow. Flow should be 100 to 110%

of design assuming 0% air leakage;

(e) adjust fan speed to obtain 100 to 110% of design airflow (m3/s);

(f) measure power requirements before and after adjustments; and

(g) after completing the balancing procedure, record the following

minimum data on the report form as indicated in Annex II,
whichever appropriate. They are:

(i) unit design data;

(ii) airflow (m3/s) from duct or coil traverse;

(iii) electrical power measurement procedure;

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 (iv) test the power in kW, if applicable;

(v) all nameplate data must be identified and verified;

(vi) test the motor rpm and fan rpm;

(vii) drive sizes, belt type, size and number;

(viii) centre-to-centre distance of the motor-base travel;

(ix) static pressure profile according to the static pressure

profile procedure; and

(x) temperature across coils according to the coil capacity

testing procedures.

4.2.2.10.4 Compliance

(a) to comply with this T&C Procedure, complete all of the above
steps and record all data on the report forms; and

(b) all deficiencies that affect the above T&C works should be
resolved by the installing contractor(s) and well include the
deficiencies into the report.

4.2.2.11 Pretreated Air-handling Units (PAUs)

All the procedures are similar to Clause 4.2.2.10 for AHUs except the testing is
for constant outside air coming directly into contact with the units.

4.2.2.11.1 Operation

(a) the systems must be put in operation; and

(b) access must be provided.

4.2.2.11.2 Inspection

(a) inspect the system to determine if it is complete and operable;

check on the condensate drains, etc.;

(b) verify that the drives are installed properly and are of correct
size and type;

(c) refer to pre-requisite for balancing;

(d) verify that the fan wheels are on a single shaft. If they are on a
split shaft, then verify that the shafts are properly connected to
the drive end;

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 (e) verify that the filters for the outdoor air are clean and of correct
size and type; and

(f) verify that the coils are piped correctly.

4.2.2.11.3 Procedures

(a) set and test the outside air quantity that could meet the
minimum requirement as specified;

(b) balance the systems that distribute outdoor air directly to the
space to the quantities specified;

(c) on systems that distribute air directly to other air-handling units,

verify that the outside air is properly mixed with the return air
so the mixed-air temperature is uniformly entering the coil. If
the air temperature is not uniform, treat it as a deficiency;

(d) verify that the outside air quality remains constant under all
modes of operation;

(e) test and set the outside air and verify that the minimum airflow
rate (m3/s) stays constant. Verify that the outside system air
operates when occupied and when the exhaust system is on; and

(f) measuring and setting outside air.

(i) the preferred method of measuring outside air is by duct

traverse. Use Pitot Tube Traverse method to test;

(ii) an air capture hood is an acceptable method for

measuring small outside air requirements, such as a unit
ventilator or fan coil unit; and

(iii) velocities at intakes are acceptable when an appropriate

factor can be field determined by Pitot Tube Traverse.

4.2.2.11.4 Compliance

(a) to comply with this T&C Procedure, complete all of the above
steps and record all data on the report forms; and

(b) outside air which makes up with the return air is also a
consideration required in balancing the outside air, and should
be reported if not included in the minimum outside air
requirement.

4.2.2.12 Fan Coil Units (FCUs)

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This T&C Procedure applies to all chilled water fan coil units including the high
static equipment.

4.2.2.12.1 Operation

(a) the system must be put in medium speed operation unless

otherwise specified; and

(b) proper access must be provided.

4.2.2.12.2 Inspection

Inspect the system to determine if it is complete and operable; check

the condensate drains, etc.

4.2.2.12.3 Procedures

Use the following procedures for chilled-water fan coil units:

(a) use manufacturer’s rated airflow unless ducted, then use a duct
traverse to determine airflow. If duct traverse is impossible,
then use summation of the outlet readings;

(b) set outside airflow to design specifications;

(c) measure entering and leaving air dry and wet bulb temperatures;

(d) measure entering and leaving water temperatures;

(e) use the room conditions to determine the cooling load;

(f) if a flow station is installed, then measure and record the

flowrates (l/s) and compare to the heat-balance flowrate;

(g) measure and record the water pressure drop across the coil and
compare to the design. Only rely upon pressure drop for flow
determination if other means noted are impossible to obtain;

(h) measure and record all unit data;

(i) measure and record motor operating amperage /voltage and

compare against full-load nameplate; and

(j) verify that controls operate properly and are in correct sequence.
Note any deficiencies and record.

4.2.2.12.4 Compliance

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 Compliance with this T&C Procedure is met when the above are
completed and the units are balanced to within the limits of the
system.

4.2.2.13 Test on Water Scrubber / Kitchen Exhaust Hood

The scope of the test is to verify effective performance of the water scrubber /
kitchen exhaust hood and its associated facilities in accordance with the
manufacturer’s technical information and the stated requirements in the
Particular Specification. The general test procedures are:

(a) the mechanical and electrical installations shall be visually inspected, tested
in conformance with manufacturer’s technical installation guide and
information;

(b) re-sealing test holes shall be provided at the main discharge duct for total
air flow and static pressure measurements. The test hole position shall be
determined on the Site. Test holes usually shall not be drilled on the bottom
side of air duct;

(c) the exhaust air fan shall be generally tested in accordance with relevant
sections for fan, and noise measurement shall be in accordance with relevant
section;

(d) the water circulating pumps should be generally tested in accordance with
relevant section for pumps;

(e) the capture velocity or slot velocity at the hood face or entry slots shall be
measured according to the appropriate standards; such as ANSI/ASHRAE
41.2-2018 and ANSI/ASHRAE 70-2006 (RA2021) on the
recommendations by the Associated Air Balance Council (AABC) U.S.;

(f) water curtain profile at the hood entry shall be visually checked and water
consumption shall be metered throughout the test period;

(g) the mist eliminators shall be installed in correct position and excessive air
mists shall not be allowed;

(h) integrated fire suppression installations, if provided shall be tested in

accordance with the engineered system recommendation;

(i) when the whole installation is featured with two speed flow control modes,
the test procedures shall be carried out for both modes;

(j) after completion of test, the air flow pattern around the hood entry shall be
further verified with smoke candle. The smoke candle shall be positioned
300 mm below hood face and 150 mm around the hood periphery;

(k) during test of hood exhaust system, the general kitchen ventilation systems
shall be put in operation;

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 (l) the overall result shall be documented in an approved test sheet; and

(m) Oil mist and odour removal performance shall be verified by recognised
testing laboratory and equipment shall be tested to meet Underwriters
Laboratories UL Standard 710 [2012] - Exhaust Hoods for Commercial
Cooking Equipment.

4.2.2.14 Outdoor Air Pre-conditioner, Heat Wheel and Air Heat Exchanger

4.2.2.14.1 Preliminary checks

All visual checks and preliminary checks shall be carried out as

recommended by the supplier/manufacturer before start up of the
equipment. In addition, electrical checks shall be carried out as per
Clause 4.1.5.

4.2.2.14.2 The following general procedures shall be adopted where

applicable:

(a) verify that all seals are properly installed and adjusted;

(b) measure and record the flow rate of air entering the exhaust
section;

(c) measure and record the flow rate of air leaving the outside air
section;

(d) measure and record the dry and wet bulb temperature of air
entering and leaving the exhaust side;

(e) measure and record the dry and wet bulb temperature of air
entering and leaving the outside air side;

(f) calculate and record the sensible and total capacity of each
airstream;

(g) measure and record the pressure drop on each side of the heat
exchange section;

(h) measure and record the starting and running current of the
equipment; and

(i) measure and record the noise level where applicable.

4.2.2.15 Split Units and Variable Refrigerant Volume (VRV) System

4.2.2.15.1 Preliminary checks

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 All visual checks and preliminary checks shall be carried out as
recommended by the supplier/manufacturer before start up of the
equipment. In addition, electrical checks shall be carried out as per
Clause 4.1.5.

4.2.2.15.2 Commissioning tests

(a) The following tests shall be carried out where applicable: static
pressure test, dynamic rotation tests and inspection of welds in
piped services;

(b) Pressure and leak tests of refrigerating piping systems are

normally carried out on completion of the system, before
pipework is insulated; and

(c) System evacuation, dehydration and charging with refrigerant

shall be carried out by skills and experienced personnel.

4.2.2.15.3 The following are general procedures to be adopted.

(a) check that the indoor and outdoor units are installed according
to supplier’s instructions and recommendations including
maximum pipe run, etc;

(b) check that the safety devices and necessary operational control
are provided as per requirements of the General Specification;

(c) check that pipeworks of correct pipe sizes are installed and
insulation is completed;

(d) check that the units are correctly wired up;

(e) ensure that the connection nuts are tightened;

(f) ensure that the system has been properly evacuated and leak-
tested;

(g) open all isolating valves where appropriate;

(h) trial run the units after water drainage test;

(i) measure the following and note down in the record sheet:

(i) starting and running current;

(ii) high and low pressure cut-out;

(iii) compressor suction and discharge pressure;

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 (iv) evaporator entering and leaving coil temperature, both
WB and DB;

(v) condenser entering and leaving coil temperature, both

WB and DB;

(vi) air flow rate;

(vii) noise level measurement as necessary;

(viii) other measurements as necessary for VRV systems; and

(j) test the control system according to design where applicable.

4.2.3 Refrigeration Systems

4.2.3.1 General

T&C of refrigeration system shall be carried out by the skilled and experienced
persons preferably assigned by the original manufacturer.

Normally the refrigeration systems are categorised by the following species (not
exhaustive).

(a) Reciprocating Compressor Systems (See Clause 4.2.3.2) ;

(b) Centrifugal Compressor Systems (Including Oil Free Compressor) (See

Clause 4.2. Necessary inspections and tests shall be arranged as required
by the Authority.);

(c) Absorption Systems (See Clause 4.2.3.4);

(d) Screw Compressor Systems (See Clause 4.2.3.5);

(e) Scroll Compressor Systems (Details should be referred to Manufacturer’s

recommendation.); and

(f) Split Units and VRV System (See Clause 4.2.2.15).

The following points are common to all systems and require careful handling:

4.2.3.1.1 System Cleanliness

(a) The chilled water and condenser water systems should be

flushed thoroughly by following the procedures as described in
Clause 4.1.6.1 and the precautions below:

(i) isolate or bypass items which are particularly sensitive to

dirts, including the shell and tube evaporators,

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 condensers, pumps, spray nozzles and automatic water
valves, and so on; and

(ii) where appropriate, remove the strainer screens, cooling

tower basins, tanks and other equipment which may have
accumulated deposits during manufacturing or
installation, and shall also be isolated and flushed
independently.

(b) check the following items for cleanliness:

(i) isolate or bypass items which are particularly sensitive

to dirts, including the shell and tube evaporators,
condensers, pumps, spray nozzles and automatic water
valves, and so on; and

(ii) air intake screens;

(iii) fan chambers of condensers and cooling towers;

(iv) fan internals;

(v) external heat exchanger surfaces of air-cooled

condensers, evaporative condensers and cooling towers;

(vi) sensing elements;

(vii) cooling tower basins, evaporative condenser tanks and

chilled water tanks;

(viii) compressor, motor and drive;

(ix) safety and control devices; and

(x) drains and overflows.

4.2.3.1.2 State of the Systems

(a) Water System

For chilled water and condenser water systems, carry out the
T&C procedures as listed in Clauses 4.1.6 and 4.2.1 in addition
to the following.

Check :

(i) that the cooling tower fill is complete and secured;

(ii) that where chilled water tank is provided the tank lid is
fitted and secured;

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 (iii) the valve connection (where specified) for blow-down
from cooling towers and evaporative condensers; and

(iv) that any splash guards for cooling towers and evaporative
condensers are fitted properly.

(b) Air System

For air handling systems and any airways associated with the
air-cooled condensers, evaporative condensers and cooling
towers, carry out the following checks.

Check:

(i) that the airways are clear;

(ii) that the condenser heat exchangers are installed correctly

in relation to air flow;

(iii) where applicable, the damper free movement, clearances,

seating, pinning to damper spindles, relative positions of
blades in multi-leaf dampers;

(iv) that dampers are secured in open position with, where

motorised, the actuator disconnected; and

(v) the airways including builder’s ductwork for air-tightness,

noting particular seals at equipment, access doors,
flexible connections, and junctions of all ductworks.

(c) Refrigerant System

Check:

(i) that the pipework is complete and secured;

(ii) that the thermostatic expansion valve (or float level

device) is fitted : thermal bulb is correctly fitted and
secured, external equaliser (where appropriate) is fitted;

(iii) that the safety and control devices are fitted : such as the
low pressure and high pressure cut-out, oil pressure cut-
out (where fitted), chilled water low temperature
thermostat, low water flow safety device and any
protective solenoid valves being specified;

(iv) that the liquid line strainer, isolating valves as specified,

sight glass with moisture indicator and drier are fitted;

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 (v) that the suction, discharge and oil pressure gauges with
isolating valves are fitted and isolated from the system;

(vi) that purging and charging connections are fitted; and

(vii) if liquid receiver is provided, the capacity, associated

works and the surveyor’s certificate (if specified) are to
be checked before commissioning.

(d) Checking of Water System before Filling

4.2.3.1.3 Carry out all checks where appropriate as described in Clause

4.1.6.3.

4.2.3.1.4 Mechanical Checks

(a) Fans

Carry out checks as described in Clause 4.1.7.4.1.

(b) Compressors

Check:

(i) external cleanliness;

(ii) that all components, bolts, fixings, etc., are properly

secured;

(iii) that the compressor shaft is free to rotate (applicable to

open type compressor only);

(iv) level and plumb of compressor and motor shaft and slide
rails (applicable to open type compressor only);

(v) anti-vibration mountings for correct deflection;

(vi) to secure and align the pulleys and couplings (if

applicable);

(vii) belt tension and match of pulleys (if applicable);

(viii) that drive guards are fitted, the access for speed
measurement is provided and nipple extension for motor
lubrication is provided (if applicable);

(ix) correct oil level in compressor;

(x) that the compressor unloading gear is fitted (if specified);

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 (xi) any special arrangements for motor cooling; oil cooling
where appropriate; and

(xii) that vibration eliminator and muffler are fitted.

(c) Drives

For gear boxes and special mechanical drives pulley/belt, direct

or flexible couplings for compressor or large cooling tower fans.

Check:

(i) that the lubrication and pre-lubrication are in order before

starting;

(ii) that drive mountings are secured;

(iii) that all shafts are correctly aligned; and

(iv) for free rotation.

4.2.3.1.5 Electrical Checks

(a) With all electrical supplies isolated, electrical check shall be

carried out according to Clause 4.1.5, also check:

(i) wiring from all safety devices and liquid line solenoid
valve are completed; and

(ii) compressor crankcase heater(s) is/are fitted and the

wiring is completed.

(b) With electrical supplies connected, electrical check shall be

carried out according to Clause 4.1.5, also check:

(i) check for satisfactory operation of any electrical controls

associated with compressor starter operation such as
liquid line solenoid valve, electrical timing heater on the
oil failure control (in this case, check for satisfactory
operation and then temporarily disconnect it), and
capacity unloading if initiated electrically;

(ii) where automatic sequencing starting for the whole

refrigeration plant and associated chilled water and
condenser water pumps is specified:

- check that the sequence is correct in order and timing;

- adjust timers, check for clean operation of all

contactors, relays and interlocks; and

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 - finally open the isolators, reset or reconnect any
device as appropriate, reinstate power connections
and close isolators;

4.2.3.2 Reciprocating Compressor System

4.2.3.2.1 Pressure and Leakage testing

Refrigeration system working and test pressures shall comply with

the requirements stipulated in the Specification.

(a) Factory Assembled Packaged Units

(i) pressure & leak test, evacuation and dehydration &

charging, either as a small holding charge or the full
amount, should have been carried out at the factory;

(ii) observe pressure gauge readings and

- if the gauge readings are unsatisfactory, the whole

programme of pressure testing, evacuation and
charging must be carried out again;

- if the gauge readings are in order, then pressure

testing and evacuation are not required; and

- where the system has a holding charge, additional

charging is necessary.

(b) Built-up Systems

Pressure and leakage testing shall be carried out on completion

of the system, before pipework is insulated and condenser is
filled up with water:-

(i) charge the system with a small amount of the refrigerant.

The refrigerant acts as a tracer for leak detection purpose;

(ii) charge the entire system to the desired test gauge pressure
in accordance with manufacturer’s instructions using dry
nitrogen;

(iii) pressure should be applied to compressor to test the

vulnerable oil lines, etc. Precautions to be made on
applied pressure to avoid damages to the shaft seal
(applicable to open drive system only) and

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 - checked all joints for leakage by electronic leak
detector, then follow by using a soap solution “bubble”
test;

- pay attention to the gasket joints, bolt heads and nuts,

sight glasses, welded joints, parting lines on castings,
gauges and gauge connections, relief valves,
evaporator and condenser water boxes; and

- on hermetic units, pay attention to the motor

terminals; on open machines, check the shaft seals;

(iv) if leaks are identified, the gas and refrigerant in the

system must be evacuated for fixing leakage area, and the
system shall be recharged and tested again;

(v) repair any leaks found in the system. Leaks must not be
repaired while the system is under pressure;

(vi) when the system is found to be free from leakage, allow

it to stand for a minimum of 24 hours under pressure. If
no pressure drop occurs (allowing for effect due to
changes of ambient temperature) the system is ready for
evacuation; and

(vii) relieve test pressure to atmosphere, reconnect all lines

and reinstate all items removed or isolated.

4.2.3.2.2 Evacuation and Dehydration

This shall be carried out by specialists assigned by the equipment

manufacturer/ supplier.

4.2.3.2.3 Associated Air Systems

(a) setting to work and adjusting air handling plant shall be carried
out in accordance with Clauses 4.1.7 and 4.2.2; and

(b) for systems employing direct expansion air coolers, check that
commissioning of the main air distribution plant has progressed
sufficiently through Clause 4.2.2 so as

(i) to enable some measure of heat exchange to take place at

the cooler;

(ii) to allow limited running of the refrigeration plant for

initial commissioning purposes; and

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 (iii) to carry out the relevant parts of Clause. 4.1.7 and all of
Clause 4.2.2.4 for equipment on the condenser side of the
refrigeration plant.

4.2.3.2.4 Charging

This shall be carried out by specialists assigned by the equipment

manufacturer/ supplier.

4.2.3.2.5 Setting to Work and Adjusting

(a) Procedures

All procedures as outlined in Clauses 4.2.3.1, and 4.2.3.2.1 to

4.2.3.2.4 shall be completed before commencing this section.
Chilled water and condenser water systems shall be checked in
accordance with Clause 4.1.6 and the setting to work
procedures in Clause 4.2.1 shall be proceeded at least to a point
where sufficient water flow is available to enable full capacity
conditions of the refrigeration plant to be checked.

(b) System Checks

Before operating the compressor continuously for the first time,

a further visual check shall be carried out on the complete
system, and in particular all refrigeration safety controls shall
be put through their complete cycle of operation, including:-

(i) set refrigeration pressure controls in accordance with

manufacturer’s instructions or ensure that all factory
settings are in the right positions:

- adjust compressor low pressure switch to cut-in

whenever suction pressure rises above the desired
gauge setting, with the differential set as wide as
possible to prevent short-cycling in accordance with
the manufacturer’s recommendation;

- adjust high pressure switch to the recommended

gauge settings; and

- adjust oil pressure switch to the recommended setting;

(ii) ensure all sequence and safety interlocks are operating

correctly;

(iii) in case the electronic expansion valve is employed:

- take refrigerant temperature at a point as close as

possible to the remote bulb of the thermostatic

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 expansion valve at the evaporator suction outlet, to
enable proper superheat measurement to be made;

- the suction pressure shall be read at a gauge installed

in the back-set port of the compressor suction valve
and converted to temperature reading using the
refrigerant table; and

- the difference between the thermometer reading at

evaporator suction outlet and the temperature
calculated from suction pressure is the superheat
(usually about 5oC to 6oC);

(iv) if abnormal pressure drop is suspected (suction lines are

normally designed for 0.07 bar maximum pressure drop),
steps shall be taken to reveal the reason;

(v) check that the condenser water valves are open and the
pressure or temperature actuated valves (where fitted) are
operative;

(vi) check the condensing system to ensure design air (if

appropriate) and/or water quantities at required
temperatures are available to enable the desired high side
pressure to be maintained;

(vii) check the associated thermostatic control system as

described in Clause 4.3.1. Set the controlling devices (e.g.
chilled water, room air, or return air thermostat, or
pressure switch, or humidistat) to the desired settings;

(viii) check, immediately prior to commencing a continuous

running test of the refrigeration system:

- that all refrigerant circuit shut-off valves are in open

position, except for the bypass valves; especially
ensure that the condenser liquid line valve is open;

- that all chilled water and condenser water circuit

valves are in the correct positions;

- that compressor suction and discharge valves are

open. Oil, suction and discharge pressure gauge
throttling valves are open;

- that solenoid stop valves of evaporator are working

on magnetic coil control

- that lubricating oil is visible (at centre, or above) in

sight glass on compressor sump; and

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 - that electrical supply is available to the crankcase
heater and the heater is all right. In case of a cold
plant, at least 1 hour of operation shall elapse prior to
running to enable the heater to boil off any refrigerant;
and

- press the reset buttons on refrigerant pressure

control(s), oil pressure control and freeze protection
thermostat and/or freeze protection pressure switch.

(c) Start-Up

(i) test and ensure free movement of all rotating parts of each
compressor. Disconnect drive coupling or vee-belt.
Check the correct direction of motor (applicable to open
type compressor only);

(ii) start on ‘manual’ control of the chilled water pump (or

relevant fan) and condenser water pump and condenser
fan (or relevant pump). If controls are arranged for
sequenced ‘auto’ start only, proceed straightly to the
automatic start; and

(iii) start the compressor and observe for plant with both
‘manual’ and ‘auto’ selection, after 2 or 3 successful
‘manual’ operations change over to automatic control
and check:

- direction of rotation of compressor;

- that motor, drive, and compressor are free from

vibration or undue noise;

- motor starting current; and

- oil and refrigerant pressure gauges.

(d) Shut-Down

(i) if the plant has ‘auto’ controls, operate an automatic shut

down. Check that all sequencing and any special shut
down requirements are operated satisfactorily;

(ii) if the plant is arranged for manual control, proceed

through the correct relevant sequence to shut the
complete plant down; observe whether all automatic or
safety features are operated satisfactorily; and

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 (iii) in either case above note whether anything abnormal
occurs during the shut down cycle (such as noise,
vibration, or unexpected pressure variation).

(e) Running-In

When all of Clauses 4.2.3.2.5 (b)(i) to 4.2.3.2.5 (b)(iv) have

been satisfactorily completed, the complete system shall be
placed in operation and allowed to run for at least 72 hours. It
is recommended that the installation be continuously
supervised by a competent person. Check and observe the
following features, and adjust if necessary. All operation
information shall be recorded hourly in a log book.

(i) The oil level in the compressor shall be monitored closely

during the entire period. The compressor must not be
allowed to run short of oil.

(ii) Maintain sufficient load to keep the plant running during

the whole period. This may mean the provision of an
artificial load.

(iii) Superheat setting of the thermostatic expansion valve

using the method given in Clause 4.2.3.2.5 (b)(iii).

(iv) Checks must be carried out under conditions

approximating to design conditions (i.e. average or
maximum load, but not light load) and with satisfactory
condensing pressure.

(v) Do not alter superheat setting until it is certain that the

reset of the system is operating satisfactorily. If incorrect
values of superheat are found, gradual adjustment of the
control setting (as given in the manufacturer’s
instructions) and rechecking of the superheat value shall
be made.

(vi) All operating temperatures and pressures (in refrigerant

cycle and chilled water and condenser water circuits) are
under normal running conditions. Refrigerant flows at
sight glasses. Bubbles indicate refrigerant shortage and
possible leak.

(vii) Amperage and voltage readings of all motors and any

sparking at commutator or slip rings should be recorded.

(viii) Check the system for refrigerant leakage. This shall be

done at least twice during the running-in period.

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(ix) When these checks have been made and the plant is
running satisfactorily and steadily, check the operation
and calibration of control and protection devices.

(x) The operation and control of the refrigeration plant by the

primary control device (thermostat, etc.). The actual
control of the condition (temperature, etc.) by the device
will be checked as given in Clause 4.2.3. and the
following procedures should be followed:

- this operation shall be achieved by a gradual

reduction of the cooling load;

- this shall be done solely so that there is ample time to

note any extended sequence of events; and

- when the refrigeration plant has stopped, load can be

gradually increased, so as to observe the automatic
starting up sequence.

(xi) During the load changing procedure, the satisfactory

operation of the liquid line solenoid valve, compressor
capacity control system, unloaded compressor start-up,
and automatic pump down, where these facilities are
specified, shall be observed.

