Old Statement
Old Statement
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SECTION 1
1. GENERAL REQUIREMENTS
Prime Technologies as Independent Testing & Commissioning agency will perform the Testing,
Balancing and Adjusting of the HVAC System in compliance with the specified tolerance and
limitations outlined with CIBSE & BSRIA standards, guidelines and with reference to project
specification.
Before commencement of any test, Prime Technologies shall determine and schedule a list of
the commissioning information requirements which shall include the following :
2. The scope of works, system functions and interrelation with other sevices if any.
4. Set of as built drawings , design drawings and approved submittal of Materials &
Equipment
5. Design Criteria
11. All other details necessary to identify the performance of the installed HVAC
plant and equipments
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6 Terminal boxes electrical wiring for both power and control as per the
recommendation of the supplier.
7 Starter, overload relay ranges, motor sizes and speed controllers verified.
2. SAFETY PRECAUTIONS
Safety awareness should be followed during execution of Testing & Commissioning works :
1. Secure Work Permit in conjunction with the approved safety plan before
starting the work.
3. Usage of proper safety shoes, safety belts, safety helmets, gloves, goggles, mask,
ear plugs & any other safety accessories as required during commissioning works.
4. Guards of approved design shall be provided for all V-belts drives, coupling
shafts and exposed rotating machinery.
5. Electrical power supply shall be isolated and panel switch gear shall be locked
whenever carrying out work on any rotating equipment or electrical panels.
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7. Approved Project Safety Plan & Procedures shall be followed during execution
of commissioning works .
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SECTION 2
Preliminary Checks
The following checks shall be carried out in order to ensure that the system is in a satisfactory
and safe condition before starting up fans.
1. Air System
A. State of the Building and System
B. System Cleanliness
System shall be free from construction debris and dust. The following checks for cleanliness
shall be carried out :
3. Fan Internals
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7. Humidifiers
C. Check that the system is installed as per the design or approved drawings.
4. Turning Vanes, thermal insulation, acoustic linings, and sensing elements have been
fitted and are undamaged.
9. VAV Units are installed as per the approved drawings & as per manufacturer
recommendation.
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F. Fan Checks
The following should be checked :
5. Motor and pulleys are level and aligned and belt tension is correct.
6. Anti-vibration mountings and the removal of transit bolts and packing materials
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8. All power and control wiring is completed in detail to the circuit diagram
2. Motor, drive and fan are free from vibration or undue noise.
4. Motor running current and voltages on all phases are within the specified motor rating
and the readings are recorded.
5. No overheating of motors
7. No overheating of bearings
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Preliminary Checks
2. Chilled Water System
A.The following Preliminary checks shall be carried out to find out that the system is in a
satisfactory and safe conditions.
1. All plant items are installed in accordance with the design drawings, specifications and
the manufacturer’s instruction
7. Drain valves and air vents of appropriate sizes are connected and free from blockage
8. Connection to FCU, AHU, etc., are correct in relation to design water flow and direction
9. Control, regulating valves and nonreturn valve are installed as per design and direction
12. Adequate space is provided to access equipment and system componenet as required.
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18. All power and control wiring is complete as per approved drawing
25. Pressure gauges and thermometers are fixed as per approved drawings.
B. Before initial start up of the Chilled water pumps for Flushing purposes, the
following checks shall be carried out
5. Components are secure, impeller is free to rotate and flow direction is correct
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Note: Chilled water system flushing and cleaning shall be carried out as per the specialist
contractor’s procedures and recommendations (Please refer to separate Method Statement
Ref: ET/MS-M-011.
C. ELECTRICAL CHECKS:
Before the first operation of any electrical component or appliance the following
procedure should be adopted
4. Transit packing has been removed from contactors and other equipments
7. All power and control wiring has been completed in accordance with the circuit diagram
10. Starter overloads are set to the motor full load current.
1. The direction and speed of rotation of the motor shaft are correct.
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2. The motor, pump and drive are free from vibration and undue noise.
3. For star-delta starters, the starter sequence timing has been adjusted as necessary in the
4. The motor running current is balanced between phases and does not exceed the motor
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SECTION 3
METHOD STATEMENT
1. AIR BALANCING
1. Check that all automatic controls are fully commissioned and operating properly
4. Set all the dampers in the duct outlet at full open position
5. Take initial total flow of the unit by adding up all the measured volume from each outlets
(initial scan)
6. Compare the reading against the designed flow. Find out the percentage of the design
flow.