(xii) Low pressure cut-out: Close the liquid line shut off valve
(isolating valve on liquid receiver or cause the liquid line
solenoid valve to close). Isolating valves shall be opened
and closed as slowly as possible and then

- the compressor shall reduce pressure in the

evaporator;

- check that the low pressure cut-out operates at the

suction pressure recommended;

- watch the suction gauge carefully, do not allow the

suction pressure (particularly with water chillers) to
fall more than 0.1 bar below the recommended setting;
and

- open the valve and check the pressure at which

compressor cuts in.

(xiii) High pressure cut-out: Gradually reduce the flow of the

condensing medium (by bypassing the condensing water
or restricting the air flow to or from the air-cooled
condenser). The condenser pressure will rise. Then

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 - check that the high pressure cut-out operates at the
condenser pressure as recommended and set;

- watch the pressure gauge carefully, do not allow the

condenser pressure to rise appreciably above the
recommended setting; and

- slowly restore flow of condensing medium and check

the pressure at which compressor cuts in (with
manual rest it will be necessary to depress reset
button).

(xiv) Condenser pressure control, where fitted. During this

period, if possible, note the operation of condenser
pressure control under either naturally occurring low
external temperature conditions or where possible
simulate the conditions on a multi-compressor plant
feeding the whole of the condensing capacity to one
machine.

(xv) If evaporator pressure regulating valve is fitted,

- reduce the cooling load, so that suction pressure tends

to drop; and

- observe the evaporator pressure (if a special gauge

has not been fitted, fit one temporarily at the
evaporator on the evaporator side of the valve); this
shall not fall below the required value, even though
the suction pressure drops to cut-out level.

(xvi) With the assistance of manufacturer’s recommendation,

check the operation of any other special control or
operating devices such as low water temperature control,
low water flow control, or hot-gas by-pass circuit
controls. Where any device is installed for protection of
the plant, care must be exercised when checking so that
should the protective device fail to operate, the plant shall
stop immediately.

(xvii) Condenser pressure against condenser temperature: If

pressure is excessive, this indicates presence of air or
other non-condensable gases. Stop the plant, allow the
condenser to cool, then purge. Restart the plant, recheck,
and re-purge if necessary.

(xviii) All mechanical equipment shall be checked for excess

heat, noise and vibration.

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 (f) First Inspection after Running-In

This cannot be carried out until the plant has been in operation
for at least 72 hours. By the end of the running-in period any
improper adjustments or sources of potential troubles shall
become apparent.

(i) Recheck the compressor oil level. If low, wait further 3

or 4 hours to see that returning oil does not restore to the
proper level. If level remains low, further lubricating oil
should be added to maintain correct level;

(ii) Ensure that the compressor crankcase heater is working

so that oil level is not high due to refrigerant distilling
into the oil;

(iii) Remove test gauges and plug tapings;

(iv) With compressor stopped, check the compressor shaft

seal for refrigerant leakage;

(v) Check the alignment and lubrication of compressor

motor. Check and tighten as necessary the holding-down
bolts;

(vi) Check the drive belts for proper tension and alignment;
and

(vii) Check the sight glass. If there is presence of appreciable

moisture, change the dryer.

(g) Final Inspection after Running-In

This shall be carried out after the system has been in operation
for not less than 1 week:

(i) drain the compressor crankcase and clean the interior

with approved cleaner;

(ii) recharge the compressor with new clean compressor oil

of the exact type and grade specified by the manufacturer;

(iii) tighten bolts in coupling between compressor motor (or

adjust belt drive as necessary); and

(iv) change the dryer element.

4.2.3.3 Centrifugal Compressor System (Including Oil Free Compressor)

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The complete plant must have been pressure and leak tested, evacuated and
dehydrated, and the system charged with refrigerant and lubricating oil by the
specialists from the supplier prior to running. The charging operation is
normally carried out by the specialists from equipment supplier on the Site. In
addition, cleanliness, stage of system, mechanical and electrical components
must be checked.

On open type centrifugal machine, ensure transmission is lined up in accordance

with manufacturer’s instructions.

Check that:

(a) the evaporator and condenser shells are correctly levelled;

(b) all flanged connections are correctly aligned and tightened, with proper
gaskets in place;

(c) the liquid line and float valve assembly are completed;

(d) vibration isolation to compressor is provided in accordance with

manufacturers’ recommendations;

(e) motor cooling connections are completed;

(f) the purge unit for negative pressure refrigerant systems, and small-bore
accessory piping are completed, including cooling water connections where
specified;

(g) oil pump accessories and connections are installed;

(h) control gauges and tubing are completed; and

(i) temperature control bulbs/sensors are correctly located, space between bulb
and well is filled and suitable heat conducting fluid, and capillary tubes are
free from damage or distortion.

4.2.3.3.1 Pressure and Leakage testing

Refrigeration system working and testing pressures are defined in

the manual of the manufacturer.

(a) Factory Assembled Units

These are factory pressure and leak tested, often insulated, and
delivered to site with a holding charge of refrigerant /nitrogen.

(i) Observe pressure gauge readings. If gauges register zero

unit may have been damaged in transit and holding
charge lost, in that case the whole programme of pressure
and leakage testing must be carried out again;

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 (ii) If gauge readings are in order then a leak test shall be
carried out around all joints. Alternatively, units may be
despatched under vacuum and in this case the
manufacturer’s recommended procedures should be
followed.

(b) Site-assembled Units

Pressure and leakage testing should be carried out on

completion of the installation, before the unit and the
immediately adjacent pipework connections are insulated, and
before condenser or evaporator is finally filled up with water.
The following actions shall be taken:

(i) a cylinder of dry nitrogen and a small amount of

refrigerant of a type recommended by the manufacturer
shall be used to pressure test the system;

(ii) the refrigerant recommended by the equipment

manufacturer/supplier shall be used for this purpose and
also serves as a tracer for leak detection;

(iii) where the required test pressures exceed the allowable

pressures on certain items, remove or isolate these
components. Ensure the system is suitably sealed to
enable the pressure testing to be carried out;

(iv) where the purge unit is subjected to a higher operating

pressure than the remainder of unit, it shall be isolated
and tested separately at a higher pressure;

(v) charge the purge unit to the desired test pressure with
proper type of refrigerant in accordance with the
manufacturer’s instructions;

(vi) check the entire purge unit for leaks using a halide torch
or electronic leak detector. Tap all joints with a mallet
and remove any flux that may be adhering to them;

(vii) repair any leaks and retest the unit. Leaks must not be
repaired while the system is under pressure;

(viii) on satisfactory completion of test, relieve test pressure

(by opening valves in connecting pipework to main unit)
and remove charging apparatus;

(ix) reinstate any items previously removed or isolated and

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 - to charge and leak test the entire unit, first connect a
cylinder of refrigerant as recommended by the
manufacturer to the charging valve; and

- to charge enough refrigerant into the system to

produce a pressure as recommended by the
manufacturer for leak test purposes;

(x) close the charging valve and remove the refrigerant

charging apparatus;

(xi) connect a cylinder of dry nitrogen to the charging valve

on the unit and charge to the desired test gauge pressure.
Suitable nitrogen injection pressure reducing valve is
fitted;

(xii) close the charging valve and remove the charging

equipment;

(xiii) check all joints for leaks by electronic leak detector, then
followed by using a soap solution “bubble” test and

- pay attention to all gasket joints, bolt heads and nuts,

sight glasses, welded joints, parting lines on castings,
gauges and gauge connections, relief valves,
evaporator and condenser water boxes; and

- pay attention to the motor terminals of hermetic units;

or check the shaft seals on open machines.

(xiv) repair any leaks found in the system. Leaks must not be
repaired while the system is under pressure;

(xv) when the system is found to be free from leakage, allow

it to stand for a minimum of 24 hours under pressure. If
no pressure drop occurs (allowing for effect due to
changes in ambient temperature) the system is ready for
evacuation; and

(xvi) relieve test pressure to atmosphere, reconnect all lines

and reinstate all items removed or isolated prior to
pressure testing.

4.2.3.3.2 Evacuation and Dehydration

This shall be carried out by specialists assigned by the equipment

manufacturer/ supplier.

4.2.3.3.3 Associated Air Systems

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 Check in accordance with Clause 4.2.3.2.3

4.2.3.3.4 Charging

The procedure to be adopted shall vary according to the make of

unit and type of refrigerant and shall be carried out by specialists.

4.2.3.3.5 Setting to Work and Adjusting

(a) Procedures

After satisfactory completion of procedures in Clauses 4.2.3.1

and 4.2.3.3.1 to 4.2.3.3.4, and before operating the centrifugal
compressor for the first time, a further visual check shall be
carried out on the complete system.

The chilled water and condenser water systems must have been
thoroughly checked in accordance with Clauses 4.1.6 and 4.2.1,
and be ready for operation. For this section to be carried out
completely, some load on the chilled water plant (probably at
least 50%) is necessary.

(b) System Check

(i) Controls

The procedures below shall be followed:

- with all electrical supplies isolated, check wire

connections for tightness and fuses for correct size;

- with centrifugal compressor motor electrically

isolated, check that chilled water pumps, condenser
water pumps, cooling tower fans, and centrifugal
refrigerant plant oil pump operate in the sequence
required, rotate in the proper direction, and that flow
rates and pressures are set to the required levels;

- ensure that centrifugal compressor motor will be

“locked-out” if other equipment essential to its
operation stops for any reason;

- set each control and safety device in accordance with

manufacturer’s instructions, or ensure that factory
settings are correct and have not been disturbed. The
complete control system shall be checked out
generally in accordance with Clause 4.2.3;

- check for satisfactory operation of pilot lights and

reset buttons;

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 - check the settings and the functional operation of the
following items as appropriate to system under
consideration:

 pneumatic/electric switches;

 oil temperature control (this may require check

on operation of sump cooling water solenoid
valve and sump heater);

 oil pressure relief valve;

 oil filter pressure cut-out switch;

 low pressure oil cut-out switch;

 high pressure oil cut-out switch;

 chilled water low temperature cut-out;

 refrigerant low temperature cut-out; and

 cooling tower thermostat and condensing water

controls.

may also be fitted with :

 time delay relay on inlet vane operator;

 vane closed switch;

 time delay relay on oil pump (to prolong running

on shut down cycle);

 timers in main motor starter;

 thrust bearing and transmission bearing high

temperature cut-out thermostat (on compressor);

 timer (to limit number of starts per hour) and

recycling device;

 motor winding high temperature cut-out switch;

and

 flow switches (chilled and/or condenser water).

(ii) Purge Unit (for negative pressure refrigerant i.e. R123)

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 The procedures below shall be followed:

Compressor purge system

Check:

- oil levels in compressor sump and oil separator

sections;

- operation of high pressure control;

- operation of temperature control and purge heater;

- alignment of the motor and compressor shafts, drive

belt adjustment, and lubrication of compressor motor
bearings in accordance with manufacturer’s
instructions; and

- that the system isolating valves are in correct

positions (open/closed).

Thermal purge system

Check:

- in accordance with manufacturer’s instructions and

ensure all valves are in correct position (open/closed).

(c) Start-Up

The procedures below shall be followed :

(i) ensure all electrical switches and starters are in “off”

position and supplies are isolated. Replace any fuses or
leads removed during Clause 4.2.3.3.5 (b)(i);

(ii) ensure all water valves are in proper position;

(iii) place chilled water pump, condenser water pump,

cooling tower fan, refrigeration machine oil pump and
purge system starters in “auto” position and close
isolators;

(iv) start the chilled water and condenser water pumps and
cooling tower fans;

(v) energise the control circuits;

(vi) start the oil pump and allow the main compressor to run;

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 (vii) check the compressor impeller rotation. If incorrect, stop
immediately, electrically isolate, and reverse any two of
the three phase connections. Recheck;

(viii) start the purge system as follows:

- Compressor type
Energise the purge heater and after 30 minutes, start
purge compressor, or in accordance with
manufacturer’s instructions. The longer in time is
better;

- Thermal type
Start in accordance with manufacturer’s instructions;

(d) Shut-Down

The procedures below shall be followed:

(i) stop the compressor and then the chilled water pumps,
condenser water pumps and cooling tower fans in
sequence;

(ii) listen for any unusual sound from compressor or

transmission housing during “closed-down” period;

(iii) check that the operation of oil pump continues until the
time delay relay causes it to stop;

(e) Running-In

The procedures below shall be followed:

(i) restart the plant in accordance with the above Clause;

(ii) check the oil pressure and temperature;

(iii) check the operation of refrigerant agitator solenoid

valves (where fitted) in relation to vane motor crank
angle;

(iv) adjust the motor overload trip mechanism in accordance

with the instructions of the compressor by the
manufacturers;

(Caution: Do not allow motor to operate in overloaded

condition beyond the time permitted by the manufacturer,

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 typically 60 minutes at 105 per cent of full load
amperage).

(v) adjust low limit relay to manufacturer’s instructions;

(vi) check for satisfactory operation of low temperature

control;

(vii) check for satisfactory operation of refrigerant low

temperature cut-out;

(viii) check operation of high pressure cut-out (if necessary

isolated switch and use metered air supply);

(ix) take the gauge and other readings and compare them with
design figures, typically;

- evaporator pressure;

- condenser pressure (measure water temperature if

necessary);

- purge drum pressure;

- oil sump temperature;

- oil level; and

- chilled water and condenser water temperatures.

4.2.3.4 Absorption System

The absorption refrigeration machine shall be factory assembled, though, certain

necessary items may be installed on the Site. Prior to running, the unit must be
pressure and leak tested, evacuated and charged with primary refrigerant
(usually lithium bromide solution) and chemicals.

The charging operations are usually carried out on the Site. In addition,
cleanliness, stage of system and mechanical and electrical components must be
checked.

Check:

(a) that the unit is correctly installed and levelled;

(b) that the chilled water and condenser water circuits are complete and are
ready to operate. Water treatment is available if specified;

(c) that the steam and condensate, or hot water piping system are completed
with adequate pressure gauges, thermometers, and test points;

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(d) for steam piping system: pressure relief valve and safety valve are correctly
set; trapping arrangements are satisfactory; control valve is correctly
installed;

(e) for hot water piping system: control valve is correctly installed;

(f) that steam, or hot water, is available at rated pressure/temperature;

(g) that auxiliary water piping and drains are completed (as may be required for
pump motor and cooling during start-up periods);

(h) that all electrical wiring, starters, motors, and controls are completed;

(i) that pneumatic controls (where used) are installed, pneumatic piping is
completed and tested, air pressure is available;

(j) that all gauges and thermometers (or test points) are installed on water inlets
and outlets to evaporator, absorber and condenser;

(k) that dry nitrogen and refrigerant are available for pressure and leakage
testing (when carried out on the Site);

(l) that lithium bromide solution and chemical oils are available for charging,
together with necessary equipment;

(m) that for the system to be operated and properly commissioned. It is usually
necessary to have at least 75% of the cooling load available;

(n) in conjunction with the manufacturer’s representative, ensure that phase

sequence of power supply is checked and that connections are properly
made before hermetic pumps are operated (for some types of machines).

4.2.3.4.1 Site Leakage testing

(a) Absorption Unit Shell

(i) isolate the purge unit (manual valve between purge drum
and purge pump);

(ii) charge a small amount of the recommended refrigerant

into the unit through the access valve on concentrator
sump;

(iii) raise the gauge pressure within the unit to test figure
(typically 0.75 bar) with dry nitrogen;

(iv) check for leakage with halide torch or electronic leak

detector. In particular, check all welds, joints, float
valves and around the hermetic pumps; and

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 (v) correct or repair any leaks, and retest as necessary.

(b) Purge System

(i) ensure gauge unit is isolated;

(ii) close the gas ballast valve on the purge pump;

(iii) connect vacuum hose to the purge pump exhaust fitting,

place open end of hose in glass container of water and
start the pump;

(iv) purge system is leak free if no bubbles appear in water

after about 10 minutes operation. Pay attention to the
power supply interruption, otherwise water may be
sucked into the system;

(v) if the result is satisfactory, slightly open the gas ballast

valve until bubbles appear in water; and

(vi) remove test equipment. Purge system is now ready for

service.

4.2.3.4.2 Evacuation

This will be carried out by specialists assigned by the equipment

manufacturer/supplier.

4.2.3.4.3 Associated Air Systems

Check in accordance with Clause 4.2.3.2.3

4.2.3.4.4 Charging

This will be carried out by specialists assigned by the equipment

manufacturer/supplier.

4.2.3.4.5 Setting to Work and Adjusting

(a) Procedures

(i) after satisfactory completion of procedures in Clauses

4.2.3.1 and 4.2.3.4.1 to 4.2.3.4.4 and before operating the
absorption machine for the first time, a further visual
check should be carried out on the complete system; and

(ii) the chilled water and condenser water systems must have
been thoroughly checked in accordance with Clauses
4.1.6 and 4.2.1 and be ready for operation. The heating

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 fluid (steam or hot water) circuit must have been
similarly checked and be ready for operation.

(b) System Checks

The procedures below should be followed:

(i) with absorption machine solution pumps electrically

isolated;

(ii) check that chilled water pumps, condenser water pumps

and cooling tower fans operate in the sequence required,
rotate in the proper direction, and that flow rates and
pressures are of the required settings;

(iii) ensure that solution pumps will be “locked-out” if other

equipment essential to their operation stops for any
reasons;

(iv) set each control and safety device in accordance with

manufacturer’s instructions or ensure that factory settings
are correct and have not been disturbed. The complete
control system should be checked out generally in
accordance with Clause 4.3.3;

(v) check the settings and the functional operation (by raising
and lowering the temperature of water at sensing element
if necessary) of the following items as appropriate to the
system under consideration;

 load controller, usually chilled water thermostat;

 operation of automatic control valve on heating

medium. Ensure medium is at the desired
temperature and pressure;

 pneumatic/electric switches (on pneumatic systems)

and set in accordance with manufacturer’s
instructions;

 high temperature control, where fitted; (Typically

factory set to cut out at 24 oC and cut-in at 18oC
refrigerant water temperature.);

 time delay relay for high temperature control;

 low temperature control; (Typically factory set to

cut-out at 2oC and cut-in at 6oC refrigerant water
temperature.);

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  chilled water flow switch (where fitted);

 condenser water flow switch (where fitted);

 cooling tower thermostat. Ensure raising and

lowering of set point can start and stop of the tower
fans;

 condensing water thermostat;

 operation of condensing water control valve;

 setting of motor temperature control protectors;

 some types of machine require refrigerant water for

lubrication of refrigerant and solution pumps. On
these machines the refrigerant sump is dry at start-
up and must be filled with distilled water in
accordance with the manufacturer’s instructions.
Air must not be allowed to enter the system; and

 check operation of float switch controlling

minimum operating level of refrigerant (after filling
of sump where applicable).

(c) Start-Up

(i) ensure all electrical switches and starters are in ‘off’

position and supplies are isolated. Replace any fuses
removed;

(ii) place chilled water pump, condenser water pump and

cooling tower fan starters in ‘auto’ position and then
close the isolators;

(iii) ensure all water valves are in proper position;

(iv) open the heating fluid isolating valve;

(v) start the chilled water and condenser water pumps, and
cooling tower fans; and

(vi) start the absorption refrigeration machine and place

solution pumps in operation (i.e. evaporator, concentrator
and absorber pumps).

(d) Shut-Down

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 The sequence of operation of the ‘dilution’ or shut-down cycle
must be checked. This dilution cycle normally allows the unit
pumps to operate under the control of a time delay relay:

(i) stop the absorption refrigeration machine. The

condenser pumps and the cooling tower fans should stop
immediately and the heating control valve should close;
and

(ii) check that the time delay relay permits the chilled water
pumps and the solution pumps to continue operation
for the period of time specified by the manufacturer
(typically about 7 minutes).

(e) Running-in

(i) with purge unit operating allow the system to operate for
approximately 8 hours and at the same time observe the
performance and make any necessary adjustments.
Ensure purge unit operates satisfactorily;

(ii) after approximately 8 hours, stop the unit, then isolate,

clean and replace all strainers. Return isolating valves to
normal position; and

(iii) if unit operation is satisfactory, arrange for final

insulation of those parts normally left incomplete until
system has been commissioned.

4.2.3.5 Screw Compressor System

The procedure described is for a factory assembled screw compressor water

chiller, which has been pressure and leak tested, evacuated and dehydrated at
the manufacturer’s works, and transported to site as a complete assembly, with
operating chargers of refrigerant and lubricating oil.

Commissioning should be carried out in accordance with the manufacturer’s

instructions.

(a) Check:

(i) that the unit refrigerant and oil charges are intact. If unsatisfactory,
arrange for checks and repair leaks; pressure test, dehydrate and
recharge by the manufacturer;

(ii) that the unit is installed in accordance with manufacturer’s

recommendations and designer’s specification;

(iii) that the unit is correctly levelled;

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 (iv) that vibration isolators (where specified) are provided in accordance
with designer’s instructions;

4.2.3.5.1 Pressure and Leakage Testing

(a) pressure and leakage testing should be carried out on

completion of the Installations, before the unit and the
immediately adjacent pipework connections are insulated, and
before the condenser or evaporator is finally filled with water.

(b) a cylinder of dry nitrogen and a small amount of refrigerant

(recommended by the manufacturer) should be used to pressure
test the system and the refrigerant also serves as a tracer for leak
detection purpose:

(i) charge a small amount of refrigerant into the low side of

the system, using convenient valve to achieve a gauge
pressure of about 2.0 bar. (It is essential to use low side
charging where compressor discharge line is fitted with
check valve.);

(ii) close the charging valve and remove the charging

apparatus;

(iii) carry out preliminary leak test using halide torch or

electronic leak detector;

(iv) connect a cylinder of dry nitrogen to the charging valve

and charge to the desired test gauge pressure
recommended by the manufacturer/supplier;

(v) close the charging valve and remove the charging

apparatus;

(vi) thoroughly re-check the entire system for leaks;

(vii) repair any leaks and retest the system. Leaks must not be
repaired while the system is under pressure;

(viii) when the system is found to be leak-free, allow to stand

for a minimum of 24 hours under pressure. If no pressure
drop occurs (allowing for effects due to changes in
ambient temperature), the system is ready for evacuation;
and

(ix) depressurise the system to atmospheric pressure (where

discharge check valve is fitted, the high side after the
check valve must be separately depressurised).

4.2.3.5.2 Evacuation and Dehydration

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 This will be carried out by specialists assigned by the equipment
manufacturer/supplier.

4.2.3.5.3 Associated Air Systems

Check in accordance with Clause 4.2.3.2.3.

4.2.3.5.4 Charging of Refrigerant

This will be carried out by specialists assigned by the equipment

manufacturer/supplier.

4.2.3.5.5 Setting to Work and Adjusting

(a) Procedure

After satisfactory completion of procedures in Sections 4.2.3.1

and 4.2.3.5.1 to 4.2.3.5.4, and before operating the compressor
continuously for the first time, a further visual check should be
carried out on the complete system.

(b) System Checks

(i) with compressor motor power circuit electrically isolated,

set all refrigeration controls in accordance with PBSE’s
instructions, or ensure that factory settings are correct and
have not been disturbed. All safety controls should be put
through their complete cycle of operation;

(ii) as a guide, typical controls are listed below. Control

settings should be in accordance with the design
specifications; safety settings should be based on
manufacturers’ recommendations;

- pressure switches;

- high pressure cut-out;

- low pressure pump down;

- low pressure cut-out;

- low pressure unload;

- high pressure oil cut-out;

- oil failure switch;

- temperature switches;

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 - freeze-up;

- low water temperature;

- oil sump temperature heater control;

- low oil sump temperature heater control;

- timing relays;

- oil failure relay;

- oil pump coast-down relay;

- compressor loading time delay;

- oil circulating time delay;

- anti-recycling relay;

- flow switches;

- set to cut-in and cut-out at flow rates recommended

by manufacturer;

- set temperature/load controller in accordance with

manufacturer’s recommendation and Clause 4.3.3
(preliminary settings only);

- other adjustments;

- certain types and sizes of screw machine may have

adjustments relating to hydraulic unloader cams,
which should be set by manufacturer’s representative;

- the hydraulic unloader level time should be set by

manufacturer’s representative; and

- this includes:

Fast unload maximum to minimum load;

Minimum load to maximum load; and
maximum load to minimum load.

(iii) with compressor power circuit energised, check:

- the oil pump for correct rotation;

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 - the compressor for correct rotation (momentary start).
Do not let the compressor attain the full running
speed, since if running backwards, high speed
operation may cause damage; and

- checks should be carried out strictly in accordance

with manufacturer’s recommendations.

(c) Start-Up

Manual sequence

(i) switch on heater in oil sump and wait until recommended

oil temperature (typically 43oC) is attained;

Note: Manufacturer may recommend warm-up period of

24 hours with compressor power circuit isolated

(ii) energise compressor control circuits;

(iii) start those items of equipment required to operate by

sequence interlock before compressor is started. Ensure
compressor will “lock-out” if items essential to its
operation stop for any reasons. Check all safety controls
and reset;

(iv) restore power to compressor power circuits, and start the

compressor in accordance with manufacturer’s
instructions, ensuring oil pump operative, compressor
unloading slide valve moves to fully unloaded position,
and other items working correctly by observation of pilot
lights;

(v) if oil pressure does not reach the required pressure the
system will automatically shut down (in approximately 5
seconds). Controls must be reset and/or fault rectified
before proceeding;

(vi) with oil pump operating and correct pressure available,

the compressor will be fully unloaded after the oil
circulating time delay;

(vii) check for satisfactory operation of all pilot lights. Ensure

items such as hot gas injection solenoid valve (when
fitted), small (or single) expansion valve and side oil
injection solenoids are operating correctly;

(viii) on completion of warm-up cycle (2 minutes loading time

delay) check that the main oil injection solenoid valve

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 and the temperature/load controller are activated, and fast
unload solenoid valve is de-energised;

(ix) check the compressor loads as required and pilot light is

operating when loading. Based on the unit with dual
expansion valves, ensure the large expansion valve
operates as loading exceeds 33 per cent;

(x) check and adjust superheat settings to design

requirements (typically within range 10 to 14oC);

(xi) check the oil gauge pressure and level at 100 per cent
capacity (typical 2.0 bar with level to bottom of upper
sight glass in sump); and

(xii) set the temperature/load controller in accordance with

designer’s brief (final settings).

(d) Shut-Down

Automatic Sequence

(i) check that the large expansion valve (if provided) closes
at approximately 25% capacity (may be activated by cam
switch in relation to unloader slide valve travel);

(ii) when the temperature of chilled water reaches the setting

of low temperature switch check that shut-down (which
normally takes place below 10% load) occurs as follows:

- small expansion valve (if provided) is de-energised;

- compressor shuts down at required suction pressure

(typically a gauge pressure of 5.4 bar);

- main and side oil injection valves are de-energised;

and

- temperature/load controller is locked out and all

appropriate pilot lights go out;

- oil re-circulating pump stops after 10 seconds (held in

by oil pump coast down relay) to complete automatic
shut-down; and

- ensure that the anti-recycle relay prevents compressor

from restarting until preset time (15 minutes
minimum) after low water temperature switch cuts
back in.

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 (e) Running-in

Note: These checks should be carried out after approximately

1000 hours of operation:

(i) change the refrigerant filter dryer(s) if moisture shows

“wet” or if the desired pressure differential exceeds
typically a gauge pressure of 0.27 bar;

(ii) take oil sample and submit to compressor manufacturer

for analysis; and

(iii) check cam settings, superheat, sub-cooling temperature

and the unloader speed.

4.2.3.6 Cooling Tower

General criteria for setting up the ground rules for proper T&C of cooling towers
are as described below.

4.2.3.6.1 Conditions for T&C

There are certain conditions that require to be fulfilled before T&C

can commence. Ensure that:

(a) the water system serving the tower has been thoroughly cleaned,
preliminary checks and setting to work and balancing have
been carried out in accordance with Clauses 4.1.6 and 4.2.1;

(b) the fan serving the cooling tower has been set to work in
accordance with Clauses 4.1.7 and 4.2.2 noting any permanent
obstruction and removing all foreign obstructions;

(c) the interior fills of the tower are properly cleaned and free from
foreign materials such as scale, algae or fur;

(d) the water level in the tower basin is maintained at the proper
level, making sure by visual check of the basin sump that the
centrifugal action during full flow does not cause any
entrainment of air which may cause pump cavitation;

(e) all valves except balancing valves in the water system are in
full open position; and

(f) provisions for facilities to determine make-up and blowdown

water flow rates are available.

4.2.3.6.2 Test Method

The actual test method consists of the following steps :-

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 (a) determine volume of water in the tower, volume of make-up
water and volume of blowdown water;

(b) record temperature of make-up water;

(c) measure the volume and temperature of make-up water at the

point of entry to the system;

(d) measure the volume and temperature of blowdown water at the

point of discharge from system;

(e) measure inlet and outlet dry and wet bulb temperatures;

(f) use entering & leaving wet bulb temperatures to determine the
tower performance against design;

(g) use entering and leaving dry and wet bulb temperatures to
determine the rate of evaporation involved;

(h) measure wet and dry bulb temperatures between 1 and 1.5
metre from the tower on all sides. These readings should be
taken half-way between the base and the top of the inlet louver
at not more than 1.5 metre spacing horizontally and averaged
out;

(i) note any unusual inlet conditions, wind velocity and wind
direction at the time of test;

(j) take readings continually with a minimum of time lapse

between readings; and

(k) if the first test indicates a tower deficiency, perform 2 additional

tests to verify the original readings.

4.2.3.7 Automatic T&C

Automatic T&C procedures of refrigeration plants described in this section are

only applicable to a refrigeration system with CCMS or otherwise specified in
the Particular Specification and are mainly on conditional and performance
basis as follows:

(a) the recommended procedures state the ways to undertake automatic testing,
monitoring and commissioning of the refrigeration system in achieving the
designed functions and performance specified;

(b) these procedures shall not be treated as the starting-up T&C for individual
refrigeration machines such as chillers, pumps, cooling towers, etc., which
require to be closely monitored, aligned, adjusted, tuned and balanced by
skilled and experience technicians in accordance with the

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 manufacturer’s/supplier’s recommendations for smooth operation without
any initial damages; and

(c) the chiller & CCMS shall have a high level integration.

4.2.3.7.1 Automatic Scanning and Logging of Status and Conditions of

Refrigeration Plants

Below is a list of the recommended output signals to be linked to

the CCMS so that the conditions of the refrigeration plants can be
closely monitored. Exact details and point schedules shall refer to
the Particular Specification and Contract Drawings.

(a) entering and leaving chilled water temperatures of each chiller;

(b) entering and leaving condenser water temperatures of each

chiller;

(c) condenser refrigerant temperature and pressure of each chiller;

(d) evaporator refrigerant temperature and pressure of each chiller;

(e) oil supply temperature and pressure of each chiller;

(f) entering and leaving condensing water temperature of each

cooling tower (for water cooled system only);

(g) entering and leaving hot water temperature of each heat

recovery unit (for refrigeration plant with heat reclaim unit);

(h) on /off / fault status of each chiller water / condensing water /

chemical dosing pumps;

(i) on / off status of each chilled water / condensing water /

refrigerant motorised on / off valves;

(j) fault signal(s) from each chiller, cooling tower, variable speed
controller and other refrigeration machines;

(k) electrical operating voltage and current of each chiller / chilled

water pump / condensing water pump / cooling tower fan; and

(l) other signals stipulated in the Particular Specification, Contract

Drawings or recommended by the manufacturer / supplier of
that particular refrigeration machine.

4.2.3.7.2 Automatic Configuration of Optimum Sequencing of Chillers

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For a refrigeration system requesting automatic optimum
sequencing control of chillers, an energy programme developed in
the CCMS shall be able to carry out the following automatic
procedures in working out the optimum chiller-sequencing
configurations. The full load and partial load energy performance
of each chiller (provided by the following automatic testing of
chiller’s performance) shall be input to the CCMS and the energy
programme shall then work out the most energy efficient chiller
combination under different load demand conditions.

Automatic testing of chiller’ s performance

(a) for constant condenser air (air-cooled chiller)/water (water-

cooled chiller) entering temperature, % full load (input) against
% full load capacity table/chart shall be provided by the
manufacturer or supplier. Database in software format shall
also be available for performance monitoring and testing at
both partial and full load conditions. In order to continuously
monitor and compare the actual chiller performance, real-time
measurements of the condenser air/water entering temperature,
leaving chilled water temperature, entering chilled water
temperature and mass flow rate of chilled water are therefore
required;

(b) for continuous measurement of condenser air/water entering

temperature, leaving chilled water temperature (T1), entering
chilled water temperature (Te), mass flow rate (m), and specific
heat capacity (Cw) the following instruments shall be
permanently installed as shown in Figure 4.2.3.7.2 below for
automatic logging of their instant values. The accuracy for
temperature sensors and flow meters shall be at least 0.5% with
the full load.

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TEMPERATURE
SENSOR

DDC
Ts Ts
Tl1 Te1
CCMS
CHILLER
m1

DDC
Ts Ts
Tl2 Te2

CHILLER
m2

DDC
Ts Ts
Tl3 Te3

CHILLER
m3
DDC
M COMMON PIPE

BY-PASS
m4
MODULATING
VALVE m5

FLOW METER

Fig. 4.2.3.7.2 Typical chilled water schematic diagram

All output data of the instruments mentioned above together

(input) (manufacturer shall normally provide built-in
measurement instruments to measure the input power). These
instant values shall be transferred to CCMS via DDCs for
calculation of the cooling capacity using the equation (Cooling
capacity of the chiller = m Cw (Te-T1)) and then used to
compare with the manufacturer’s chiller performance
table/curve/ database at the same condenser air/water entering
temperature. The real-time chiller’s performance and
comparison result can be read directly from the monitor or
printed-outs. For chillers without built-in % full load (input)
against % full load capacity database, separate instrument for
measurement of % full load (input) shall be provided;

(c) for full load performance test, the following procedures are
used:

(i) for parallel chillers as shown in Fig.4.2.3.7.2, except the

branch containing the chiller to be tested, all other chillers
should be decoupled and isolated from the chiller system
by shutting down the chillers and closing the
corresponding motorised valves at the common pipe i.e.
the (by-pass de-coupler) under the control of the CCMS;

(ii) at the same time, the testing chiller will sense the
substantial temperature difference between the entering
and leaving chilled water. The compressors of the testing
chiller will cut-in one by one until the testing chiller
reaches the full load condition; and

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 (iii) from the data obtained from the instruments mentioned
above via DDC, the full load cooling capacity of the
chiller will be calculated by the CCMS using the equation
(Cooling capacity of the chiller = m Cw (Te - T1)) at that
condenser air/water entering temperature. Those results
are then compared with the database (supplied by the
chiller manufacturer) for full load cooling capacity of the
chiller at the same condenser air/water entering
temperature. The real-time chiller’s full load
performance and comparison result can be read directly
from the monitor or print-outs.

4.2.3.7.3 Automatic Performance Data Logging

If so specified in the Particular Specification or Contract Drawings,

an energy programme shall be so designed in the CCMS that a
continuous performance monitoring of the refrigeration plants can
be undertaken automatically by the CCMS.

(a) for the implementation of this test, energy meters shall be

installed to measure the actual chilled water energy output and
the actual power consumption of each chiller and its associated
chilled water pump and condenser water pump;

(b) the chilled water energy output will then be plotted against the
actual power consumption under different load profile in order
to work out performance curves for each chiller;

(c) for a full range of performance data, the test should be carried
out for a sufficient long period of time (say 12 months or within
the whole Maintenance Period) such that data can be obtained
from each chiller from its full load condition to the lowest
partial load condition; and

(d) the information obtained in the test will form an important

database in the CCMS to monitor the conditions of the
refrigeration plants and hence the arrangement and scheduling
of maintenance works after the Maintenance Period.

4.2.3.7.4 Testing of Safety Devices for Refrigeration Plants

For testing of safety devices in chillers such as high pressure cut,

low pressure cut, no flow trip, high oil temperature / pressure cut,
etc., the T&C works can be carried out manually or if specified by
using a simulator provided by the manufacturer / supplier and
undertaken by a skilled and experience personnel assigned by the
manufacturer / supplier. Every necessary step shall be taken to
prevent the refrigeration machines from being damaged
accidentally during the tests.

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4.3 Other Relevant Tests and Inspections

4.3.1 Indoor Air Quality (IAQ)

Before completion of the Installations, testing and commissioning of IAQ equipment

and system shall be carried out to the satisfaction of the Supervising Officer or to meet
the requirements as stated in the Particular Specification.

Testing and commissioning of IAQ installation shall be undertaken by the contractor’s

own competent specialist staff or by a competent independent commissioning
specialist nominated by and acting for the contractor and approved by the Supervising
Officer. The option chosen shall be declared in the Tender Document.

4.3.1.1 IAQ Parameters

Detailed requirements relating to IAQ shall be under Section 6.3 of the General
Specification. IAQ parameters and their level of control are specified in the
Particular Specification.

All IAQ parameters shall be measured by calibrated real-time monitors with

data logging except the following:

(a) airborne bacteria colony count; and

(b) HCHO and O3 may use passive sampling methods but real-time monitoring
is still preferred to passive sampling methods.

4.3.1.2 General Commissioning Requirements

Systems shall be properly adjusted and commissioned to ensure that the

equipment achieve the designed airflow rates. The following general
requirements shall be met before actual testing and commissioning of IAQ
installation are carried out.

(a) Plant rooms are free of construction waste and debris;

(b) Access doors to plant rooms are fitted and lockable;

(c) All builder’s works associated with the IAQ systems must be completed
and painted with dust preventing compound;

(d) All ceiling works are completed;

(e) All dust generating activities by other trades are completed and all areas
thoroughly cleaned to prevent ingress of building dust and debris into the
return air or fresh air intake systems;

(f) Air intake screens and louvres are unobstructed and clean;

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 (g) Fan and other equipment chambers are clean and free of construction debris;

(h) Fans are checked for proper operation;

(i) Floor gullies and drainage traps are clear and operational;

(j) All condensate drains and trays are clear and water can be drained away
satisfactorily;

(k) Dampers are clean;

(l) Ducting and other air passage ways are clean;

(m) All outside air, return air and spill air dampers are operative;

(n) All volume control dampers are fitted and are at appropriate opening
positions;

(o) Ductwork systems are cleaned by purging of the supply air fan, or by robot
duct cleaning recommended by the ductwork cleaning specialist;

(p) All VAV and CAV terminals are installed, together with grilles and
diffusers;

(q) All filter media are installed; and

(r) Air conditioning systems and the building indoor area are purged to the
standard acceptable by the Supervising Officer.

4.3.1.3 T&C Requirements

After the general commissioning requirements have been verified by inspection,

testing and commissioning of the following IAQ equipment and systems shall
then be carried out in accordance with the relevant BSB T&C Procedures.

(a) All air handling : Fans, AHUs, FCUs, water scrubbers, Terminal Air
equipment Control devices, grilles and diffusers.

(b) Air cleaning : All pre-filters, main filters, high efficiency filters
equipment and chemical filters, UV sterilising light assembly
and activated oxygen air purifier

(c) All ductwork : All ductwork, hoods and dampers.

and accessories

T&C procedures shall be carried out by licensed personnel as shown in Clause

6.3.1.2.1 of the General Specification to adjust and regulate the system and
equipment so as to achieve the IAQ parameters.

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 The IAQ T&C shall be in-charged by a qualified personnel with qualifications
indicated in Clause 6.3.1.2.1 of the General Specification.

4.3.1.4 IAQ Assessment and Methodologies

IAQ assessment shall be performed as the last part of the testing and
commissioning process upon completion of the ACMV installation. Further
assessments shall also be done six months after the building has been occupied
and at two months before the expiry of the certified Maintenance Period, i.e.,

(a) First Assessment : After testing & commissioning

(b) Second Assessment : 6 months after occupation of building or

substantial completion

(c) Third Assessment : expiry of Maintenance Period

IAQ compliance shall be proved by results of measurements. In addition, an end

user satisfaction survey shall be conducted before expiry of the certified
Maintenance Period.

4.3.1.5 IAQ Measurement

For measuring IAQ compliance, assessment shall be carried out by the real-time
monitoring method, the integrated sampling method or airborne bacteria
sampling method. Real-time monitoring shall be used for detection of pollutant
sources and provide information on variation of pollutant levels throughout the
day. The integrated sampling method, either active or passive sampling, shall
be carried out by taking samples of a particular pollutant over 24-hour basis to
obtain the total exposure level data. If it is not practicable to have 24-hour
samples, short-term sampling to cover the worst scenarios shall be considered
subject to approval of the Supervising Officer. All measurements shall be
conducted with the use of calibrated instruments and equipment, standards and
reference materials with traceability to international or national standards. The
corresponding reporting forms of these three methods are as follows:

(a) IAQ Measurement using Real-time Monitors;

(see Reference no. 4.25 & 4.26 of Annex II & Reference No.1 of Annex V )

(b) IAQ Measurement using Integrated Sampling Methods; and

(see Reference no. 4.25 & 4.27 of Annex II)

(c) IAQ Measurement using Airborne Bacteria Sampling.

(see Reference no. 25 and 29 of Annex II)

4.3.1.6 Sampling Method

The sample method, location of measuring & monitoring IAQ parameters and
measurement method of IAQ parameters shall refer to Part D and as detailed in
the Particular Specification requirement.

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 A walkthrough inspection shall be carried out to identify any inadvertent faults
rendering the premises failed to attain the IAQ Objectives, a walkthrough
inspection checklist is provided at Reference no. 4.24 of Annex II.

Proper sampling positions shall be determined during the walkthrough

inspection and mark the positions on the building layout plans. The guidelines
for the minimum number of sampling points required are as follows:

Total floor area to be tested Minimum Number of

(served by MVAC system) (m2) Sampling Points
< 3,000 1 per 500 m2
3,000 to < 5,000 8
5,000 to < 10,000 12
10,000 to < 15,000 15
15,000 to <20,000 18
20,000 to < 30,000 21
 30,000 1 per 1,200 m2

However, the qualified examiner should exercise his/her professional

judgements to take additional samples if he/she considers necessary.

All air samples shall be collected at 1.0 - 1.2 m above the floor level.

Use real-time monitors to sample the levels of IAQ parameters at a minimum

25% of sampling positions, each position for 5 minutes. Check if they can meet
the prescribed control levels. If yes, carry out IAQ measurements.

4.3.1.7 IAQ Measurement using Real-time Monitors

(a) real time monitors shall be incorporated with data logging facilities. The
logged data shall be uploaded to suitable devices for storage and data
analysis. The measurement principles of the monitors are provided at
Reference no. 1 of Annex V. Alternative measurement principles shall be
allowed subjected to the approval of the PBSE;

(b) except air velocity, the measurement time at each sampling position shall
be of minimum 8 hours and covering the whole normal operation hour of
the building, at least one reading should be taken every 5 minutes. Shorter
sampling time shall be allowed subject to the approval of the PBSE;

(c) before sampling, a unique identification code should be assigned to each

sample to be collected. These identification codes will indicate the IAQ
parameter, the sampling location, and whether the sample is a primary or
duplicate sample. In addition to labelling, documentation of sampling
equipment, pump airflow rates, start/stop times, sampling conditions,

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 names of technicians, and other appropriate sampling collection
information are also necessary;

(d) turn on the real-time monitor, check correctness of operation parameters

(e.g. mode, logging interval, etc.), and then allow the monitor to log data;

(e) after logging data for the required sampling period, upload the data to
suitable devices for storage and data analysis. Ignore the readings of the
initial 10 minutes, and then obtain the highest value of 8-hour average;

(f) sample the outdoor air condition in parallel with the sampling of the indoor
condition, the minimum sample of outdoor shall be 4 number 5-minutes
samples taken at 4 time slots distributed within an 8-hour sampling period;

(g) report and record the results, a record form is provided at Reference no. 4.26
of Annex II; and

(h) since the air velocity usually will not fluctuate with time, therefore a shorter
sampling time can be allowed and to be determined by the qualified
examiner.

4.3.1.8 IAQ Measurement using Integrated Sampling Methods

(a) before sampling, a unique identification code should be assigned to each

sample to be collected. These identification codes shall indicate the IAQ
parameter, the sampling location, and whether the sample is a primary or
duplicate sample. In addition to labelling, documentation of sampling
equipment, pump airflow rates, start/stop times, sampling conditions,
names of technicians, and other appropriate sample collection information
are also necessary;

(b) the sampling time at each sampling position shall be of minimum 24 hours
and covering a normal operation day of the building;

(c) take a 24-hour sample of the outdoor condition in parallel with the sampling
of the indoor condition;

(d) send the samples to the laboratory for analysis within 5 days. Before
analysis, the sampling tubes / filters / bags / canister should be treated and
stored as per manufacturers' recommendations. The laboratory results
should be signed by an approved signatory; and

(e) report and record the results, a record form is provided at Reference no. 4.27
of Annex II.

4.3.1.9 IAQ measurement of Airborne Bacteria Sampling

(a) before sampling, a unique identification code should be assigned to each

sample to be collected. These identification codes shall indicate the
sampling location, and whether the sample is a primary or duplicate sample.

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 In addition to labelling, pump airflow rates, start/stop times, sampling
conditions, names of technician, and other appropriate sample collection
information are also necessary;

(b) at each sampling position collect 5-minute samples using Andersen multi-
hole impactor samplers with Tryptic soy agar plates at 4 time-slot evenly
distributed within an 8-hour sampling period covering periods of highest
number of occupancy of a normal operation day;

(c) collect 5-minute samples of outdoor air at 4 time-slots in parallel with

sampling of indoor air;

(d) send the plates for incubation in less than 24 hours. Incubate the plates at
30C for 48 hours, and then perform bacterial count. Standard aseptic
techniques should be practised throughout the whole process; and

(e) report and record the results, a record form is provided at Reference no. 4.28
of Annex II.

4.3.1.10 10% of the integrated samples shall be performed for quality control including
duplicate samples, and field blanks.

4.3.1.11 Report the T&C Result of IAQ measurement by using the report form provided
at Reference no.4.25 of Annex II.

4.3.2 Energy Efficiency Equipment & Systems

T&C shall be demonstrated by carrying out that the installed air-conditioning and
ventilation equipment and system can satisfactorily perform to the requirements on
energy efficiency and energy conservation as stipulated in the Code of Practice for
Energy Efficiency of Building Services Installation issued by the Electrical and
Mechanical Services Department (EMSD), hereinafter referred to as the “Building
Energy Code” or “BEC”.

T&C should be properly carried out before the handover of projects in order to verify that
the energy efficiency performance of the following equipment and system, but not limited
to, based on technical documents and calculations submitted, can be adequately achieved.

(a) minimum coefficient of performance of major air-conditioning and ventilation

equipment;

(b) minimum working efficiency of fans, pumps and motors;

(c) maximum amount of system energy reclaimed; and

(d) optimum working performance of motion detecting sensing device, enthalpy control
device of free cooling, heat pipe installation, solar heating installation, dehumidifiers
and outdoor air pre-conditioners.

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Tests for evaluating the energy efficiency performance of equipment would be classified
into factory test and field test.

(a) factory test on equipment should be conducted according to the recognised testing
standards such as AHRI, ISO, BS EN and so on. Certificates should be issued in
order to demonstrate that the technical requirements on energy efficiency as laid
down in the Particular Specification are being complied with satisfactorily;

(b) field test should only be conducted after a set of working details agreed between the
contractor and PBSE. Full set of calibrated instruments should be provided for taking
record on design temperature, volumetric and mass flowrate and pressure of air and
water at relevant locations, air relative humidity, equipment operating current and
voltage and overall power input to the air-conditioning and mechanical ventilation
installations (ACMV);

(c) before the commencement of actual T&C works, the relevant forms specified by the
EMSD under the Buildings Energy Efficiency Ordinance should be updated and
submitted;

(d) factory endorsed T&C guidelines for illustrating the compliance of energy efficiency
performance requirement should be submitted for checking and agreement;

(e) calibration certificates of instruments to be used in T&C should be submitted for

checking;

(f) initial visual inspection of the installed air conditioning and ventilation equipment
and system shall be carried out;

(g) if the actual site condition could not allow full load for system testing, a simulated
load shall be agreed and generated for testing;

(h) run in the installed air conditioning and ventilation equipment and system for a short
period of time before it becomes steady;

(i) monitor the steady state system performance;

(j) measure relevant system performance parameters such as air and water temperature,
flowrate, pressure, relative humidity, on/off position of dampers and valves and so
on. Based on those measured data and valid scientific equations to verify if the
attained energy efficiency performance of the equipment and system is acceptable
according to the Particular Specification;

(k) results of T&C works should be properly documented and certified by the contractor
and PBSE; and

(l) post-occupation energy efficiency and consumption audit has to be held before the
issuance of Maintenance Certificate for deciding on whether there is any adjustment
and correction to the system operation logic to be made in order to maximise the
working efficiency of the system.

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4.3.3 Control Systems

The T&C of CCMS and Building Automation System (BAS) should be carried out by
specialists. Control systems as defined herein relate to ‘on the plant’ control systems,
including pressure/temperature sensing points, motorised valves, dampers, etc. with
which the CCMS/BAS may interface.

It is essential that all wirings within the control panel should be checked to avoid any
loose connections and to ensure correct terminations in compliance with wiring diagrams.
In addition, it is also assured that functional checks to ensure that all interlocking and
sequencing have been carried out in accordance with the requirements and specifications.
It is also critical that the procedures described elsewhere relating to the regulation of air,
water, refrigeration systems and any other connected equipment/systems have been
carried out prior to commissioning the control system.

Generally, the commissioning procedure shall comply with that set out in the CIBSE
Commissioning Code "C" - Automatic Control.

4.3.3.1 Automatic Control System

4.3.3.1.1 Off Site Preparatory Work

Positions for all space thermostats are provisionally shown on the

Contract Drawings. The exact final locations shall be selected to
give maximum coverage of each space by the control system. The
location shall be proposed in the installation drawings and shall be
approved by the Supervising Officer before installation of the
conduit/box and thermostat.

The following document and drawing shall be prepared and

submitted to the PBSE for approval before carrying out T&C work
for the Automatic Control System. The document and drawing
shall include but not limit to the followings:

(a) list of systems, plants and equipment to be carried out T&C;

(b) list of systems, plants and equipment to be interfaced with the

CCMS and BAS if any;

(c) schematic and control wiring diagrams of Automatic Control

System;

(d) location and quantity of sensing, monitoring and control

equipment;

(e) detailed system description for Automatic Control System;

(f) logic diagrams for Automatic Control System;

(g) list of tools and equipment for on the Site T&C;

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 (h) calibration certificates of tools and equipment for on the Site
T&C; and

(i) form of T&C checklist (refer to Annex II).

4.3.3.1.2 On the Site T&C Works

(a) Preliminary Checks

This section is common to all types of system. Before

attempting to set up automatic controls, it should be ascertained
that the following requirements are satisfied;

(i) all electrical supplies are isolated;

(ii) all control components are installed in accordance with

specified requirements and manufacturers’ instructions,
e.g., that control valves are correctly positioned and
ported and that temperature and humidity elements suit
the temperature ranges so involved;

(iii) all safety devices including circuit interlocks and cut-out

shall be correctly inserted into the overall operational
plan and will effectively carry out the purpose intended;

(iv) all sensing elements are located in a position which will

give good representation of the controlled variable and
are not subject to extraneous influence;

(v) measuring instruments have been calibrated against

certified standards;

(vi) After installation of all the instruments and connecting

leads and sampling points, the commissioning engineers
shall check the installation and adjustment of the
instruments to ensure they are in proper working order.
Calibration charts shall be provided together with the test
certificates. Records of settings / pressure-levels /
positions of actuators, limits, etc. shall be provided;

(vii) As far as practical, the adequacy of the interlocking alarm

circuits shall be demonstrated, by simulation of fault
conditions and

(viii) Functional tests shall be carried out for equipment inter-

related with fire services and CCMS control.

(b) Operating Checks

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 Check:

(i) that at full rated flow of the controlled media, the pump
and fan pressures are within design tolerances
immediately prior to setting-up;

(ii) that the input temperature of the controlled media and the
pressure at the input of the controlled device at full design
flow condition are each within specified design limits and
that the pressure difference across the device comply to
design requirements;

Note: In the case of variable fluid flow the pressure

available at any particular controlled device will tend to
vary in relation to demands at other points of regulation
within the system. There will also be some variations of
the temperature of fluid available at the inlet of the device
particularly at low-flow condition; and

Checks must be made to ensure that at any point in the

system the fluid to be controlled is not only available
within the specified limits of temperature and pressure
but that the controlled device continues to provide the
degree of control required throughout the range of
variations in flow and pressure to which the system may
be subjected;

(iii) that the movement of the controlled device matches with

the travel of the actuator. For example, examine the
damper-actuator assemblies.

(c) Electricity Supply and Wirings

The following checks are to be made before switching on the

electricity supply:

(i) that the wiring has been installed to the required

standards and regulations and is in accordance with
manufacturers’ requirements. Special care should be
taken to ensure that the cable possesses suitable physical
and electrical characteristics and that earthing suits the
regulations of the equipment;

(ii) that all connections are in accordance with the relevant

wiring diagrams supplied; and

(iii) that the electrical supply at the point of distribution for

the control system is correct and that suitably rated fuse
is available.

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 (d) Connection to Electrical Supply

Switches for the electrical supply is provided.

4.3.3.1.3 Electrical and Electronic Control Systems

(a) Check-out, Calibration and Setting-up Procedures

The procedure applies main component parts of the system as

follows:

(i) valves, dampers and other actuators; and

(ii) controllers and detectors.

(b) Actuating Units

Check:

(i) that the actuator has the correct movement so that it will
give the required travel of the final control device;

(ii) that any linkage adjustments for rotation lift or close-off

have been suitably set;

(iii) that in the case of spring return motor is fitted, the

position assumes, upon interruption, the power supply is
correct;

(iv) that all actions intended to succeed an interruption of

power, and the subsequent reinstatement, are properly
followed; and

(v) that throughout the procedures there are smooth and

regular movement of the actuating motor and regulator.

Note: In the case of valve control, it calls for attention to

gland packings and in the case of dampers that they do
not bind at the bearings or are mechanically unsound.

(c) Controllers

Calibrate as follows:

(i) move the set-point to the controller so that it is equivalent

to the condition measured at the detector. It may be
necessary to stabilise the conditions at the detector during
this T&C Procedure;

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 (ii) set the proportional band of the controller to the design
value. For 2 and 3 term controllers, these settings should
suit the characteristics of the plant;

(iii) in the case of controllers, which are to be reset by other

source signals, or other stage, signal inputs shall be
connected in accordance with the calibration procedure
for that particular instrument. For example, adjust
‘Authority’ settings as required and where applicable;

(iv) with proportional controllers, incremental movements of

the set-point should give proportional movement of the
final control device in the required direction. Check that
the total movement of the set-point to give full movement
of the control device corresponding to the proportional
band setting;

(v) in the case of two-position control check that the

switching action is correct and any internal heaters are
disconnected during calibration;

(vi) adjust the set-point to the specified desired value; make

‘Dead Zone’ adjustment where applicable;

(vii) cancel any measures that may have been taken to stabilise
the conditions at the detector thus returning the plant
ready for normal working; and

(viii) adjust proportional bands of controllers to attain the

minimum deviation consistent with stable control. In the
case of timed two-position and floating control systems,
set the design differential and where applicable, the time
interval which is consistent with stable control and the
minimum deviation.

(d) DDC Controller

(i) use an engineering tool e.g. portable computer;

(ii) verify whether the control program is downloaded or not;

(iii) verify the time and date of the real time clock;

(iv) set correctly the data transmission rate of the controller;

and

(v) verify the proper communication in the network by

checking the network indication;

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(vi) check the performance of the controller and calibrate the
input and output points as follows:

1. Analogue input

• take the reading of the sensor connected to the

controller;

• compare the reading with gauge reading or

instrument reading; and

• calibrate the sensor if necessary. (calibration

certificates should be submitted).

2. Digital input

• read the initial status of the point;

• manually start the equipment or simulate an

alarm condition;

• verify the change of the status or appearance of

alarm;

• resume the condition back to initial state; and

• verify the resumed condition.

3. Analogue output

• force the controller to give 0% output signal;

• verify the position of the actuator by sight or the

running condition of the equipment by gauge
reading;

• repeat the verification for 33%, 66% and 100%

output signals; and

• calibrate the actuator if necessary. (calibration

certificates should be submitted).

4. Digital output

• read the initial state of the point;

• force the controller to send ON or OPEN signal

• verify the proper action of the actuator or

equipment by sight;

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 • force the controller to send OFF or CLOSE
signal; and

• verify the resumed signal of the actuator or

equipment by sight.

(e) Sequence Control

any interlocking or overriding devices should be checked to

ensure that the overall sequence of control is achieved.

(f) Plant Operation

following the T&C procedures, the design conditions should be

achieved and maintained for a suitable period of observation
with a minimum of one operation. If the conditions cannot be
achieved or maintained, then a check on the final control
devices should be carried out to ascertain that maximum
correction has been applied. If this is not satisfied, investigation
beyond the control system is needed.

4.3.3.1.4 Completion of T&C

Record document and drawings shall be submitted after the

completion of T&C.

The final T&C report shall be kept in the Operating and

Maintenance Manual for permanent reference and easy access.

4.3.3.2 Central Control Monitoring System (CCMS)

4.3.3.2.1 Off Site Preparatory Work

Document and drawing as specified in the General Specification

shall be prepared and submitted to the PBSE for approval before
carrying out the CCMS T&C work.

4.3.3.2.2 On the Site T&C Works

Pre-commissioning

Pre-commissioning shall include the checking of the installed

software and hardware (e.g. wiring, sensors and actuators) and any
items of plant with integral controllers;

The test equipment and instruments shall have been calibrated within
the specified period according to the manufacturer’s
recommendations. The calibration certificates shall be submitted to
PBSE for record;

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All physical adjustments to the CCMS field devices shall be marked.
Volt free and control terminals shall be checked such that they are
separated from mains voltage.

(a) Checking and Set-up

(i) Level of CCMS Performance Checking

Checking the performance of a CCMS shall be conducted at

several different levels:

- Level 1 : Component level

e.g. sensors, actuators, controllers / routers /gateways,
terminal workstations, field devices;

- Level 2 : Sub-system performance

e.g. individual chillers, air handing units and equipment,
etc.; and

- Level 3 : Building and zone performance

e.g. environmental control in zone or building.

The checking can be performed from the workstations (in a

remote control room) or in the plant room itself. Level of
CCMS performance testing is as shown in Figure 4.3.3.2.2
below.

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 Level 3 – Level 2 – Sub-system and Level 1 –
Building/Zone equipment Component

Test: Test: Test:

 Zones  Chillers Analogue inputs
 Building  Air handling units  Temperature sensors
 Any systems/equipment  Humidity sensors
specified in the Contract  Pressure sensors
 Voltage
 Current
 Flowrate

Digital inputs
 Relays
 Switches

Analogue outputs
 Actuators

Digital outputs
 Relays

Test for: Test for: Test for:

 Temperature  System response  Accuracy
 Humidity to inputs  Operation
 Light  Control loops  Alarms
 Carbon dioxide  Sequencing  Address
 Ventilation rate
 Energy consumption

Fig. 4.3.3.2.2 – Levels of CCMS Performance Testing

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(ii) Preliminary check

All major components are installed in accordance with the

drawings.

(iii) Electrical Supply & Batteries

To check for correct power supply to the CCMS

(iv) Visual/Physical inspection

A checklist shall be submitted but not limited to the following

for visual checking: -

1. CCMS wiring;

2. Field devices;

3. Controller /Router /Gateway /Interfacing Unit; and

4. CCMS Workstation/Server;

Visual inspection shall be carried out to check for any

physical damage and assess the readiness for pre-
commissioning. Defect list shall be raised to initiate the
remedial work before commissioning;

5. Wiring

• correct type of cables according to the specification;

• identification of cables;

• security of fixing/protection of cables, etc.;

• secure termination of wires; and

• in accordance with the Electricity (Wiring)

Regulations;

6. Sensors and actuators

• correct location/orientation;

• type as specified;

• actuator linkage connected and adjusted; and

• identification correct;

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7. Digital inputs/outputs

• location as specified; and;

• identification correct

8. Controller/Router/Gateway/Interfacing Unit

• type as specified;

• mechanical fixing for Controller / Router / Gateway

/ Interfacing Unit firmly located;

• identification correct;

• all cables terminated and identified;

• power available, i.e. correct and healthy electrical

power supply;

• hardware configuration in line with design;

• all electronic devices in place; and

• wiring diagram;

9. CCMS workstation/server

• type as specified;

• sufficient power outlets available;

• cleanliness for operation; and

• data ports for network connection;

10. Control wiring connection

• cable type as specified;

• cable identified at both ends;

• correct input/output;

• correct and secure termination;

• separation of mains and signals cables; and

• no short circuits (line to line and line to earth).

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(b) Component and System Checking

(i) Control Strategy/Software

The logic diagrams for CCMS can be used to check the

software of CCMS

1. Set Points

• check that realistic numbers and ranges have been

entered for all set points;

2. Time Control

• Check that suitable on/off times are entered for all

timed routines, and that they operate the relevant
plant as required;

3. Interlocks

• Check that all interlocks are in place and work-test

by individually switching interlocked items of plant;

4. Control Loops

• Check that each control loop is in place and that the

necessary default values have been added to enable
testing to proceed;

• Test the operation of control loop.

5. Sequencing

• Check that sequence control is provided and it

sequences plant in the specified manner;

6. Start-up & Shut down

• Check the start-up routine for the correct sequence

of operations for the plant controls;

• Check that the defined restart routine is effective

when power is reinstated after failure; and

• Run a similar check on the shut-down routine and

check status of dampers, valves etc. after shut-down;

7. Plant Change Over

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 • The automatic change over of plant on plant failure
or when a specified number of hours run has been
reached should be checked by failing plant or
“manually” increasing the hours run;

8. Alarm Function

• Check the operation of each alarm function; and

• Check the level or category of alarm, its destination

and how it is reported;

9. Graphics

• Check the text display and graphics to avoid

inconsistencies.

(ii) Controller/Router/Gateway/Interfacing Unit

1. Check that the “as built” drawings incorporate the latest

modifications;

2. Check metalwork; hinges on doors, flush doors, opening

and closing of doors, no sagging or drooping of doors
when open, interlocking of doors;

3. Check secure operation of door locks;

4. Check for location and labelling of switches and

indicators (including colour). Check that plastic rivets or
screws are used to mount labels;

5. Check the scale of analogue/devices;

6. Check that: -

• access for incoming/outgoing cables;

• all doors/gland plates to be earthed;

• tightness of all connections;

• colour coding and numbering of all cables as

specified;

• numbering of all terminals;

• segregation of power cabling and switchgear from

control cabling and electronic equipment.;

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 • connections between panel sections are numbered
as specified, accessible and physically simple to
connect / disconnect.;

• link type terminals for CCMS cables.;

• spare space is provided as specified.;

• labelling of equipment in Controller/Router/

Gateway/Interfacing Unit; and

• screen and earth connections cabling associated

with CCMS equipment in compliance with
manufacturer’s installation requirements.

7. Sensors (See Annex IV Fig. 1)

• Check that the sensor output is within the expected

range. The sensor output shall be compared with
the reading on the test instrument;

• If a sensor is not linear over its working range,

check the sensor at the upper, middle and lower
points of its normal working range; and

• Check for offsets in the software.

8. Digital Signal (See Annex IV Fig. 2 )

• Check that the signal is sensed correctly by the

CCMS;

• Check that each contact is correctly at open or

closed state and that it can change in response to the
relevant item of plant being switched;

• If available, feedback signals from the digital

outputs should be checked against the controlling
digital outputs;

• Check the status lights on the digital output boards

in the Controller/Router/ Gateway/Interfacing Unit;

• If a device is switched on or off, the effect can

usually be monitored by another CCMS input; and

• Check that no unexpected / additional / temporary

software override or interlock have been enabled.

9. Analogue Signal (See Annex IV Fig. 3)

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 • Check the position indication signal that agrees with
the analogue output signal to the actuator;

• Check the direction of movement and accuracy of

position;

• Check that the relevant actuator is functioning

correctly;

• With the valve or damper actuator in the closed

position, check that there is no temperature changes
across the heater/ cooler;

• Check that the actuator has the correct movement to

give the required travel of the final control device;

• Ensure that any linkage adjustment for rotation, lift

or close off have been suitably set;

• Check that in the case of spring return motor being

fitted, the position assumed upon interruption of the
power supply is correct; and

• Check that there is a smooth and regular movement

of the actuating motor and regulator throughout this
T&C Procedure.

10. Alarm Signal (See Annex IV Fig. 4)

• Adjust the alarm level to cause an alarm. Check that

the address, alarm message and destination are
correct; and

• Alarms can also apply to digital inputs, e.g. an

overheat thermostat or a switch for a pump or fan;

11. Response to Sensor Failures

• Inspect the control strategy software; and

• Should there be a sensor failure where the output is

used in a control loop, then the action of the loop
should be checked;

12. Interlocks

• Check interlocks through written logic diagrams

and read the text;

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 • Check when one particular activity happens, all
related and interlocked activities also occur
(positive checks); and

• Check that interlocked and related activities cannot

occur in isolation (negative checks);

13. Control Loops (See Annex IV Fig. 5)

• Determine if loop is open (without feedback) or

closed (with feedback); and

• Before checking the loops, verify the correct

operation of the valve or dampers. Damper linkages
may be disconnected, dampers jammed, valve
jammed or passing etc.;

14. Open Loop Test (See Annex IV Fig. 5)

• Set up trend logs for the input and output of the loop;

• Switch the control loop to manual mode;

• Vary the signal to the actuator in a predefined test

sequence covering the span from fully closed to
fully open and log the output;

• Note that some control loops allow limits to be

applied to an output signal, so an output range of 0-
100% may not be achievable;

• Examine the profiles of the output and input; and

• Reset the controller to the required set point and to

automatic mode;

15. Close Loop Test (See Annex IV Fig. 5)

• Trend-log the input and output to the control loop;

• Set the control to achieve the desired test conditions;

• Select the controls to achieve the desired test

conditions;

• Select 2 set point values (they should be within 10%

of each other) and set the controller to the first value;

• Check that the controller can maintain the set point;

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 • Monitor (trend-log) the transient behaviour and
check if it is acceptable (i.e. the initial time taken
for the response to settle to a steady level);

• Change the control to the second set point and check

the transient behaviour and output level;

• If the set point cannot be achieved or maintained, or

the system does not stabilise, the control loop
should be returned and retested; and

• Reset the controller to the required set point and the

automatic mode;

16. Field Device Location

• Check that the correct type of device is located in

the correct position; and

• The identification or reference number of the device

should be checked;

17. Field Device Wiring

• Visual check the wiring to the device, see if it is of

the correct type, termination etc.; and

• At the Controller / Router / Gateway / Interfacing

Unit and automatic control panel, check that the
wiring is terminated and the manual/off/auto
switches are set to automatic.

Commissioning

(a) commissioning involves completing all the checks and the settings
of control values to ensure the correct operational state of the
Installations;

(b) the CCMS Workstation shall be used to evaluate the performance

of the completed system;

(c) all variable parameters and switches shall be set to appropriate

values and settings to ensure compliance with the Particular
Specification;

(d) check that the Controller/Router/Gateway/ Interfacing Unit

continues to function independently and in real time irrespective
of any failure of the remainder of the CCMS;

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(e) CCMS workstation/server shall be used to check the
communication networks, such as graphic functions, CCMS
software, etc; and

(f) a mains failure shall be simulated to check if the CCMS operation

meets the Particular Specification when the electrical supply is
interrupted;

Functional Test of System Performance

(a) Functional Test of Workstation/Server

(i) Hardware Installation

1. Check ambient environment i.e. temperature and relative

humidity;

2. Check the electrical power supply cable connected to

UPS and eventually all workstation equipment power
cables well terminated at UPS;

3. Check the cable connected to Controller / Router /

Gateway / Interfacing Unit and ensure the wiring is
correct; and

4. Check the LAN cable connected from Controller /

Router / Gateway / Interfacing Unit to workstation.

(ii) Software Installation

1. Check correct type of software to be installed for the

workstation;

2. Ensure the above software have been installed at

workstation and check the set up of control system;

3. Test and execute the control task;

4. Demonstrate that all relevant information can be

monitored and controlled through the Workstation; and

5. The software license of operation and ownership shall be

included in the Operating and Maintenance Manuals.

(b) Functional Test of Controller / Router / Gateway / Interfacing Unit

(i) Installation

1. Check the Controller / Router / Gateway / Interfacing

Unit and accessories are properly set;

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 2. Check the sensors, transducers, valves, actuators, AHU,
PAU, FCU, VAV, ventilation fans, frequency inverters
are properly installed according to drawings, etc.;

3. Check the Installations and services interfacing with

CCMS; and

4. Check the gateway/interfacing Unit for relevant systems

and equipment;

(ii) Testing Procedures for Controller

1. Put controller into operation (on-line);

2. Check the controller is functioning;

3. Check the data communication among workstation when

controller start operating;

4. Check the input and output of controller as well as the

field points and ensure the system can transmit a correct
signal;

5. Check whether the field points can be assigned through

workstation;

6. Test I/O points with controllers and Building Services

Installations which monitor and control through CCMS
to ensure whole system is installed correctly;

7. Put the system into an auto mode and test if the program
can run properly; and

8. Use the workstation or Portable Operator Terminal to

carry out the modification;

(c) Interface between CCMS and Other Connected Equipment/

Systems

T&C with other contractors shall be carried out to ensure the

success of signal input/output between the CCMS and any other
connected equipment/systems; and

(d) Commissioning Data and Storage

A copy of all commissioning data of each system/equipment shall

be submitted to the PBSE for approval. The commissioning data
shall be included in Operating and Maintenance Manuals at
handover. The commissioning data shall include sensor accuracy,

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 alarm delays, actuator movement, control loop settings plus input
and outputs.

4.3.3.2.3 Completion of T&C

The following record documents and drawings shall be submitted after

the completion of commissioning and testing:

(a) Backup copy of CCMS software

the back-up copies of the latest version of all the software shall be
made. After changes have been made in the software following
the performance tests, a new back-up copy of the software shall be
made, while still retaining a copy of the previous version shall
problems arise;

(b) O&M manual

since the control strategies, set points, alarm levels etc. are
software based, an up-to-date hard copy needs to be kept in the
Operating and Maintenance Manual for permanent reference and
easy access.

4.3.4 Noise and Sound Tests

4.3.4.1 Checking Procedures

Before noise level tests are undertaken, the following preliminary checks shall
be carried out:-

(a) All air-conditioning and mechanical ventilation (ACMV)systems are

dynamically tested and balanced in accordance with the relevant Sections
of this document;

(b) All building works are completed and areas under test are vacated or under
control for carrying out the noise test;

(c) All other noise generating activities and equipment are stopped.

Where circumstances require certain equipment to be kept operational, then

this shall be clearly indicated on the final test data sheets; and

(d) All areas under test are provided with safe access.

4.3.4.2 Noise Screening Test

Screening test on all noise emitting plant and machineries shall be carried out
during the pre-commissioning phase of the installation work to identify potential
problems that might infringe the Noise Control Ordinance.

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 The test results shall be submitted to the Supervising Officer and notify the
Supervising Officer on any likely problematic areas so that prompt action could
be followed up.

4.3.4.3 General Requirements

Site ambient noise levels shall be recorded prior to the commencement of tests.
In order to minimise the effect of background noise, noise levels at external
areas shall be measured at night or at other representative time as agreed with
the Supervising Officer.

Prior to measurement of noise levels, all the plants in the air system and the
water system are running shall be checked.

If any item of plant is not running during the test, it shall be clearly identified on
the test sheets.

Noise levels shall be measured by an approved noise level meter (or sound meter)
capable of measuring noise levels in the frequency range of 63 Hz to 8 kHz.

Noise level tests of the selected A/C system shall include sound pressure
readings relating to the NC levels in each room where stated in the Contract
Drawings or in the Particular Specification.

In each selected area, noise levels shall be measured at 1.5 metres above the
finished floor level and at a distance of 1.5 metres from the walls or doors of the
areas.

In large areas, the floor area shall be divided into equal areas and readings
carried out in each area.

External noise level tests shall be carried out in locations at agreed boundary
positions.

In order to minimise the effect of background noise, noise levels at external

areas shall be measured at night or at other representative time as agreed with
the Supervising Officer.

Upon completion of the noise level tests, a further set of noise level
measurement shall be carried out with all plant off, so as to verify again the level
of background noise.

In cases where measured noise levels are in excess of the specified criteria,
additional checks shall be carried out to identify the sources of excessive noise
generation.

All noise level readings are to be recorded and plotted on octave wave band
frequency charts.

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 The date and time of test are also to be recorded together with any relative
comments.

4.3.4.4 Indoor Noise Level Measurement

All the effort in designing the indoor ACMV system with care and thought might
be wasted if installation and commissioning of the equipment is not proper. The
following check points shall be followed to determine if the total noise level in
occupied areas within the building exceed the limits as specified in the
Specification.

(a) calibrate the sound level meter with sound level calibrator supplied with the
meter according to the procedures specified in the operation manual of the
meter;

(b) switch on the ACMV equipment or plant serving the area in which noise is
to be assessed. The corresponding fan coil units, ventilation fans and other
sound source(s) affecting the area shall also be turned on;

(c) measure Sound Pressure Levels (SPLs) in dB. Measurement shall be made
as close to the diffuser as possible and the position of the sound level meter
shall be at a height of 1.5 m above floor level is considered appropriate for
general situations;

(d) indicate clearly the locations of measurement on a floor layout plan for the
area(s) concerned;

(e) record the SPLs measured from the 63 Hz octave band through the 8000 Hz
octave frequency band in Certificate no. 21.1 of Annex II;

(f) plot the SPLs on typical Noise Criteria (NC) curves to determine the
measured NC level in each area;

(g) also indicate other relevant information including date and time of
measurement; type, model and calibration date of the meter used as well as
other observations during the measurement process in Certificate no. 21.1
of Annex II;

(h) re-calibrate the meter with the calibrator after the noise measurement; and

(i) measure background noise level only if the ambient noise level in the area,
with the ACMV equipment not operating, exceeds the NC limits as
specified in the Specification.

4.3.4.5 Outdoor Noise Level Measurement

The noise level measurement is performed to assess the noise generated from
ACMV equipment like chillers, ventilation fans, etc., which may cause nuisance
to noise sensitive receivers outside the building in which the equipment is placed.

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 The procedures below are generally in compliance with those set in the
requirements in the Noise Control Ordinance:

(a) calibrate the meter with sound level calibrator supplied with the meter
according to the procedures specified in the operation manual of the meter;

(b) measure noise levels at the location/point to be assessed. The location/point

to be assessed could be the potential ‘noise sensitive receiver’ according to
the ‘Technical Memorandum for the Assessment of Noise from Places other
than Domestic Premises, Public Places or Construction Sites’ (TM) issued
by the Environmental Protection Department (EPD);

(c) indicate clearly the locations of the noise emitting source and measuring
point(s) on a site plan.

(d) where a measurement is to be carried out at a building, the assessment point

shall be at a position 1m from the exterior of the building façade but may
be at any other point considered to be appropriate by the EPD. Where a
measurement is to be made of noise being received at a place other than a
building, the assessment point shall be at a position 1.5m above the ground,
at a particular point considered appropriate by the EPD;

(e) measure the Equivalent Continuous Sound Level (Leq) in dBA over a
period of 30 minutes according to the TM. Measurement can be made over
any shorter period when the EPD is satisfied that the noise under
investigation is essentially steady over a 30-minute period;

(f) record the figures of Leq measured together with the corresponding time
period at which the measurement is conducted in Certificate no. 21.2 of
Annex II;

(g) correction for Tonality, Impulsiveness and/or Intermittency shall be

required according to the conditions set out in the TM;

(h) also indicate other relevant information including date of measurement;

type, model and calibration date of the meter used; weather condition as
well as other observations during the measurement process in Certificate no.
21.2 of Annex II; and

(i) re-calibrate the meter with the calibrator after the noise measurement.

4.3.5 Vibration Tests

Testing for equipment vibration is necessary as an acceptance test to determine

whether equipment is functioning properly and to ensure that objectionable vibration
and noise are not transmitted. As the vibration acceptance test is based on root mean
square (r.m.s.) velocity (mm/s) only, frequency measurement is not required. Vibration
measurement shall be taken after the equipment had been running for 2 weeks.

Page 118 of 122 T&C Procedure for Air Conditioning, Refrigeration and
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(TCP-AC-2022)
 (a) record the operating speeds of the equipment (i.e. driving speed of motor and driven
speed of fan wheel, rotor or impeller) indicated on the nameplates, drawings or
measured by speed-measuring device in Certificate no. 22 of Annex II;

(b) determine acceptance criteria from the Particular Specification or as indicated below;

Equipment Allowable rms velocity, mm/s

Pumps 3.3
Centrifugal Compressors 3.3
Fans 2.3

(c) perform visual and audible checks for any apparent rough operation of the equipment
or any defective bearings, misalignment, etc;

(d) calibrate the vibration measuring instrument according to the user’s manual;

(e) measure and record in Certificate no. 22 of Annex II vibration at bearings of driving
and driven components in horizontal, vertical and, if possible, axial directions. There
should be at least one axial measurement for each rotating component (fan motor,
pump motor);

(f) indicate other relevant information including date of measurement, type, model and
calibration date of the instrument used as well as other observations in the
measurement process in Certificate no. 22 of Annex II; and

(g) re-calibrate the instrument after the measurement.

4.3.6 Electrical Tests

4.3.6.1 Electrical Tests on Motor Control Switchboard

(a) The tests shall be carried out before and after connection of power supply.
The tests shall follow the requirements for L.V. Cubicle Switchboard as
stipulated in the General Specification for Electrical Installation in
Government Buildings of the HKSAR issued by ArchSD; and

(b) The tests to be carried out for the high voltage motor control switchboard
shall strictly follow the tests as recommended by the equipment
manufacturer.

4.3.6.2 Electrical Tests on Motor

(a) Required Tests

The following tests on all electrical motors shall be carried out and test
certificates shall be provided in duplicate:-

Page 119 of 122 T&C Procedure for Air Conditioning, Refrigeration and
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(TCP-AC-2022)
 (i) Check motor nameplate characteristic such as voltage and frequency
& etc.;

(ii) Check motor rotation and speed, prior to connection of the driven
equipment;

(iii) Ascertain maximum kW absorbed by fan at the most demanding point

of the pressure/volume characteristic curve at the specified fan speed;

(iv) Check the earth continuity loop resistance for every motor starter;

(v) Check the insulation to earth resistance for every motor starter taken
with 500 V "Meggar" tester;

(vi) Test the full load current taken by all motors on each phase;

(vii) Test the tripping time of starter overloads set to 10% above the motor
nameplate rating;

(viii) Test the function of each control unit in accordance with the
specification (e.g. selector switches correctly wired, high or low
circuit cut-out operates, level switches correctly operating);

(ix) Check motor temperature; and

(x) Check starting current of each motor.

(b) Type Tests

Type tests and abbreviated tests shall meet the requirements of IEC 60072-
1 [1991], IEC 60072-2 [1990] and IEC 60072-3 [1994]. The Supervising
Officer has the discretion to agree or accept type-test results for
performance in place of individual unit tests but these will not be accepted
in place of practical on the Site, pressure, insulation, resistance tests which
shall still be carried out on individual units.

(c) Contractor’s Responsibility

Approval of test certificates shall not absolve the contractor from providing
motors capable of driving the various items of plant under the conditions of
loading stated in the tender documents.

4.3.7 Final Air Conditioning System Performance Tests

4.3.7.1 General

On completion of all inspections and tests, a final overall performance test shall
be carried out on the air-conditioning installation.

4.3.7.2 Instruments

Page 120 of 122 T&C Procedure for Air Conditioning, Refrigeration and
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(TCP-AC-2022)
 The following calibrated instruments shall be provided for this test:-

(a) All necessary wet and dry bulb mercury-in-glass thermometers;

(b) A wet and dry bulb weekly recorder;

(c) Where specified, multi-point recorders with service devices for monitoring
temperature, humidity, current, voltage, etc.;

(d) Surface contact dial indicating pyrometer;

(e) A sound meter capable of reading the noise level at 62.5, 125, 250, 500,
1000, 2000, 4000 and 8000 Hertz; and

(f) Other equipment as found necessary or instructed.

4.3.7.3 Method of Testing

During this test, the air conditioning systems shall be operated for a period of 5
days minimum. During which time, the following shall be noted and the results
compared with the design criteria:-

(a) Note occupation rates, internal heat and humidity loads, and external
conditions at time of test;

(b) Obtain temperature and humidity levels throughout all spaces;

(c) Obtain sound levels for all critical areas;

(d) Record exhaust and outdoor air extract system ventilation rates;

(e) Check efficiency of individual direct expansion refrigeration/cooling

systems in accordance with CIBSE Commissioning Code 'R' - Refrigerating
Systems;

(f) Check capability of chilled water system to maintain chilled water flow and
return temperature under full load conditions; and

(g) Check electrical loadings of all plants when operating under both full load
and part load conditions.

4.3.7.4 Full Load Requirement

When full load conditions cannot be achieved during the commissioning tests,
returning to site shall be allowed to carry out a full load test when the desirable
external and internal design conditions occur at the first opportunity during
the Maintenance Period.

Page 121 of 122 T&C Procedure for Air Conditioning, Refrigeration and
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(TCP-AC-2022)
 For particularly sensitive areas such as computer rooms, simulated full load
tests shall be carried out at the time of commissioning using electric heaters
to simulate the sensible load and electric steam pan humidifiers to simulate
the latent load.

4.3.7.5 When calculating the required simulated load, the following shall be taken into
account.

(a) the anticipated heat gain from plant and machinery;

(b) the extra heat gain through the structural fabric due to the difference
between the design external air temperature and the external air temperature
at the time of the tests;

(c) the extra solar heat gain at maximum design conditions over that
experienced at the time of the tests;

(d) the extra heat gain from the fresh air quantity due to the difference between
the design external air temperature and the external air temperature at the
time of the tests;

(e) the extra sensible and latent (if significant) heat gains due to the increase in
the number of occupants normally present (i.e. allowed for in the design)
over the number present at the time of the tests; and

(f) NOTE: The areas where simulated load tests are to be carried out shall be
clearly indicated in the Particular Specification.

Page 122 of 122 T&C Procedure for Air Conditioning, Refrigeration and
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(TCP-AC-2022)
 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

Contract Number :
Contract Title :
Name of Sub-contractor :
Name of Main Contractor :
Contract Period: __/__/20__ to __/__/20__ *Revised /Actual Completion Date: __/__/20__
dd/mm/yyyy dd/mm/yyyy

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure
1. Chillers
1.1 Cleanliness & Clause
State Check 4.2.3.1.1
1.1.1 Air System Clause
4.2.3.1.2(b)
1.1.2 Water System Clause
4.2.3.1.2(a)
1.1.3 Refrigeration Clause
System 4.2.3.1.2(c)

Submission of
test record

1.2 Mechanical Clause

Check 4.2.3.1.4
1.2.1 Fans Clause
4.2.3.1.4(a)
1.2.2 Pumps

1.2.3 Compressors Clause4.2.3.1.

4(b)
1.2.4 Drives Clause (iii)c of
4.2.3.1.4(c)

Submission of
test record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 1 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure
1.3 Electrical Check Clause
4.2.3.1.5
1.3.1 Electrical Supplies Clause
Isolated 4.2.3.1.5(a)
1.3.2 Electrical Supplies Clause
Connected 4.2.3.1.5(b)

Submission of test
record

1.4 Test of Reciprocating Clause

Compressor System 4.2.3.2
1.4.1 Pressure & Leakage Clause
Test 4.2.3.2.1
1.4.2 Evacuation & Clause
Dehydration 4.2.3.2.2
1.4.3 Charging of Clause
Refrigerant 4.2.3.2.4
1.4.4 Setting to Work & Clause
Adjusting 4.2.3.2.5

Submission of test
record

1.5 Test of Centrifugal Clause

Compressor System 4.2.3.3
(Including Oil Free
Compressor)
1.5.1 Pressure & Leakage Clause
Test 4.2.3.3.1
1.5.2 Evacuation & Clause
Dehydration 4.2.3.3.2
1.5.3 Charging of Clause
Refrigerant 4.2.3.3.4
1.5.4 Setting to Work & Clause
Adjusting 4.2.3.3.5

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 2 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure
1.6 Test of Screw Clause
Compressor System 4.2.3.5
1.6.1 Pressure & Leakage Clause
Test 4.2.3.5.1
1.6.2 Evacuation & Clause
Dehydration 4.2.3.5.2
1.6.3 Charging of Clause
Refrigerant 4.2.3.5.4
1.6.4 Setting to Work & Clause
Adjusting 4.2.3.5.5

Submission of test
record

1.7 Testing of Clause

Absorption Chillers 4.2.3.4
1.7.1 General Check of Clause
System Components 4.2.3.4
1.7.2 Leak Test of Clause
Absorption Shell and 4.2.3.4.1
Purge Unit
1.7.3 Evacuation of Clause
Absorption System 4.2.3.4.2
1.7.4 Charging of Clause
Refrigerant 4.2.3.4.4
1.7.5 Setting to Work & Clause
Adjusting 4.2.3.4.5

Submission of test
record

1.8 Functional Test for Clause 4.2.3 Setting to work & record
Air & Water Cooled &
Chillers Annex II

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 3 of 21 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure
1.8.1 Chilled Water Leaving
Temperature
1.8.2 Chilled Water
Entering Temperature
1.8.3 Chilled Water Flow
Rate
1.8.4 Condenser Entering
Temperature (Water
Cooled Chillers)
1.8.5 Condenser Leaving
Temperature (Water
Cooled Chillers)
1.8.6 Compressor Motor
Speed
1.8.7 Compressor Running
Current
1.8.8 Air Flow Rate (Air
Cooled Chillers)
1.8.9 Fan Speed (Air
Cooled Chillers)
1.8.10 Fan Motor Speed (Air
Cooled Chillers)
1.8.11 Fan Motor Running
Current
1.8.12 Supply Voltage

Submission of test
record

1.9 Functional Test for Air Clause Setting to work &

Absorption Chillers 4.2.3 & record
Annex II

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 4 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure
2. Chilled Water System
2.1 Cleanliness & State Clause
Check 4.1.6.1
G/F
1/F
2/F
3/F
4/F

Submission of test
record

2.2 Mechanical Check Clause

4.1.6.4
G/F
1/F
2/F
3/F
4/F

Submission of test
record

2.3 General Checking Clause

4.1.6.3
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 5 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure
2.4 Electrical Check Clause 4.1.5
(Pumps)
2.4.1 Electrical Supply Clause
Isolated 4.1.5.1
Pri.
Sec.

Submission of test
record

2.4.2 Electrical Supply Clause

Available 4.1.5.2
Pri.
Sec.

Submission of test
record

2.5 Initial Running of Clause

Pump Sets 4.2.1.4
2.5.1 Pump Discharge Rate Clause
4.2.1.4
Pri.
Sec.

Submission of test
record

2.5.2 Pump Suction Clause

Pressure 4.2.1.4
Pri.
Sec.

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 6 of 21 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure
2.5.3 Pump discharge Clause
Pressure 4.2.1.4
Pri.
Sec.

Submission of test
record

2.5.4 Pump Motor Speed Clause

4.2.1.4
Pri.
Sec.

Submission of test
record

2.5.5 Pump Motor Clause

Current 4.2.1.4
Pri.
Sec.

Submission of test
record

2.5.6 Supply Voltage Clause

4.2.1.4
Pri.
Sec.

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 7 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

2.5.7 Non-return Valve Clause 4.2.1

Operation
Pri.
Sec.

Submission of test
record

2.5.8 Isolation Valve Clause 4.2.1

Operation
Pri.
Sec.

Submission of test
record

2.5.9 Flexible Joint Clause 4.2.1

Pri.
Sec.

Submission of test
record

2.6 Chemical Treatment Clause 4.2

2.6.1 Cleanliness & State
Check
2.6.2 Mechanical Check
2.6.3 Electrical Check
2.6.4 General Check
2.6.5 Initial Running of
Chemical Dosing
Pump

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 8 of 21 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3. Air Distribution
System
3.1 Cleanliness & State Clause
Check 4.1.7.1
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.2 Fire & Smoke

System Check
3.2.1 Regulating Device Clause
4.1.7.2
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.2.2 Visual Check on Air Clause

Tightness 4.1.7.3
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 9 of 21 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.2.3 Leakage Test Clause 4.1.4

G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.2.4 Mechanical Check Clause

on Fans & Dampers 4.1.7.4
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.2.5 Initial Running of Clause 4.2.2

Fans & Dampers
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 10 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.2.6 Regulating of Air

Flow
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.2.7 Functional & Clause 4.3.2

Performance Test
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.3 Fire Tripping &

Safety Cutout
3.3.1 Electrical Check Clause 4.1.5
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 11 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.3.2 Functional & Clause 4.3.2

Performance Test
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.4 Fire & Smoke

Dampers Check
3.4.1 Cleanliness & State Clause
Check 4.1.7.1
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.4.2 Functional & Clause 4.3.2

Performance Test
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 12 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.4.3 Electrical Check Clause 4.1.5

G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.5 Mechanical
Ventilation System
Check
3.5.1 Cleanliness & State Clause
Check 4.1.7.1
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.5.2 Regulating Device Clause

4.1.7.2
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 13 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.5.3 Visual Check on Air Clause

Tightness 4.1.7.3
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.5.4 Leakage Test Clause 4.1.4

G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.5.5 Electrical Check Clause 4.1.5

G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.5.6 Mechanical Check Clause

of Fans, etc. 4.1.7.4
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 14 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.5.7 Initial Running of Clause

Fans 4.2.2.4
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.5.8 Regulating of Flow Clause

4.2.2.5
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.5.9 Function & Clause 4.3.2

Performance Test
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 15 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.6 Check of
Conditioned Air
Distribution
3.6.1 Cleanliness & State Clause
Check 4.1.7.1
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.6.2 Regulating Device Clause

4.1.7.2
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.6.3 Visual Check on Air Clause

Tightness 4.1.7.3
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 16 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.6.4 Leakage Test Clause 4.1.4

G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.6.5 Electrical Check Clause 4.1.5

G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.6.6 Insulation Check Clause 4.1.5

G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.6.7 Mechanical Check Clause

4.1.7.4
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 17 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.6.8 Initial Running of Clause

Fans & All Moving 4.2.2.4
Parts
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.6.9 Regulating Air Flow Clause

4.2.2.5
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.6.10 Flow Balancing Clause

4.2.2.5.2
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 18 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

3.6.11 Functional & Clause 4.3.2

Performance Test
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.7 Check of Control Clause

System 4.3.1.1.1
3.7.1 Visual Inspection
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.7.2 Basic Function Test Clause

4.3.1.1.2
G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 19 of 21 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure
3.7.3 Electrical Check Clauses
4.3.1.1.3
4.3.1.3
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.8 Noise & Sound Clause 4.3.4

Check
G/F
1/F
2/F
3/F
4/F

Submission of test
record

3.9 Vibration Check Clause 4.3.5

G/F
1/F
2/F
3/F
4/F

Submission of test
record

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 20 of 21 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex I

Testing and Commissioning Progress Chart for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

T&C Progress Chart for Air Conditioning, Refrigeration and Mechanical Ventilation Installation (Rev. ) (Note 1)
Dates Remark
(Note 2)

Activities Reference to S A S A S A S A S A S A S A S A
T&C
Procedure

4.0 Submission of T&C Clause

Certificate 4.1.6.6.6

Notes
* Delete as appropriate
(1) Insert revision no.
(2) Insert additional columns as necessary
S - schedule % completion
A - actual % completion

Annex I T&C Procedure for Air Conditioning, Refrigeration and

Page 21 of 21 Mechanical Ventilation Installation 2022 Edition
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 Annex II

Testing and Commissioning Certificate for

Air Conditioning, Refrigeration and Mechanical Ventilation Installation

Contract Number :
Contract Title :

Part 1 Details of Project

1.1 Project title :

1.2 P.W.P. No. :

1.3 Contract Number :

1.4 Sub-contractor :

1.5 Main Contractor :

1.6 Name of *PBSE :

1.7 Name of *PBSI :

Part 2 Declaration

2.1 I certify that the Air Conditioning, Refrigeration and Mechanical Ventilation Installation as
specified in the Contract/Sub-contract/Quotation at the above location has been inspected,
tested and commissioned in accordance with this Testing and Commissioning (T&C)
Procedure and/or any other procedures as agreed between the *PBSE and the Contractor.
The results are satisfactory in the aspects as mentioned in Part 3 and/or as recorded in Part 4
of this Certificate, except that indicated in the COMMENTS items.

2.2 I also certify that site tests have been performed in accordance with the requirements set in
this T&C Procedure and that the results are satisfactory. A record of the tests has been
prepared and submitted to the *PBSE.

Name of Authorised Contractor’s Representative: Signature:

Designation /Post of Contractor’s Representative: Date Signed:

Name and Stamp of Contractor: Telephone Number:

* delete /amend if required

Note:
Plant performance can be substantiated only when the test data have been recorded and validated against the design data. Proforma for
recording such data can be found in the succeeding pages and these should be properly filled in before submission to the designers with
any relevant comments related to site conditions. Peak Load Test shall be carried out for the entire system with test record submitted
accordingly

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 1 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

Items tested/ checked Items witnessed

by the by
Contractor PBSE/PBSI
Part 3: Items Inspected and Tested
3.1 The General Requirements as indicated in the T&C Procedure have *Yes/No/N.A. *Yes/No/N.A.
been complied with.

3.2 Pre-commissioning Checks

3.2.1 Water Distribution System

(a) The system has been properly cleaned, flushed and filled with water. *Yes/No/N.A. *Yes/No/N.A.

(b) The equipment associated with the system has undergone the *Yes/No/N.A. *Yes/No/N.A.
mechanical and electrical checks and the results are satisfactory.

3.2.2 Air Distribution System

(a) The system has been properly cleaned and usually checked for air *Yes/No *Yes/No
tightness.

(b) The equipment associated with the system has undergone mechanical *Yes/No *Yes/No
and electrical checks and the results are satisfactory.

3.3 Setting to Work & Balancing

3.3.1 Water Distribution System

(a) The water pumps have been commissioned in accordance with this *Yes/No/N.A. *Yes/No/N.A.
T&C Procedure and the pumps are operating satisfactorily.

(b) The water flow rates of the system have been regulated and balanced *Yes/No/N.A. *Yes/No/N.A.
in accordance with this T&C Procedure. The results are satisfactory
meeting the specified requirements.

3.3.2 Air Distribution System

(a) The filters have been commissioned according to *this/manufacturer’s *Yes/No/N.A. *Yes/No/N.A.
procedure and the results are satisfactory, meeting the specified
requirements.

(b) The fans have been commissioned according to *this/manufacturer’s *Yes/No/N.A. *Yes/No/N.A.
procedure and the results are satisfactory meeting the specified
requirements.

(c) The air flow rates of the system have been regulated in accordance with *Yes/No/N.A. *Yes/No/N.A.
this T&C Procedure and the system is delivering the designed air
volumes at the terminal outlets.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 2 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

Items tested/ checked Items witnessed

by the by
Contractor PBSE/PBSI
3.3.3 Ventilation and Air-conditioning Control (VAC) interfacing with Fire
Alarm Signal

3.3.3.1 Method A

Compartment: ____________________________________________________

Serial/ Code No. of Fans serving the compartment : _______________________

(a) The compartment is provided with a smoke detector automatic fire *Yes/No/N.A. *Yes/No/N.A.
alarm system.

(b) Any smoke detector of the compartment is activated; all fans severing *Yes/No/N.A. *Yes/No/N.A.
the compartment shall be shut down.

(c) All fans unable to restart while fire signal exist. *Yes/No/N.A. *Yes/No/N.A.

(d) Manual Override Switch shall be installed adjacent to the Fire Control *Yes/No/N.A. *Yes/No/N.A.
Panel of the building and easy to operate.

(e) All fans involved in the VAC system shall be shut down when Manual *Yes/No/N.A. *Yes/No/N.A.
Override Switch is activated.

(f) Fail Safe test for the circuit of Manual Override Switch. *Yes/No/N.A. *Yes/No/N.A.

(g) Other fan shall be interlocked. *Yes/No/N.A. *Yes/No/N.A.

3.3.3.2 Method B

(a) Probe-type Smoke Detector is provided in the ductwork. *Yes/No/N.A. *Yes/No/N.A.

(b) The fan shut down by probe-type smoke detector. *Yes/No/N.A. *Yes/No/N.A.

(c) Fail Safe test for the circuit of probe-type detector. *Yes/No/N.A. *Yes/No/N.A.

(d) The fans unable to restart while fire signal exists. *Yes/No/N.A. *Yes/No/N.A.

(e) Manual Override Switch shall be installed adjacent to the Fire Control *Yes/No/N.A. *Yes/No/N.A.
Panel of the building and easy to operate.

(f) All fans involved in the VAC system shall be shut down when Manual *Yes/No/N.A. *Yes/No/N.A.
Override Switch is activated.

(g) Fail Safe test for the circuit of Manual Override Switch. *Yes/No/N.A. *Yes/No/N.A.

(h) All fans serving the same compartment shall be interlocked *Yes/No/N.A. *Yes/No/N.A.

(i) Other fan shall be interlocked. *Yes/No/N.A. *Yes/No/N.A.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 3 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

Items tested/ checked Items witnessed

by the by
Contractor PBSE/PBSI

3.3.3.3 Method C

(a) All fans involved in the VAC System shall be shut down when building *Yes/No/N.A. *Yes/No/N.A.
fire alarm system is achieved.

(b) All fans unable to restart while fire signal exists. *Yes/No/N.A. *Yes/No/N.A.

(c) Manual Override Switch shall be installed adjacent to the Fire Control *Yes/No/N.A. *Yes/No/N.A.
Panel of the building and easy to operate.

(d) All fans involved in the VAC System shall be shut down when Manual *Yes/No/N.A. *Yes/No/N.A.
Override Switch is activated.

(e) Fail Safe test for the circuit of Manual Override Switch. *Yes/No/N.A. *Yes/No/N.A.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 4 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

Items tested/ checked Items witnessed

by the by
Contractor PBSE/PBSI
3.3.4 Refrigeration Systems

3.3.4.1 The system has been satisfactorily cleaned and the equipment has *Yes/No *Yes/No
undergone electrical and mechanical checks.

3.3.4.2 Reciprocating Compressor System

(a) The refrigeration system has been commissioned by a specialist in *Yes/No/N.A. *Yes/No/N.A.
accordance with the manufacturer’s recommendations.

(b) The refrigeration system has satisfactorily completed the running-in *Yes/No/N.A. *Yes/No/N.A.
period as specified in this T&C Procedure and all necessary
adjustments/ repairs/ replacements have been carried out.

3.3.4.3 Centrifugal Compressor System (Including Oil Free Compressor)

(a) The refrigeration system has been commissioned by a specialist in *Yes/No/N.A. *Yes/No/N.A.
accordance with the manufacturer’s recommendations.

(b) The refrigeration system has satisfactorily completed the running-in *Yes/No/N.A. *Yes/No/N.A.
period as specified in this T&C Procedure and all necessary
adjustments/ repairs/ replacements have been carried out.

3.3.4.4 Absorption System

(a) The refrigeration system has been commissioned by a specialist in *Yes/No/N.A. *Yes/No/N.A.
accordance with the manufacturer’s recommendations.

(b) The refrigeration system has satisfactorily completed the running-in *Yes/No/N.A. *Yes/No/N.A.
period as specified in this T&C Procedure and all necessary
adjustments/ repairs/ replacements have been carried out.

3.3.4.5 Screw Compressor System

(a) The refrigeration system has been commissioned by a specialist in *Yes/No/N.A. *Yes/No/N.A.
accordance with the manufacturer’s recommendations.

(b) The refrigeration system has satisfactorily completed the run-in period *Yes/No/N.A. *Yes/No/N.A.
as specified in this T&C Procedure and all necessary adjustments/
repairs/ replacements have been carried out.

3.3.4.6 Cooling Tower

(a) The cooling tower(s) of the installation *has/have been field tested in *Yes/No/N.A. *Yes/No/N.A.
accordance with this T&C Procedure and the results are satisfactory,
meeting the specified requirements.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 5 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

Items tested/ checked Items witnessed

by the by
Contractor PBSE/PBSI

3.3.5 Automatic Control System

(a) Audit of the cabling and hardware installation *Yes/No *Yes/No

(b) All the safety devices including circuit interlocks and cut-outs have *Yes/No *Yes/No
been checked for correct installation and operation.

(c) Demonstration that sensors and actuators are correctly connected and *Yes/No *Yes/No
addressed.

(d) Demonstration of the physical and logical integrity of the system. *Yes/No *Yes/No

(e) Demonstration of sensor calibrations *Yes/No *Yes/No

(f) Demonstration of all control actions *Yes/No *Yes/No

(g) Demonstration of successful system control commissioning and *Yes/No *Yes/No

testing.

(h) Verification of specified training requirements *Yes/No *Yes/No

(i) Verification of handover of all specified operating manuals, *Yes/No *Yes/No

documentation and drawings

Comments :

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 6 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

Items tested/ Items witnessed

checked by the by Checked
Contractor PBSE/PBSI by/Date
3.3.6 Central Control Monitoring System

3.3.6.1 Controller/Router/Gateway/Interfacing Unit

(a) "As built" drawings incorporate latest modifications *Yes/No/N.A. *Yes/No

(b) Secure door locks *Yes/No/N.A. *Yes/No

(c) Switches - location & labelling *Yes/No/N.A. *Yes/No

(d) Access for incoming/outgoing cables *Yes/No/N.A. *Yes/No

(e) Doors & gland plates earthed *Yes/No/N.A. *Yes/No

(f) Tightness of connections *Yes/No/N.A. *Yes/No

(g) 20% spare capacity *Yes/No/N.A. *Yes/No

(h) Cable identification *Yes/No/N.A. *Yes/No

(i) Terminals numbered *Yes/No/N.A. *Yes/No

(j) Segregation of electronic equipment *Yes/No/N.A. *Yes/No

(k) CCMS cables – link type terminals *Yes/No/N.A. *Yes/No

(l) Labelling of equipment *Yes/No/N.A. *Yes/No

3.3.6.2 Inspection Checklist for CCMS Workstation/Server

(a) Installation of CCMS workstation *Yes/No/N.A. *Yes/No

(i) Physical inspection of facility *Yes/No/N.A. *Yes/No

(ii) Power supply connection *Yes/No/N.A. *Yes/No

(b) CCMS workstation operation *Yes/No/N.A. *Yes/No

(i) From 'Switch On' Central reaches operational state *Yes/No/N.A. *Yes/No
unaided

(ii) Central real time clock operational *Yes/No/N.A. *Yes/No

(iii) Central makes correct attempts to establish *Yes/No/N.A. *Yes/No

communications

(iv) Central responds to incoming communications *Yes/No/N.A. *Yes/No

(v) Operation of peripheral equipment *Yes/No/N.A. *Yes/No

(vi) Data acquisition speed satisfactory *Yes/No/N.A. *Yes/No

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 7 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

Items tested/ Items witnessed

checked by the by Checked
Contractor PBSE/PBSI by/Date

(c) Central Functions *Yes/No/N.A. *Yes/No

(i) Data logging routines *Yes/No/N.A. *Yes/No

(ii) Control parameter update *Yes/No/N.A. *Yes/No

(iii) Alarm system *Yes/No/N.A. *Yes/No

(iv) Password facility *Yes/No/N.A. *Yes/No

(v) Data archiving system *Yes/No/N.A. *Yes/No

(vi) Reporting & monitoring functions *Yes/No/N.A. *Yes/No

(vii) Graphics *Yes/No/N.A. *Yes/No

(d) Commissioning successful & documented *Yes/No/N.A. *Yes/No

(e) Documentation, spares & software backup *Yes/No/N.A. *Yes/No

(f) Training complete *Yes/No/N.A. *Yes/No

(g) Other functions *Yes/No/N.A. *Yes/No

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 8 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

Items tested/ checked Items witnessed

by the by
Contractor PBSE/PBSI

3.3.7 Noise and Sound Tests

The noise and sound levels in areas as specified have been checked *Yes/No/N.A. *Yes/No/N.A.
in accordance with this T&C Procedure and are found in compliance
with the Specification.

3.3.8 Vibration Tests

The vibration tests for equipment as specified have been carried out *Yes/No/N.A. *Yes/No/N.A.
in accordance with this T&C Procedure and the results are
satisfactory, meeting the specified requirements.

3.3.9 Full-load Performance Test

(a) A full-load performance test has been carried out and the results, *Yes/No/N.A. *Yes/No/N.A.
which were recorded separately, were found meeting the specified
requirements.

(b) a full-load performance test has NOT been carried out but it will be *Yes/No/N.A. *Yes/No/N.A.
carried out during the free-maintenance period.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 9 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

Items tested/ checked Items witnessed by

by the PBSE/PBSI
Contractor

3.4 Comments *Yes/No/N.A. *Yes/No/N.A.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 10 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

Part 4: Test Results and Records

4.1 Packaged Water Chillers

Location: _____________________ No.: ____ Design Test Result Test Result

Data (full load) (part load) Remarks

Machine Type

Refrigerant Type

Capacity (kW)

Leaving Chilled Water Temperature (oC)

Leaving Chilled Water Temperature (oC)

control Limited

Entering Chilled Water Temperature (oC)

Chilled Water Quantity (l/s)

Entering Condenser Water Temperature (oC)

Leaving Condenser Water Temperature (oC)

Condenser Water Quantity (l/s)

Evaporator Fouling Factor N/A N/A

Condenser Fouling Factor N/A N/A

Evaporator Working Pressure (kPa)

Evaporator Test Pressure (kPa)

Evaporator Entering Temperature (oC)

Evaporator Leaving Temperature (oC)

Condenser Working Pressure (kPa)

Condenser Test Pressure (kPa)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 11 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.1 Packaged Water Chillers (Cont’d)

Location: _____________________ No.: ____ Design Test Result Test Result

Data (full load) (part load) Remarks

Condenser Entering Temperature (oC)

Condenser Leaving Temperature (oC)

Motor Type

Starting Method/Type

Motor Speed (rev/s)

Motor Power (kW)

Staring Current (A)

Running Current (A)

Motor Power (kW)

Overload Current (A)

Tripping Time of Starter Overload (S)

Motor Full-load Condition (amp. & volt)

Motor No-load Condition (amp. & volt)

Drive Arrangement

Machine Mountings

Supply Voltage (V)

Index of Protection (IP)

Emergency Stop

Note: Full load and part load (40% ~ 60% of full load) tests of the chillers shall be carried out at different
seasons separately.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 12 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.2 Air-Cooled Chillers

Location: _____________________ No.: ____ Design Test Result Test Result

Data (full load) (part load) Remarks

Compressor

Refrigerant Type

Capacity (kW)

Saturated Suction Temperature (oC)

Saturated Discharge Temperature (oC)

Total Heat Rejected (kW)

Compressor Absorbed Power (kW)

Motor Nameplate Rating (kW)

Motor Type

Motor Speed (rev/s)

Drive

Motor Full-load Condition (amp. & volt)

Motor No-load Condition (amp. & volt)

Supply Voltage (V)

Starting Current (A)

Running Current (A)

Emergency Stop

Condenser

Capacity (kW)

Condensing Temperature (oC)

Summer Design External Dry Bulb (oC)

Sub-cooling (oC)

Head Pressure Control Method

Fan Type

Drive

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 13 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.2 Air-Cooled Chillers (Cont’d)

Location: _____________________ No.: ____ Design Test Result Test Result

Data (full load) (part load) Remarks

Motor Type

Motor Nameplate Rating (kW)

Motor Speed (rev/s)

Motor Full-load Condition (amp. & volt)

Motor No-load Condition (amp. & volt)

Supply Voltage (V)

High Pressure Cut-in (kPa)

High Pressure Cut-out (kPa)

Low Pressure Cut-in (kPa)

Low Pressure Cut-out (kPa)

Oil Pressure Cut-out (kPa)

Motor High Temperature Cut-out (oC)

Freeze up Temperature Cut-out (oC)

Flow Switch Cutout (l/s)

Anti-Recycle Logic

Bad Phase Protection

Under Voltage Protection

Emergency Stop

Condensate Fan Start-up Sequencing

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 14 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.3 Cooling Towers

Location: _____________________ No.: ____ Design Test Result Test Result

Data (full load) (part load) Remarks
Type : __________________________

Cooling Capacity (kW)

Summer Design Wet Bulb Temperature (oC)

Altitude above Sea Level (m)

Entering Dry Bulb Temperature (oC)

Entering Wet Bulb Temperature (oC)

Leaving Dry Bulb Temperature (oC)

Leaving Wet Bulb Temperature (oC)

Make-up water Quantity (l/s)

Constant Bleed Water Quantity (l/s)

Cooling Water Flow Rate (l/s)

Cooling Water Entering Temperature (oC)

Cooling Water Leaving Temperature (oC)

Fan Type

Fan Outlet Size (m2)

Fan Volume (l/s)

Fan Drive

Motor Type

Motor Speed (rev/s)

Motor Rating (kW)

Tower Water Connections Diameter (mm)

Balance Pipe Connection Diameter (mm)

Supply Voltage (V)

Starting Current (A)

Running Current (A)

Emergency Stop

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 15 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.4 Pumps
Location: _____________________ No.: ____ Design Test Result Test Result
Data (full load) (part load) Remarks

Volume Flow Rate (l/s)

No Flow Head (kPa)

Full Flow Discharge Head (kPa)

Full Suction Pressure (kPa)

Full Flow Differential (kPa)

Impeller Diameter (mm)

Motor Type

Motor Speed (rev/s)

Rated Power (kW)

Motor Full-load Condition (amp. & volt)

Supply Voltage (V)

Starting Current (A)

Running Current (A)

Overload Setting (A)

Tripping Time of Starter Overload (S)

Auto-changeover *Yes/No/N.A. *Yes/No/N.A.

Emergency Stop *Yes/No/N.A. *Yes/No/N.A.

Low Level Cut-in *Yes/No/N.A. *Yes/No/N.A.

Low Level Cut-out *Yes/No/N.A. *Yes/No/N.A.

High Level Cut-out *Yes/No/N.A. *Yes/No/N.A.

Horn Buzzer *Yes/No/N.A. *Yes/No/N.A.

Lamp Test Button *Yes/No/N.A. *Yes/No/N.A.

Degree of Protection of Enclosures (IP) *Yes/No/N.A. *Yes/No/N.A.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 16 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.5 Pump Alignment Test

Location: _____________________________

Ref. No.: _____________________________

Rim Check Reading Face Check Reading

T B L R T B L R
Pump No.

Pump No.

Pump No.

Pump No.

Remarks:
T : Top Reading
B : Bottom Reading
L : Left Hand Side Reading
R : Right Hand Side Reading
Maximum allowable misalignments refer to the recommendation in
the General Specification or Manufacture’s Recommendation.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 17 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.6 Air Handling Units

Location: _____________________ No.: ____ Design Test Result Test Result
Data (full load) (part load) Remarks

Outdoor Air Condition

Dry Bulb Temperature (oC)

Wet Bulb Temperature (oC)

Time of Day (Hrs)

Condition (Cloudy/Sunny)

Total Air Quantity (l/s)

Fresh Air Quantity (Minimum) (l/s)

Fresh Air Quantity (Maximum) (l/s)

Smoke Detector *Yes/No/N.A. *Yes/No/N.A.

Fan

Type

Speed (r/s)

Drive

Driven Belt (Type/No.)

Inlet pressure (kPa)

Discharge pressure (kPa)

Fan Static Pressure (kPa)

(Discharge - Inlet)

Supply Voltage (V)

Overload Setting (A)

Tripping Time of Overload (S)

Starting Current (A)

Running Current (A)

Rated Power (kW)

Emergency Stop

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 18 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.6 Air Handling Units (Cont’d)

Location: _____________________ No.: ____ Design Test Result Test Result
Data (full load) (part load) Remarks

Filter

Type :

Inlet Pressure (kPa)

Outlet Pressure (kPa)

Effective Area (m2)

Velocity (m/s)

Cleanliness

Alarm Buzzer

Filter Clogged Light

Cooling Coil

Entering Air Dry Bulb Temperature (oC)

Entering Air Wet Bulb Temperature (oC)

Leaving Air Dry Bulb Temperature (oC)

Leaving Air Wet Bulb Temperature (oC)

Entering Water Temperature (oC)

Leaving Water Temperature (oC)

Entering Water Pressure (kPa)

Leaving Water Pressure (kPa)

Water Quantity (l/s)

Evaporator Suction Pressure (kPa)

Evaporator Suction Temperature (oC)

Evaporator Discharge Pressure (kPa)

Evaporator Discharge Temperature (oC)

Effective Area (m2)

Velocity (m/s)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 19 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.6 Air Handling Units (Cont’d)

Location: _____________________ No.: ____ Design Test Result Test Result
Data (full load) (part load) Remarks

Heating Coil (Medium)

Entering Air Dry Bulb Temperature (oC)

Leaving Air Dry Bulb Temperature (oC)

Effective Area (m2)

Velocity (m/s)

Entering Water Temperature (oC)

Leaving Water Temperature (oC)

Entering Water Pressure (kPa)

Leaving Water Pressure (kPa)

Water Quantity (l/s)

No. of steps

Capacity of Each Steps (kW)

Air Quantity (l/s)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 20 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.7 Heating Coils (Not included in Air Handling Unit)

Location: _____________________ No.: ____ Design Test Result Test Result
Data (full load) (part load) Remarks

Medium

Entering Air Dry Bulb Temperature (oC)

Leaving Air Dry Bulb Temperature (oC)

Effective Area (m2)

Velocity (m/s)

Air Quantity (l/s)

Entering Water Pressure (kPa)

Leaving Water Pressure (kPa)

Water Quantity (l/s)

Capacity of Coil (kW)

No. of Steps

Capacity of Each Step (kW)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 21 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.8 Ducts, Grilles, Diffusers, etc.

Location: _____________________ No.: ____ Design Test Result Test Result
Data (full load) (part load) Remarks

Air flow rate (l/s)

Access Panel for maintenance provided *Yes/No/N.A. *Yes/No/N.A.

Use the air flow sheets and indicate the design and test figures as indicated in Annex V Section 2.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 22 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.9 Pressure Test

(Remark: After replacement or repair of the compressor/refrigeration system work, this

test shall be carried out.)

Location: _____________________________

Ref. No.: _____________________________

High Side Test Pressure, kPa Low Side Test Pressure, kPa
Refrigerant Specification Specification
Test Result Test Result
Requirement Requirement
R 134a (Air-cooled)
R 134a (Water-cooled)
Others

In performing pressure test for refrigerant system and circuit containing blend refrigerant, e.g.
R407C and R410a, manufacturer’s recommended procedures and test pressure shall be followed.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 23 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.10 Evacuation Test

(Remark: The evacuation shall be pulled down to between absolute pressure of 170 Pa and
340 Pa)

Location: _____________________________

Ref. No.: _____________________________

1st Duration of Test

4 hours
nd
2 Duration of Test
3 hours
rd
3 Duration of Test
2 hours
Refrigerant Type:

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 24 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.11 Air Duct Leakage Test Sheet

Project Title (with location) ______________________________

Programme NO. ______________________________
* Contract/Sub-contract/Quotation No. ______________________________
Date of Test ______________________________
Type, Model & Serial No. of Instrument used ______________________________
Date of Calibration ______________________________

Part 1 – Physical Details

(i) Section of ductwork to be test ______________________________
(ii) Surface area of duct under test ______________________________
(iii) Test static pressure ______________________________
(iv) Leakage factor ______________________________
(v) Maximum permitted leakage ______________________________
(b x d)

Part 2 – Test Particulars

(i) Duct static pressure reading ______________________________
(ii) Type of flow measuring device ______________________________
(iii) Range of measurement of flow ______________________________
measuring device
(iv) Reading of flow measuring device ______________________________
(v) Interpreted air flow leakage rate ______________________________
(vi) Duration of test (normally 15 ______________________________
minutes)

Width and Depth or

Length, mm Periphery, mm Area, mm2
Diameter, mm

Total

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 25 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.12 Fan Coil Unit

Location: _______________________
No.: _______________________
Test
Description: Design Result Remarks
Result
Manufacturer
Model No.
Serial No.
Country of Origin
Motor Type
Supply Voltage (V)
Rated Power (kW)
Cooling Coil Valve Operate in Normal Condition *Yes/No/N.A.
No. of Blower(s)
Air Flow Rate (l/s)
Water Flow Rate (l/s)
Chilled Water Entering Temperature (oC)
Chilled Water Leaving Temperature (oC)
Hot Water Entering Temperature – if any (oC)
Hot Water Leaving Temperature – if any (oC)
Supply Air Temperature (oC)
Return Air Temperature (oC)
Heating Element (oC)
Electric Heater (oC)
Maximum Output Power (kW)
Overheat Cut-off Operate within 90sec at 50°C ±10% *Yes/No/N.A.
Air Flow Switch *Yes/No/N.A.
Manual Reset Switch Installed *Yes/No/N.A.
Warning Label Provided *Yes/No/N.A.
A Small Hole Provided for Inserting a Testing *Yes/No/N.A.
Thermometer
Heater and Blower Interlock *Yes/No/N.A.
No Internal Insulation within 1m from Heater *Yes/No/N.A.
Assess Panel for Maintenance Provided *Yes/No/N.A.
Warning Label Provided *Yes/No/N.A.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 26 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.13 Variable Air Volume (VAV) Box

Location: _______________________
No.: _______________________
Test
Description: Design Result Remarks
Result
Manufacturer
Model No.
Serial No.
Country of Origin
Air Flow Rate (max. flow and min. flow) (l/s)
Pressure (kPa)
Supply Air Temperature Setting Point (oC)
Supply Air Temperature (oC)
Air Flow Control Damper operate in Normal Condition *Yes/No/N.A.
CCMS Control in Normal Condition *Yes/No/N.A.

Electric Heater
Output Power (kW)
Temperature (oC)
Maximum Current (A)
Overheat Cut-off Operate within 90sec at 50°C ±10% *Yes/No/N.A.
Air Flow Switch *Yes/No/N.A.
Manual Reset Switch Installed *Yes/No/N.A.
Warning Label Provided *Yes/No/N.A.
Heater and Blower Interlock *Yes/No/N.A.
No Internal Insulation within 1m from Heater *Yes/No/N.A.
Emergency Stop Provided *Yes/No/N.A.
Assess Panel for Maintenance *Yes/No/N.A.
Assess Panel Provided *Yes/No/N.A.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 27 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.14 Split type Air-conditioning Unit

Location: _______________________
No.: _______________________
Test
Description: Design Result Remarks
Result
Manufacturer
Model No. (Indoor Unit)
Serial No.
Model No. (Outdoor Unit)
Serial No.
Country of Origin
Supply Fuse
Control Fuse
Compressor Rated Current (A)
Condenser Fan Rated Current (A)
Evaporator Fan Rated Current (A)
Cooling Capacity
Overload Setting
Refrigerant Type
Starting Current (A)
Running Current (A)
High Pressure Cut-out (kPa)
Low Pressure Cut-out (kPa)
Compressor Suction Pressure (kPa)
Compressor Discharge Pressure (kPa)
Evaporator Entering Coil Dry Bulb (DB-oC)
Temperature
Evaporator Entering Coil Wet Bulb (WB-oC)
Temperature
Evaporator Leaving Coil Dry Bulb Temperature (DB-oC)
Evaporator Leaving Coil Wet Bulb Temperature (WB-oC)
Condenser Entering Coil Dry Bulb Temperature (DB-oC)
Condenser Entering Coil Wet Bulb Temperature (WB-oC)
Condenser Leaving Coil Dry Bulb Temperature (DB-oC)
Condenser Leaving Coil Wet Bulb Temperature (WB-oC)
Emergency Stop
Pressure Gauge(s) Installed *Yes/No/N.A.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 28 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.14 Split type Air-conditioning Unit(Cont’d)

Pressure Test – (Refer to the General Specification)

Refrigerant High Side Test Pressure, kPa Low Side Test Pressure, kPa

R 134a (Air-cooled) 2080 1190

R 134a (Water-cooled) 1270 880
R 717 (Air-cooled) 3230 1820
R 717 (Water-cooled) 1940 1340
Others * *

In performing pressure test for refrigerant system and circuit containing blend refrigerant, e.g. R407C and R410a,
manufacturer’s recommended procedures and test pressure shall be followed.

Evacuation Test - (Remark: The evacuation shall be pulled down to between absolute pressure of 170 Pa and
340 Pa)- Refer to the General Specification
1st Duration of Test
4 hours
nd
2 Duration of Test
3 hours
rd
3 Duration of Test
2 hours
Refrigerant Type:

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 29 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.15 Variable Refrigerant Volume (VRV) System

Manufacturer: Location
Air Distribution System:
Pressure testing of pipe servicing system or any section of a *Yes/No/N.A. *Yes/No/N.A.
completed system, shall be completed prior to the application
of any thermal insulation to the cleaned pipe surfaces. The
pressure test for this system is recommended by the
Manufacturer’s.
The system is required to vacuum by a vacuum pump. *Yes/No/N.A. *Yes/No/N.A.
Add the refrigerant to the indoor unit through the refrigerant *Yes/No/N.A. *Yes/No/N.A.
pipe.
The refrigerant is extracted by the new vacuum pump. *Yes/No/N.A. *Yes/No/N.A.

High Side Test Pressure, kPa Low Side Test Pressure, kPa
Refrigerant General General
Specification Test Result Specification Test Result
Requirement Requirement
R22 (Air-cooled) 2950 1780
R22 (Water-cooled) 1900 1360
R134a (Air-cooled) 2080 1190
R134a (Water-cooled) 1270 880
Others

In performing pressure test for refrigerant system and circuit containing blend refrigerant, e.g. R407C and R410a,
manufacturer’s recommended procedures and test pressure shall be followed.

Evacuation Test - (Remark: The evacuation shall be pulled down to between 170 Pa absolute and 340 Pa
absolute)- Refer to the General Specification
1st Duration of Test
4 hours
nd
2 Duration of Test
3 hours
rd
3 Duration of Test
2 hours
Refrigerant Type:

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 30 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.15 Variable Refrigerant Volume (VRV) System (Cont’d)

Description: Design Data Test Result Remark

Operating Voltage (V)
Capacity (kW)
Compressor Operating Current (A)
Evaporator Operating Current (A)
Discharge Pressure (kPa)
Suction Pressure (kPa)
Discharge Gas Temperature (oC)
Heat Exchanger Liquid Pipe Temperature (oC)
Emergency Stop Operation
High Pressure Cut-out (kPa)
Low Pressure Cut-out (kPa)
Frequency Inverter (Hz)
Outdoor Fan Step
Outdoor Unit Expansion Valve Opening
Indoor Unit (Unit No.) (Unit No.)
Expansion Valve Opening
Heat Exchanger Liquid Pipe Temperature (oC)
Discharge Gas Temperature (oC)
Intake Air Temperature (oC)
Outlet Air Temperature (oC)
Capacity (kW)
Return Air Temperature (oC)
Supply Air Temperature (oC)
Room Air Temperature (oC)
Air Flow Rate (l/s)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 31 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.16 Water Scrubbers

Location: _______________________
No.: _______________________
Description: Design Data Test Result Remark
Manufacturer
Model No.
Serial No.
Country of Origin
Supply Voltage

Centrifugal Fan
Motor Power (kW/hp)
Overload Setting (A)
Starting Current (A)
Running Current (A)
Motor Speed (r.p.m.)
Fan Speed (r.p.m.)

Circulating Pump
Motor Power (kW/hp) No.1 No.2 No.3
Overload Setting (A)
Starting Current (A)
Running Current (A)
Pump Head Pressure (kPa/Bar)
Pump Flow Rate (l/s)

pH Meter / Sensor
Set Point
Alarm
ORP Meter / Sensor *Yes/No/N.A.
Set Point (mV)
Alarm
Chemical Dosing Pumps operate in normal *Yes/No/N.A.
condition

Scrubber
Scrubber High level sensor interlock with water *Yes/No/N.A.
supply valve
Scrubber Low level sensor interlock with *Yes/No/N.A.
circulating pump
Chemical Tank Low Level Sensor interlock *Yes/No/N.A.
with Chemical Pump

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 32 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.16 Water Scrubbers(Cont’d)

Sampling Odour Test
Date of Test: _______________________
Location: _______________________
Description: Design Data Test Result Remark
Chemical Weight (Na2S) (g)
Volume of H2SO4 (ml)

Sample Inlet
Initial time for sampling
Final time for sampling
Total sampling time (Min)
Pump Flow Rate (l/ min)
Volume of absorbent used (ml)

Sample Outlet
Initial time for sampling
Final time for sampling
Total sampling time (min)
Pump Flow Rate (l/ min)
Volume of absorbent used (ml)

Sampling Oil Mist Test

Date of Test: _______________________
Location: _______________________
Description: Design Data Test Result Remark
Weight of Oil used (g)
Pumping Rate (g/min)

Sample Inlet
Initial time for sampling
Final time for sampling
Total sampling time (min)
Pump Flow rate (l/ min)

Sample Outlet
Initial time for sampling
Final time for sampling
Total sampling time (min)
Pump Flow rate (l/ min)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 33 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.17 Exhaust Hood

Location: _______________________
No.: _______________________

Description: Design Data Test Result Remark

Water Circuit Cycle Time
Fresh-supply Water Inlet Time
Detergent Inlet Time
Pump Outlet Pressure
Working Performance *Satisfactory /
Failed
Mounting Fixture
Water Seepage *Satisfactory /
Failed
Indication Lighting

Description: Design Data Test Result Remark

Manufacturer:
Model No.:
Serial No.:
Country of origin:
Air Flow Rate (m3/s)
Static Pressure (N/m2)
Exhaust Hood
Material:
Size (L x W x H) (mm)
Pressure Loss (kPa)
Main Fold & Jet Spray Nozzle
Material:
Number of nozzle:
Flow Rate (l/s)
Rotating Baffle
Material:
Number of baffle:
Size: (mm)
Control Panel
Control:
Control Fuse Rating:
Number of Control Fuse:
Control Function Indication Lamp & Fault Alarm *Yes/No/N.A. *Yes/No/N.A.
Buzzer Provided
Circulating Pump
Model:
Serial No.:
Type:
Casing Material:

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 34 of 54 Mechanical Ventilation Installation 2022 Edition
(TCP-AC-2022)
 Annex II

4.17 Exhaust Hood(Cont’d)

Description: Design Data Test Result Remark
Impeller Material:
Shaft Material:
Flow Rate (l/s):
Pressure Head (kPa)
Speed/Revolution (r.p.m.)
Pump Motor Power (kW):
Type of Drive:
Supply Voltage (V)
Starting Current (A)
Running Current (A)
Power (kW)
Efficiency (%)
Overload Tripping Setting (A)
Emergency Stop
Detergent
Manufacturer/Trade Mark:
Chemical Composition:
Detergent Capacity/each (L)
Grease Filter
Manufacturer
Model:
Type:
Size (L x W x Thick) (mm)
Grease Extraction Efficiency (%)
Face Velocity (m/s)
Pressure Drop (kPa)
Exhaust Fan
Manufacturer:
Model No.:
Serial No.:
Country of origin:
Supply Voltage (V)
Motor Power (kW/hp)
Overload Setting (A)
Starting Current (A)
Running Current (A)
Motor Speed (r.p.m.)
Emergency Stop *Yes/No/N.A. *Yes/No/N.A.

Others
Make-up water tank size (m3 or litre)
All valve is/are open *Yes/No/N.A. *Yes/No/N.A.
Waste oil is through a Grease / treatment tank to *Yes/No/N.A. *Yes/No/N.A.
floor drain

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

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 Annex II

4.18 Ventilation and Air-conditioning (VAC) Control Systems interfacing with Fire Alarm Signal

Description: Design Data Test Result Remark

Ventilation and Air conditioning Control Systems Method A / B / C
Location of Fan / FCU/ AHU serving the
compartment / Building
Location of Probe-type smoke Detector
Number of Fan / FCU/ AHU serving the
compartment / Building
Emergency Stop
Air Flow Rate (l/s) *Yes/No/N.A.

Fan / AHU / FCU unable to start while fire signal *Yes/No/N.A.

exist
As indicated Fail / defect / equipment *Yes/No/N.A.

Details refer to BSB Fire Services T&C Procedure:

Method of overriding control (Refer to relevant requirements in the latest COP for Minimum Fire
Service Installations & Equipment): Method A/B//C/combination of

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

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 Annex II

4.19 Outdoor Air Pre-conditioner (OAP)

Location: ____________________________
No.: ________________________________

Description: Design Data Test Result Remark

Manufacturer:

Model No.:
Serial No.:
Motor Supply Voltage (V)
Running Current (A)
Supply fuse (A)
Total Air Flow Rate (l/s)
Supply Air Flow Rate (l/s)
Return Air Flow Rate (l/s)
(a) Outdoor Intake Temperature (c)
(b) Indoor Intake Temperature (c)
(c) Exchanged Air Temperature (c)
(d) Indoor Exhaust Temperature (c)

(a) (c)
Outdoor Intake Exchanged Air
Temperature Heat Temperature
Outside Room
Exchange
Indoor Exhaust Indoor Intake
Temperature
r Temperature
(d) (b)

Outdoor Air Pre-conditioner

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 37 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.20 Noise & Sound Test

4.20.1 Indoor Noise Level Measurement Record

Name of Project :
Measuring Instrument used : Model No.:
Serial No.:
Last date of calibration:

Date & time of measurement :

Measured by :

Weather Conditions :

Location of Sound Pressure Level in dB

measurements Octave Band Centre Frequency (Hz) Overall
NC Level
(at 1.5m above dB
floor level) 63 125 250 500 1k 2k 4k 8k

Observations/Remarks:

Attachments include: (1) NC curves for individual location; (2) floor layout plan indicating locations of noise
measurements

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 38 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.20 Noise & Sound Test(Cont’d)

4.20.2 Outdoor Noise Level Measurement Record

Name of Project :
Measuring Instrument used : Model No.:
Serial No.:
Last date of calibration:

Date & time of measurement :

Measured by :

Weather Conditions :

Description Position of Time Leq,30 mins Correction for Tonality, Observations/Remarks

of Noise Measurement in Impulsiveness and/or
Source made dB(A)* Intermittency
according to the TM

* The measurement shall be made over any 30-minute period according to the Technical Memorandum
for the Assessment of Noise from Places other than Domestic Premises, Public Places or Construction
Sites (TM) issued by the Environmental Protection Department (EPD). Measurement can be made over
any shorter period when the EPD is satisfied that the noise under investigation is essentially steady over
a 30-minute period.

Attachments include: (1) calibration results of the measuring instrument; (2) site plan indicating locations of
noise source & noise level measuring point(s)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 39 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.21 Vibration Test – Equipment Vibration Measurement Record

Name of Project :
Measuring Instrument used : Model No.:
Serial No.:
Last date of calibration:

Date & time of measurement :

Measured by :

Weather Conditions :

Indicated operation speed (rev/s) Measured speed (rev/s) Visual/ audible Vibration acceptance Vibration measured (mm/s) Other observations/
Equipment
Motor Equipment Motor Equipment check criteria (mm/s) Horizontal Vertical Axial remarks

Attachment includes a sketch showing the positions of measuring points for each equipment.

Tested / Checked by : Signature - Post :

(Name of Contractor’s Representative)
Tel. No. :
( ) Date :
Witnessed by: Signature - Post :
(Name(s) of *PBSE/PBSI)
Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and Mechanical

Page 40 of 54 Ventilation Installation 2022 Edition
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 Annex II

4.22 Room Temperature Record – Handover/ Peak Load /Wet & Humidity Season/ Expiry of
Maintenance Period

Name of Project :
Measuring Instrument used : Model No.:
Serial No.:
Last date of calibration:

Date & time of measurement :

Measured by :

Weather Conditions
Dry Bulb Temp (oC) : Wind Speed (m/s) :
Wet Bulb Temp (oC) : Atmospheric Pressure (kPa) :

Dry Bulb Wet Bulb R.H.(%) (From Chart or

Floor Room No.: Point No.:
Temp.(C) Temp.(C) Calculation)
1/F Room 1 A
B
C
D
E

1/F Room 2 A
B
C
D
E

Observations/Remarks:

Attachments include: (1) test certificate of measuring instrument (if any);(2) site floor layout plan indicating
locations of temperature measurements; (3) measuring point shall be indicate on attached layout plan; (4)
numbering of points to be agreed by PBSE/PBSI.

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

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 Annex II

4.22 Room Temperature Record – Handover/ Peak Load /Wet & Humidity Season/ Expiry of
Maintenance Period (Cont’d)

Example :1/F Layout Plan

A B A B
Open Area Office
Room 1 Room 2
E E

C D C D

Lift Lobby

Lift 1 Lift 2

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

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 Annex II

4.23 Solar Water Heating System

Location: _______________________
No: ___________________________

Designed Test
Description Remarks
Data Results
Visual Inspections
Pipe Work Pressure Test Records Acceptable (Yes/No)
Panels Securely Fixed on Support (Yes/No)
Panel Absorber Surfaces Has Obvious Sign of (Yes/No)
Oxidation or De-colourisation
Pipe Work, Heat Exchangers and Solar Hot Water (Yes/No)
Calorifier Are Well Insulated and With UV
Protection Layer
Hydraulic System Has Been Balanced (Yes/No)
All Valves Setting Are Appropriate (Yes/No)
All Electrical/Signal Connections of Sensors, (Yes/No)
Controllers and Data Acquisition Devices Are
Properly Connected
All Sensors Are Properly Installed (Yes/No)
All Sensors Have Been Calibrated (Yes/No)
All Sensors’ Location Appropriate (Yes/No)
Automatic Air Vent Location Appropriate (Yes/No)
All Labels & Signages Are Provided (Yes/No)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

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 Annex II

4.23 Solar Water Heating System(Cont’d)

Location: _______________________
No: ___________________________

Designed Test
Description Remarks
Data Results
Measurements

Collector Panel Array

Solar Collector Type
Solar Collector Grosse Area of Each
Panel (mm x mm)
Solar Collector Net Area (Absorber
Area) of Each Panel (mm x mm)
No. of Solar Collector Panels
Connected In Serious Within A Bank
No. of Solar Collector Panels Bank
Connected In Parallel Within The
Array
Panel Tilted Angle (  to
Horizontal)
Panel Array Orientation
Water Flow Rate of Solar Panel (l/s)
Array
Panel Array Entering Water (C)
Temperature
Panel Array Leaving Water (C)
Temperature
Panel Array Pressure Drop (kPa)
Ambient Air Temperature (C)
Wind Speed (m/s)
Solar Irradiation (W/m2)
Chemical Treatment (Yes/No)
- _____________ (chemical) (ppm)
- _____________ (chemical) (ppm)
- _____________ (chemical) (ppm)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 44 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.23 Solar Water Heating System(Cont’d)

Location: _______________________
No: ___________________________

Designed Test
Description Remarks
Data Results
System Controller
Circulation Pump Auto Start-Stop Setting (C)
- Temperature Different Between Solar
Panel Output and Water Tank for Pump
On

- Temperature Different Between Solar (C)

Panel Output and Water Tank for Pump
Off

Calorifier
Calorifier Storage Volume (m3)
Vent Type (Vented/
Unvented)
Calorifier Shell/lining Materials
Pressure/Temperature Relief Valve Setting
- Purging Temperature (C)
- Purging Pressure (kPa)
Auxiliary Heater Type
Auxiliary Heater Rating (kW)
Over Temperature Thermostat Setting (C)
Calorifier Maximum Heat Transfer Capacity (kW)
Pressure Drop of Calorifier Heating Loop (kPa)
Insulation Type
Insulation Thickness (mm)

Circulation Pumps
Voltage (V)
Current (A)
Power (W)
Flow Rate (l/s)
Pump Head (kPa)

Tested / Checked by : Signature - Post :

(Name of Authorised Contractor’s Representative) Tel. No. :
( ) Date :
Witnessed by : Signature - Post :
(Name(s) of *PBSE/PBSI) Tel. No. :
( ) Date :

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 45 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.24 Checklist for Walkthrough Inspection

The walkthrough inspection is used to identify areas with a high potential for IAQ problems.

4.24.1 The following general requirements should be met before IAQ measurement:

(a) Platforms are free of construction waste and debris;

(b) Access doors to plantrooms are fitted and lockable;

(c) All builder’s works associated with IAQ systems completed and painted with dust preventing
compound;

(d) All ceiling works are completed;

(e) All dust generating activities by other trades are completed and all areas thoroughly cleaned to
prevent ingress of building dust and debris into the

(f) Air intake screens and louvers are unobstructed and cleaned;

(g) Fan and other equipment chambers are clean and free of construction debris;

(h) Fans are checked for proper operation;

(i) Floor gullies and drainage traps are clear and operational;

(j) All condensate drains and trays are clear and water can be drained away satisfactorily;

(k) Dampers are clean;

(l) Ducting and other air passage ways are clean;

(m) All outside air, return air, and spill air dampers are operative;

(n) All volume control dampers are fitted and are at appropriate opening positions;

(o) Ductwork systems are cleaned by purging of the supply air fan, or by robot duct cleaning
recommended by the ductwork cleaning specialist;

(p) All CAV and VAV terminals are installed, together with grilles and diffusers;

(q) All filter media are installed;

(r) Air conditioning systems and the building indoor area are purged to the standard acceptable by
the Supervising Officer

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 46 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.24 Checklist for Walkthrough Inspection(Cont’d)

4.24.2 The following are general indicators of IAQ problems:

(a) Odour;

(b) Dirty or unsanitary conditions (e.g. excessive dust);

(c) Visible fungal growth or mouldy odour (often associated with problem of too much moisture);

(d) Staining or discolouration of building materials;

(e) Sanitary conditions in equipment such as drain pans and cooling towers;

(f) Inadequate ventilation;

(g) Inadequate exhaust air flow;

(h) Blocked vents;

(i) Uneven temperature;

(j) Overcrowding;

(k) Poorly-maintained filters;

(l) Personal air cleaners (e.g. ozone generators);

(m) Presence of hazardous substances; and

(n) Unsanitary mechanical room, or trash or stored chemicals in mechanical room.

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 47 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.24 Checklist for Walkthrough Inspection(Cont’d)

4.24.3 Specifically, the following should be addressed:

4.24.3.1 Thermal comfort

(a) Check for any evidence of high or low temperature. Are these due to occupant
interference, such as installation of new equipment?

(b) Check for evidence of thermal gradients; the floor-to-ceiling differential should not
exceed 3C.

(c) Check for any obstruction of air circulation, such as partitions, taped diffusers, or
blocked by paper, books, or cabinets.

(d) Ensure that thermostats are functioning, calibrated, correctly located, and not
obstructed or enclosed.

(e) Is there system intervention, such as blockage of the ventilation grilles?

4.24.3.2 Potential sources of contaminants

(a) Enquire about any recent change in the physical set-up and use of the space (e.g.
open office space converted to closed offices, transformation of office space into a
waiting room, computer room etc.).

(b) Inspect the loading dock and car parks connected with the premises:

• Are they properly ventilated?

• Are stairways, elevator shafts, and ducts acting as pathways for automobile
exhaust and diesel fumes?

• Are carbon monoxide sensors (for ventilation control) and alarms installed in the
garage calibrated and operating properly?

(c) Are stoves and other sources fitted with exhaust system?

(d) Is the building less than a year old, or has any area been renovated, redecorated or
newly furnished within the past month?

(e) Are suitable cleaning products being employed? Is time of use optimum, so as to
reduce exposure of occupants?

(f) Do any activities involve the use of large amounts of chemicals, especially highly
volatile solvents? Is solvent odour present? Are soaked materials and solvents
being disposed of properly?

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 48 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.24 Checklist for Walkthrough Inspection(Cont’d)

(g) Have pesticides been improperly applied?

(h) Is the trash properly disposed of daily?

(i) Is extra ventilation or a separate ventilation system being used where there are
localised sources? Is the ventilation system recirculating volatile organic
compounds from a source throughout the building?

(j) Any mouldy, damp odour, evidence of a previous flood or water leak?

(k) Records should be examined for evidence of recent renovation, painting,

installation of plywood or particleboard, replacement of carpets, and installation of
new furniture.

(l) Are there dirt marks or white dust on diffusers, indicating particulates entering from
the ventilation system?

(m) Is smoking only restricted to designated areas with independent ventilation system?

(n) Are the carpets cleaned regularly?

4.24.3.3 Air-conditioning and Mechanical Ventilation (ACMV) system

(a) Is the amount of fresh air provided to the premises in line with the
"ANSI/ASHRAE Standard 62.1-2019: Ventilation for Acceptable Indoor Air
Quality"?

(b) Where is the fresh air intake duct located? Is it blocked up? Is it near the cooling
tower? Is it at street level or near a car park (Air intakes located below third-floor
level can conduct fumes from vehicular traffic, parking garages)? Are heavy
industries located nearby? Is there any construction work going on nearby?

(c) Are the outside air controls and dampers functioning properly?

(d) Is the minimum outside air damper opening set at approximately 15%?

(e) Are all air distribution dampers functioning properly and cleared of obstruction?

(f) Are filters installed and maintained properly (e.g. no bypassing, not overloading
with dust)?

(g) Is the filtering system designed for primary filters, rated between 10% and 30%
dust-spot efficiency, and for secondary filters, rated between 40% and 85% dust-
spot efficiency?

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 49 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.24 Checklist for Walkthrough Inspection(Cont’d)

(h) Are the drain pans clean, properly drained, and without visible mould growth?

(i) Are the fan motors and belts working properly?

(j) Are diffusers and exhaust outlets close together, thereby causing short-circuiting?

(k) Is the air-conditioning system turned off any time during the day?

(l) Is there a regular schedule for cleaning and maintenance of the ACMV system in
the building?

(m) Are all the components of the ACMV system regularly inspected for leaks,
breaches, etc.?

(n) Do the cooling towers treated according to the "Code of Practice for Prevention of
Legionnaires' Disease" published by Prevention of Legionnaires' Disease
Committee, Hong Kong?

(o) Are the mechanical rooms clean and free of contaminant (e.g. refuse, chemicals)?

(p) Are the exhaust fans operating properly?

(q) Are all air distribution path unobstructed?

4.24.3.4 Other Conditions not mentioned above but considered as relevant to IAQ

Qualified Examiner: ______________________ ________________ ______________

(Name in Block Letter) (Signature) (Date)

Annex II T&C Procedure for Air Conditioning, Refrigeration and

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 Annex II

4.25 Testing and Commissioning Results of IAQ Measurement

Site/Project: _____________________________

Control level
Date/time
IAQ specified at Measured outdoor
of the Methodology Remark
Parameter Particular result level
sampling
Specification

Remark and comments:

Qualified Examiner: ______________________ ________________ ______________

(Name in Block Letter) (Signature) (Date)

Annex II T&C Procedure for Air Conditioning, Refrigeration and

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 Annex II

4.26 Testing and Commissioning Records of IAQ Measurement by Real Time Monitor with Data
Logger

Site/Project: _____________________________ Parameter: _____________

Highest value Instrument

Sampling Date/time of the Last calibration
of 8-hour model and serial Remark
position sampling date
average no.

Total average:

Outdoor air:

Sample no. 1 2 3 4
Date/time of
the sampling
Average value Total average:

Instrument model and serial no: __________________

Last calibration date: __________________

Sample taking technician:

Qualified Examiner:
(Name) (Signature) (Date)

Printout of logged data and calculations should be attached to the copy submitted to the PBSE

Annex II T&C Procedure for Air Conditioning, Refrigeration and

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 Annex II

4.27 Testing and Commissioning Records of IAQ Measurement by Integrated Sampling Method

Site/Project: ___________________________________ Parameter: _____________

Name and model of active/passive sampler:________________

Name of Laboratory: ____________________________

Sampling Date/time of the Identification and Batch

Average Remark
position sampling no. of sampler

Total average:

Outdoor air:
Identification and Batch no. of sampler:
Date/time of the sampling:
Average value:

Sample taking technician:

Qualified Examiner:
(Name) (Signature) (Date)

The Original of Laboratory Report should be attached to the copy submitted to the PBSE.

Annex II T&C Procedure for Air Conditioning, Refrigeration and

Page 53 of 54 Mechanical Ventilation Installation 2022 Edition
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 Annex II

4.28 Testing and Commissioning Records of IAQ Measurement by Airborne Bacteria Sampling

Site/Project: _____________________________

Sampling position 1: _______________________

First Second Average Sampling Colony

Sample ID Air volume
Plate count Plate count Plate count Date/Time (cfu/m3)

Average of this position:

(Prepare the following data entry table for each Sampling position: - )

Sampling position _________________________

First Second Average Sampling

Sample ID Air volume Colony (cfu/m3)
Plate count Plate count Plate count Date/Time

Average of this position:

Average of Colony Count of all sample positions: ___________________ cfu/m3

Colony Count of Outdoor Air: ___________________ cfu/m3

Impactor model and serial no: ____________ Last calibration date: _______________
Agar type: ____________ Agar Batch no.: _______________
Name of technician /Supplier preparing the Agar: _________________
Date of agar prepared: _________________

Sample taking technician:

Incubation technician:
Qualified Examiner:
(Name) (Signature) (Date)

Annex II T&C Procedure for Air Conditioning, Refrigeration and

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 Annex III

List of Calibrated Equipment/ Instruments Necessary for the Testing and Commissioning Works

Serial No. of Calibration Date of

Type Make/ Model
Instrument Certificate No. Calibration

Note: The measuring and testing equipment shall be calibrated by laboratories accredited by the Hong
Kong Laboratory Accreditation Scheme (HOKLAS) or other recognised accredited laboratories.

Annex III T&C Procedure for Air Conditioning, Refrigeration and

Page 1 of 1 Mechanical Ventilation Installation 2022 Edition
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 Annex IV

Flow Charts

START

(A) Submission of T&C equipment (B) Submission of T&C (C) Submission of T&C
c/w calibration records by procedures by Contractor programme by Contractor
Contractor

Approved by N Approved by N Approved by N

PBSE PBSE PBSE

Y Y Y

(A) & (B)

& (C)
Yes

Request for inspection (RFI) shall be submitted by Contractor when

the installation is completed. (Installed material / equipment shall
be approved)

N
Inspection passed

Y
Request for witness (RFWT) shall be submitted by Contractor
(T&C to be carried out by Contractor and draft record to be
attached with the relevant RFWT.)

T&C Works
- witnessed by PBSE & PBSI

(D) T&C progress report

- shall be submitted by Contractor.
- shall be up-dated & checked by PBSI.

N
T&C passed

Y
(E) T&C certificate and test record
- shall be submitted by Contractor.
- shall be up-dated & checked by PBSI.

Certificate of Substantial Completion

- necessary T&C works should be completed.

END

Fig.1 Flow Chart for T&C Procedure

Annex IV T&C Procedure for Air Conditioning, Refrigeration and

Page 1 of 6 Mechanical Ventilation Installation 2022 Edition
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 Annex IV

START

Is sensor reading N
within expected
range?

Is reading similar N
to those in same
zone?

Can this N
difference be
Y explained?

Y Proceed to visual
check of sensor

Y
Is sensor type N
correct? Is sensor at N
correct location? Position
correctly
Configure sensor for
Y correct type
Y

Are sensor and N

wiring
undamaged?

Repair
Y
Check sensor against
calibrated instrument

Is sensor N
acceptable?

Y Replace / repair sensor

Complete checklist

N
Next sensor Repeat test

All completed?

Y
END

Fig.2 Sensor Checking Flow Chart

Annex IV T&C Procedure for Air Conditioning, Refrigeration and

Page 2 of 6 Mechanical Ventilation Installation 2022 Edition
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 Annex IV

START

Is there a N
feedback signal
for the DO?

Does the feedback N

signal give correct
indication?

N Y Is there an input to N
monitor the effect of
the DO?
Y
All completed?
Y

N Does this input give N

correct indication of
END the operation of DO?
Does a visual check N
indicate correct
operation of the DO?
Y
Y
Next DO Is CCMS
DO relay
N operating?

N Is CCMS Y
Set switch to auto on hand, off
or auto?
N Is controller
relay
Repeat test Y operating?

N Is DO Y
overridden?
Check Check device
controller under control
Is DO N
interlocked? Y
Check reason for
Change strategy overridden Rectify
Y configuration fault

Check reason for

interlock Delete overridden if
not required

Delete if not
required

Fig.3 Digital Output (DO) Checking Flow Chart

Annex IV T&C Procedure for Air Conditioning, Refrigeration and

Page 3 of 6 Mechanical Ventilation Installation 2022 Edition
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 Annex IV

START

Is there a N
feedback signal
for the AO?

Does the feedback N

signal give correct
indication?

N Y Is there an input to N
monitor the effect of
the AO?
Y
All completed?
Y
N
N Does this input give N
correct indication of
END the operation of AO?
Does a visual check N
indicate correct
operation of the AO?
Y
Y
Next AO Does CCMS AO
indicator lamp show
N correct operation of
Repeat test AO?

N Is CCMS Y
Set switch Check why hand/off/auto on
to auto not on auto auto?

Is device
Set switch hand/off/auto on
to auto Y auto?

N Is AO Y
overridden?

Is AO N
interlocked? Y Is controlled device
ON, i.e. power supply?
Check reason for relay operating?
Change strategy overridden
Y configuration

Check reason for Delete overridden if Put power on to Check device

interlock not required device under control

Delete if not
required

Fig. 4 Analogue Output (AO) Checking Flow Chart

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START

Alarm levels, dead N

bands, time delays as Set correct levels, dead
specified? bands, time delays

Y
Check consequence of
forcing an alarm

Y
N
Is it safe to force
an alarm?

Y
N Is sensor type
correct? Adjust alarm level to
force alarm

Enable Y
alarm

Is alarm message N
category destination Set correct alarm message
correct? destination etc.

Reset alarm level

Cancel alarm

Test next alarm

N
All completed?

Y
END

Fig. 5 Alarm Checking Flow Chart

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START

Set up log for control

variable

Check control loop

stability

N
Is response Time loop
steady?

Y
Alter set point

Log change in
controlled variable
over time

N Is final steady state

response similar to set
point?

N Is control plant Y
operating efficiently?

N Time loop setting gain

Is response steady? integral & derivative
Repair Y values
plant
Check loop again
Y

Complete checklist Repeat test

Repeat test

N
Next loop

All completed?

Y
END

Fig. 6 Control Loop Checking Flow Chart

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 Annex V

Reference For Testing and Commissioning Procedures

1. IAQ Measurement Principles of Real-time Monitors

IAQ
Measurement Principle Accuracy Example of Calibration Method
Parameter
Temp. Thermistor  0.6C Platinum PRT's calibrated against NIST
primary cells
RH Thin-film capacitive  5% Environmental chamber with extreme accurate
RH control traceable to international or
national standards
Air Hot-wire anemometer The larger of Flow tubes as primary standards with their
movement  5% or flowrate calibrations directly traceable to
 0.1m/s length and time standards
CO2 Non-dispersive infrared The larger of Bottled Standard Reference gas traceable to
 5% or international or national standards
 50 ppm
CO Electrochemical The larger of Bottled Standard Reference gas traceable to
 5% or international or national standards
 2 ppm
NO2 Chemiluminescence  1% Bottled Standard Reference gas traceable to
international or national standards
TVOC Photo-ionisation sensor with The larger of Bottled Standard Reference Isobutylene gas
super bright 10.6eV calibrated  10% or traceable to international or national standards
against Isobutylene  20 ppb
HCHO Electrochemical or Electrolysis Environmental chamber with known HCHO
concentration traceable to international or
national standards
Rn Electrostatic collection of alpha- Environmental chamber with known Rn
emitters with spectral analysis concentration traceable to international or
looks at the 6 MeV alpha national standards
particles from the Polonium-218
decay.
RSP 90 degree light scattering The larger of Arizona Road Dust (ARD) compared with
laser photometer fitted with  0.1% or NIOSH Method 0600 for respirable dust
filter for measurement of PM10  1 m/m3
particles
O3 Heated metal oxide  10% Comparison with an NIST traceable UV
semiconductor / Electrochemical analyser

The calibration of all monitors shall be traceable to international and/or national standards
(e.g. National Institute of Standards and Technology standards).

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2. Example of Air Flow Sheet

v a
v = velocity
Design vol. a = area
vol. = volume
Test vol.

Design vol.

Test

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3. Illustration of Balancing Procedures

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FEED AND
EXPAN SION
TANK
CO NSTANT/ VARIABLE EVAPO RATO R
SPEED SECO NDARY PUM P

EVAPO RATO R
6

DIFFERENTIAL
BY-PASS FLOW
VALVE SET SECO NDARY F M ETER
VENTURI ENTHALPY
(SEE NO TE) CO NSTANT
M ETER
PR IM ARY PUM P
PRIM AR Y
VENTURI
7
C

C2
C'

KEY
C1

PRESSU RE/ TEM PERATURE TAPPING

B
STRAINER
B3 a b REGULATING VALVE W ITH BUILT-IN
B' PRESSU RE TAPPING
DO UBLE R EG ULATING VALVE

M O TO RIZED O N/O FF VALVE

B2 M O TO RIZED M O DU LATING VALVE

G ATE VALVE

G LO BE VALVE
AIR/ W ATER HEAT EXCH ANGER
B1 (TERM INAL UNIT)

A N O TE: D IFFERENTIAL BY-PASS VALVE SET APPLIES O NLY

TO CONSTAN T SPEED SECONDARY PUM PS
5 A5
A'

4 A4

3 A3

2 A2

1 A1

Fig. V - Example of Water Distribution System

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3.1 General Description of the Water Distribution System

(a) chilled water system as shown in Fig. V will be used to illustrate the balancing procedures.
The procedures for chilled water circuitry are equally applicable to heating and
condensing water circuitry;

(b) the performance of terminal plant in chilled water systems is considerably more sensitive
to any deviations from the design water flow rate. Hence, the T&C procedure for chilled
water systems requires more exacting tolerances than heating system when balancing;

(c) the flow to each branch circuit is controlled by a two-way motorised on/off control valve;

(d) the return line from each terminal unit is fitted with a motorised modulating valve.
Downstream in series is a regulating valve which has built-in pressure tapings. This valve
is used for both the water flow regulations and measurement. This valve is locked in
position after the balancing procedure is completed.

3.2 Initial Check of System Water Flow Rates

(a) check the pressure drop across the associated flow regulating valve of each terminal unit
and branch by connecting a manometer between points a and b of the regulating valve
with built-in pressure tapping. (Refer to Fig. V);

(b) compute the square root of the ratio of the actual-to-design pressure drop for each branch
and terminal;

(c) determine which is the least favoured (index) branch and which is the most favoured
branch. The branch with the highest ratio is taken as the most favoured branch, whereas
the branch with the smallest ratio is the least favoured branch, i.e. the index branch.

3.3 Balancing of Terminals

(a) start by balancing the most favoured branch first;

(b) balance the water flow rate of each terminal unit to the water flow rate of the index
terminal unit in that branch;

(c) balance the water flow rate of each branch independently. (The main branch valves A,
A’, B, B’, C, C’ regulating valves with built in pressure tappings and motorised
modulating valves of terminal units in Fig. V are all fully open at this stage);

(d) assume branch A-A’ has the highest ratio (i.e. the most favoured) and unit A1 (remote in
hydraulic terms relative to the circulating pump) is the least favoured. If it is not, connect
1 manometer across valve No. 1 and a second manometer across the regulating valve at
the least favoured terminal unit; (take regulative valve No. 2 in this case for illustration)

(e) regulate valve No. 2 until the percentage of design water flow rate across the 2 valves is
equal (or within the designer’s tolerances);

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(f) leave the first manometer connected across valve No. 1 (a and b) while the rest of the
branch A-A’ is balanced;

(g) connect the second manometer across valve No. 3. Regulate valve No. 3 until the
percentage of design water flow rate is the same (or within the designer’s tolerances) as
valve No. 1;

(h) repeat this T&C Procedure for all valves on branch A-A’;

(i) remove both manometers and start on the next most favoured branch;

(j) repeat until the water flow rates of all terminal units on all branches are balanced within
each branch.

3.4 Balancing of Complete Branches

(a) for this stage, the branch regulation valves (A, B and C) will be the measuring stations;

(b) check the percentage of design water flow rate across each branch regulating valve and
determine which is the index branch (say branch B-B’);

(c) set the first manometer across valve No. B’ and the second manometer across valve A’
until the percentage of design water flow rates across the valves A and B are equal (or
within the designer’s tolerances for branch balance);

(d) leave the first manometer connected across valve B. Repeat this T&C Procedure for all
branches (in this example for branch C-C’) working back from the most remote branch
to the branch nearest the pump. (Where, at the start of branch balancing, if the most
remote branch is not the index or least favoured branch, it should be made so, in the
manner described for terminal balance.)

3.5 Balancing of Secondary Pumps

(a) set the pump speed at designed maximum flow conditions for variable speed pump;

(b) measure the water flow by connecting a manometer across the regulating valve No.6.
Adjust the regulating valve until the pressure drop across the valve equals the design
pressure drop;

(c) counter check the flow by using the secondary venturi or other flow meters in the circuit;

(d) repeat the procedures for all secondary pumps.

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3.6 Balancing of Primary Pumps

(a) measure the water flow by connecting a manometer across the primary venturi. Adjust
the regulating valve or globe valve No.7 until the pressure drop across the venturi equals
the design pressure drop;

(b) counter check the flow by referring to other flow meters in the circuit;

(c) repeat the procedures for all primary pumps;

(d) re-scan all measuring stations for record and monitoring purposes including the pump
differential pressures.

4. Principle of Proportional Air Balancing

This is demonstrated in Table V1, X is the main flow, and Y and Z the branch-offs. The essence
of the method is to regulate flow by targeting on the ratio between branch-offs Y and Z.
Balancing is done by taking Y as the reference point.

X Y Z

Y m3/s
% of
m3/s m3/s % of Y
design
X Z
Design flow 3 1 2 200%
Measurement and Regulation
Initial condition before balancing with
3.43 1.58 1.85 117%
Dampers at Y and X fully open
Carry out Balancing by Regulating Damper
at Y to bring the flows at Y and Z to the same 3.3 110% 1.1 2.2 200%
proportion as at design (i.e. Z at 200% of Y)
Finally Regulate Damper at X to bring all 3 1 2
flows to design condition
Note: Device at X may be a fan speed controller (e.g. variable speed drive) instead of
damper

Table V1- Principle of Proportional Air Balancing

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4.1 Preparation
The proportional balancing method, including preparatory work, is illustrated below in the
following typical low velocity supply air system diagram (Fig. V1).

SUPPLY MAIN DUCT

AIR FAN DAMPER

OUTDOOR BRANCH BRANCH A BRANCH BRANCH B BRANCH BRANCH C

AIR DAMPER DAMPER BA DAMPER BB DAMPER BC
OA
SA1 SB1 SC1
SUB-BRANCH A1
RETURN
AIR DAMPER
RA
A11 A12 A13 A14
SA2 SB2 SC2
SUB-BRANCH A2

SA3 SB3 SC3

SUB-BRANCH A3

SA4 SB4 SC4

SUB-BRANCH A4

Note: Terminals A21 to A44, B11 to B44 and C11 to C34 on

corresponding sub-branches are not shown for simplicity C41 C42 C43 C44

Fig V1 - A Typical Low Velocity Supply Air Diagram

(a) check that dampers on all terminal grilles/diffusers A11, A12, A13, A14, A21 to 24, A31
to A34, A41 to A44, B11 to B44 and C11 to C44 are fully open, adjustable louvers without
deflection, and adjustable cones fully open;

(b) set all Branch dampers BA, BB, BC, and Sub-branch dampers SA1 to SA4, SB1 to SB4
and SC1 to SC4 fully open;

(c) set OA and RA to opposite extreme positions, either OA fully open with RA fully closed
or vice versa. Set main duct damper (M) if available to fully open;

(d) carefully monitoring the running current, start the fan. It will deliver a higher than design
airflow since all the dampers are open. Avoid overloading the fan motor. If the current
appears to be excessive, stop the fan. Simulate an increase in system losses before restart.
This can be done by slightly throttling OA (or RA, depending on which has been chosen
to be fully open) or M;

(e) measure the air flow rates of all air Terminals. The measurement shall be carried out
preferably using the same measuring device (for Terminals in the same system). This is
to avoid irregularity between different measuring devices;

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(f) for the purpose of having truly comparable readings, these measurements shall be made
in one quick continuous operation to avoid change of operating conditions and site
environment over time;

Measured flow of air Terminals Total

Sub-Branch A1 Sub-Branch A2 Sub-Branch A3 Sub-Branch A4 Branch
11 12 13 14 A1 21 22 23 24 A2 31 32 33 34 A3 42 42 43 44 A4 A
Measured flow

Ratio of measurement to design in %

Sub-Branch B1 Sub-Branch B2 Sub-Branch B3 Sub-Branch B4 Branch

11 12 13 14 B1 21 22 23 24 B2 31 32 33 34 B3 42 42 43 44 B4 B
Measured flow

Ratio of measurement to design in %

Sub-Branch C1 Sub-Branch C2 Sub-Branch C3 Sub-Branch C4 Branch

11 12 13 14 C1 21 22 23 24 C2 31 32 33 34 C3 42 42 43 44 C4 C
Measured flow

Ratio of measurement to design in %

System flow
% of design flow

Table V2 – Measured Flow of Air Terminals

(g) prepare a table (similar to Table V2) readily indicating the initial measured flows of each
Terminal, Sub-branch, Branch and Main. Express the measurements as percentages of
design values;

(h) study the general pattern of these initial readings. Check for any abnormalities:

(i) flow lower than 100%,

(ii) large differences between branches of similar run and size,

(iii) large differences between adjacent air terminals etc.

abnormalities may indicate excessive leakage, improper closing of dampers and other
problems. Refer unresolved problems to the PBSE if necessary;

(i) for Branches, the preferred sequence is in descending order of measurement to design
ratio, i.e. start balancing with the Branch having the highest measurement to design ratio.
Usually, the Branch nearest (duct run distance) to the fan would have the highest ratio;

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(j) for Sub-branches, the preferred sequence is again in descending order of measurement to
design ratio. Usually, the Sub-branch nearest (duct run distance) to the fan would have
the highest ratio;

(k) for Sub-branches, the preferred sequence is again in descending order of measurement to
design ratio. Usually, the Sub-branch nearest (duct run distance) to the fan would have
the highest ratio;

(l) should there be inadequate airflow in a Sub-branch for measurement taking, the dampers
in other Sub-branches may be slightly closed so as provide more flow to the Sub-branch
in question.

4.2 Regulating of Air Terminals

(a) determine the Terminals on each Sub-branch with the lowest measurement to design ratio.
This Terminal (T) is to be used as the Index Terminal (IT) during balancing of the
corresponding Sub-branch. It is usually the farthest Terminal downstream;

(b) for each Sub-branch, prepare a table listing the ratio of measurement to design flow rates
of all Terminals, such as the one shown in Table V3;

Sub-branch SA1 Index Terminal Terminal

IT T
A14 A11 A12 A13
Ratio of measurement to design
(%)

Table V3 – Ratio of Measurement to Design Flow Rates of Terminals

(c) assuming that Sub-branch SA1 has the highest measurement to design flow ratio, it shall
be the one to be balanced first (according to (k) in section 4.1 above);

(d) assuming that Terminal A14, the one farthest away from the fan, has the lowest
measurement to design flow ratio, it is taken as the IT;

(e) should A14 turns out not to be the Terminal with minimum measurement to design ratio,
gradually close A14’s damper until it has the lowest ratio. Take A14 as the IT;

(f) proceed with the reiteration steps according to the flow chart in Fig V2. Start off with a
Terminal adjacent to IT, in the direction of duct path towards the fan;

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(1) Determine the Terminal (T) to regulate

＃ Range refers to the tolerance

(2) Measure airflow of T and IT (Index Terminal) limit, usually highest for the first
comparison and decreases for
progressive Terminals. A 120%
may be taken for the 1st
(3) Express measured data in (2) as % of design comparison, 110% for the 2nd
etc. Refer to Section 4.6.

(4) Compare the 2 figures in (3)

＃
No (5) Close damper on T by a
Within small amount (usually the least
Range? amount, as determined by
experience, below the upper
limit)
Yes

(6) Proceed to next T until completion on Sub-branch

Fig. V2 - Flow chart for Regulation of Terminals

(g) it is impractical to have identical measured flows from 2 identical Terminals with same
design flow. Tolerance in measurement is allowed in accordance with section 4.6 below;

(h) it is preferable to use the same set of measuring device to avoid irregularities. For the
purpose of having truly comparable readings, these measurements shall be made in one
continuous operation to avoid change of operating conditions and site environment over
time;

(i) it is preferable to use the same set of measuring device to avoid irregularities. For the
purpose of having truly comparable readings, these measurements shall be made in one
continuous operation to avoid change of operating conditions and site environment over
time;

(j) lock (or mark, if locking not practical) the positions of dampers of regulated Terminals;

(k) after setting of dampers of all Terminals in the Sub-branch, carry out the same for all
other Sub-branches;

(l) after setting of dampers of Terminals in all Sub-branches, carry out the same balancing
work for all other Branches;

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(m) throughout the process, maintain the balanced Sub-branches at between 70% and 130%
of design flow rate. (This can be done by adjusting OA/RA or M. However if such an
adjustment is made whilst regulating the Terminals in a certain Sub-branch,
measurements have to repeat for all Terminals of the Sub-branch in question.);

(n) throughout the process, make sure that dampers in all Sub-branches and Branches are not
disturbed;

(o) it should be noted that the Terminals are still not operating at their design flow rates at
this stage. However, all Terminals are handling the same ratio of flow to their
corresponding design values;

(p) only after completing the regulating works for all Terminals can the balancing of Sub-
branch is proceeded.

4.3 Air balancing of Sub-Branches

(a) the method is similar to section 4.2 above, except this time it is the dampers in Sub-
branches that are to be regulated. Start off by measuring the flow in each Sub-branch;

Measured flow of Sub-branches Total of Branch/System

A1 A2 A3 A4 Branch A

Ratio of measurement to design in %

B1 B2 B3 B4 Branch B

Ratio of measurement to design in %

C1 C2 C3 C4 Branch C

Ratio of measurement to design in %

System flow
% of design
Table V4A – Measured Flows of Sub-Branches

(b) prepare a table (similar to Table V4A) readily indicating the measured flows of each Sub-
branch, Branch and Main. Express the measurements as percentages of design values;

(c) should there be inadequate test holes for measurement in Sub-branch, measurement can
be taken at the Index Terminal. The Index Terminal’s measurement to design ratio in
percentage can be used to represent the percentage of measurement to design flow of the
Sub-branch;

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(d) assuming that Branch A has the highest ratio, it shall be the one to be balanced first
(according to (a) in section 4.1 above);

(e) determine the Sub-branch on each Branch with the lowest measurement to design flow
ratio. This Sub-branch (SB) is to be used as the Index Sub-branch (IS) during balancing.
Assuming SA4 has the lowest measurement to design ratio, it is taken as the IS;

(f) for each Branch, prepare a table listing the ratio of measured flow rates of all Sub-branch
to their corresponding design flow rates, such as the one shown on Table V4B;

Index Sub-branch Sub-branch

Branch A IS SB
SA4 SA1 SA2 SA3
Ratio of measurement to design
(%)

Table V4B – Ratio of Measured Flow Rate of Sub-Branches

(g) proceed with the reiterative steps of balancing according to the flowchart in Fig. V3 Start
off with an adjacent Sub-branch.

(1) Determine the Sub-branch (SB) to regulate

＃Range refers to the tolerance

(2) Measure air flows of SB and IS (Index Sub-branch) limit, usually highest for the
first comparison and decreases
for progressive Sub-branches.
120% may be taken for the 1st
(3) Express measured data in (2) as % of design comparison, 110% for the 2nd
etc. Refer to Section 4.6

(4) Compare the 2 figures in (3)

＃
No (5) Close damper on SB by a
Within small amount (usually the
Range?
least amount, as determined
by experience, below the
upper limit)
Yes

(6) Proceed to next SB until completion of the Branch

Fig. V3 - Flow chart for Air-balancing of Sub-Branches

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(h) it is preferable to use the same set of measuring device to avoid irregularities. For
purpose of having truly comparable readings, these measurements shall be made in one
continuous operation to avoid change of operating conditions and site environment over
time;

(i) tolerance in measurement is allowed in accordance with section 4.6 below;

(j) lock the positions of dampers of balanced Sub-branches;

(k) after setting of Dampers on all Sub-branches in the same Branch, carry out the same for
all other Branches;

(l) throughout the process, maintain the balanced Sub-branches at between 70% and 130%
of design flow rate;

(m) throughout the process, make sure that dampers in all Branches are not disturbed;

(n) it should be noted that the Sub-branches are still not operating at their design flow rates
at this stage. However, all are handling the same ratio of flow to their corresponding
design values;

(o) only after completing the air balancing works for all Sub-branches can the balancing of
Branch is proceeded.

4.4 Air balancing of Branch and regulation of total system flow

(a) branch Dampers BA, BB & BC are to be regulated. The method is same as for balancing
for Sub-branches;

(b) determine the Branch with the lowest measurement to design flow ratio. This Branch is
to be used as the Index Branch (IB) during balancing. Assuming BC has the lowest
measurement to design ratio, it is taken as the IB;

(c) carry out similar exercise as described in (g) in section 4.3 above, and take note of the
pre-cautions and remarks in (h) to (o).

4.5 Regulation of total system flow

(a) after completing air balancing of all Branches, it is time to regulate the total system flow;

(b) measure the total airflow in the main duct. Where it is not practical to do so, Branch flow
rates can be added together to establish the total flow;

(c) wherever practical, filters if any in the system should be cleaned;

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(d) compare the measured figure with the corresponding design value. Regulate the fan
output until the measured value is within the tolerance of the total flow;

(e) where the system contains automatically operated dampers for varying proportions of
fresh/exhaust/recirculation or face and by-pass dampers, measurement of the total air flow
and regulations of the fan output should be conducted with these dampers in the full fresh
air, full exhaust or full face positions, in accordance to the different design modes of
operation. Measurement of flow with damper positions at the other design extremes
should be taken. These measured results should be compared to corresponding design
values;

(f) wherever a system is directly connected with another system, e.g. supply connected with
an extract via a recirculation duct with fixed or variable mixing dampers, first
proportionally balance the duct run of both systems independently. Then regulate the total
airflow in both systems with the dampers set as described in (e). Care should be exercised
to mark or register on the damper linkage mechanism the established settings;

(g) take measurements and record readings of all Terminals, Sub-branches, Branches and
system after air balancing. Use the same set of measuring devices preferably and complete
the work in a continuous manner;

(h) finally, set the adjustable louvers, diffuser and cones to desired positions.

4.6 Tolerances in measurement

the Table V5 provides the recommended tolerance limits of measured airflow:

Performance
System type Terminal Branch Total air flow
effect
Mechanical ventilation, Low +20% of design +10% of design +10% of design
Comfort cooling value value value
Process air conditioning, Medium +15% of design +8% of design +10% design
Escape route value value value
pressurisation
Close control air High +10% of design +5% of design +5% of design
conditioning value value value
Notes:
Where the supply flow tends towards a tolerance limit, the associated extract flow should be regulated
towards the same limit.
Tolerances shown for Terminal are those accumulated during Terminal and Sub-branch regulation.

Table V5 - Recommended Tolerances Limits of Measured Airflow

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