2. Measure the motor ampere & fan rpm of all fans and shall be set to provide total air volume
within acceptable tolerances
3. Fan speed & motor current shall not exceed the maximum allowable range set by the
manufacturer
4. Set all the main duct & branch duct dampers at full open position
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6. Check the flow in all branches and find out the index branch
7. Balance the branches in proportion with the same percentage of total flow by adjusting the
volume control dampers and keeping the index branch damper at fully open position.
8. Measure the index branch and proportionally balance it to the same percentage.
Find out the index terminal and keep the damper fully open
Balance the other outlets proportionally to the same percentage of flow set in the
branch duct.
Check the flow in each outlet and record including the index terminal
10. Take the total flow in the main duct again and record by using traverse duct method.
11. After Total System balance , the following values shall be measured and recorded:
Fan RPM
12. Static pressure entering and leaving the fan shall be measured as follows:
Static pressure readings leaving the fan shall be taken as far as from the fan as is
practical, but shall be before any restrictions in the duct (such as duct turns )
No readings shall be taken directly at the fan outlet or through the flexible
connection
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Static pressure entering the fan shall be measured in the inlet duct upstream of any
Static pressure entering a double inlet fan shall be measured through the wall of
In all cases, the reading shall be taken to represent as true a value as possible.
True value is actual measured static pressure .
2. Fan speed shall not exceed the maximum allowable rpm as established by
the fan manufacturer.
3. Set all the main duct & branch duct dampers and outlet dampers at full open position.
4. Check the total flow of the fan by duct traverse method, flow will be set to 105 % of design
flow
5. Check the flow in all branches and find out the index branch.
6. Balance the branches in proportion with the same percentage of total flow by adjusting the
volume control dampers and keeping the index branch dampers at fully open condition.
7. Measure the index branch and proportionally balance the air terminals.
8. The final setting of fan rpm shall not result in overloading the fan motor in any mode of
operation. Dampers shall be modulated, and the ampere of the supply fan motor shall be
measured to ensure that no motor overload can occur.
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Depending upon location and access to air terminals, various types of airflow measuring
instruments will be utilized to record the actual airflow at terminals.
Assuming adequate access provided, a direct reading balometer would be used which
gives a direct reading of volume rather than velocity, which cancels out the need for
effective grille areas, terminal configuration consideration and velocity corrections.
If access is restricted then a rotating vane anemometer shall be used and the velocity
reading obtained would be converted to volume (velocity x free area = volume) and a
comparison between the pitot traverse reading will be made to obtain a correction factor
which would be incorporated to give a true velocity reading . Alternatively, the effective
area provided by the register / grille manufacturer will be incorporated in the design
velocity calculations.
1. Air quantities shall be measured according to CIBSE Application Guide 3/89 Standards.
2. Any main branch may be chosen to start with but as normal practice and having carried
out a rough balance of main and sub-branches, start with the most remote branch and then
sub-branch.
3. Locate the terminal which is discharging the lowest percentage of its design flow
rate. This is generally the last terminal in the run. if not, adjust the damper in the last
terminal unit until it is working with the same percentage as the lowest one previously
measured.
4. Measure the flow from the terminal next to the index and work out the percentage flow as
close as possible to that of the index. Fix the damper in position.
5. Repeat the procedure for the next terminal, again comparing it with the index.
6. As the dampers are closed along the run, more air will be driven towards the downstream
terminals and the volume of air discharged at the terminal index will rise. This does not
affect the balancing procedure since each terminal being adjusted is related in turn with
the index.
7. When all the terminals have been balanced on a sub-branch, each terminal will be
running with an equal percentage of the design flow rate, within the allowable tolerances.
8. The flow rates at each terminals must be measured and recorded. Once again a
summation should be made to check that the total is in reasonable agreement with the
measured sub-branch flow.
9. Test results shall be recorded in the approved test sheets and documents.
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2. Set the all dampers in the duct outlet at full open position.
3. Take the initial flow of fan by adding up all the measured volume from each
outlet (Initial scan)
4. Compare the readings against the design volume, find the percentage of design
flow rate.
5. Find the index outlet (least favored circuit) from the scan.
7. Then throttle the air volume at each outlet to get the design percentage of flow
proportionally by any anemometer with effective area.
8. Each time when you throttle the outlet by closing the damper, the index outlet
the air flow rises gradually, measure the index point of each time.
2. Measure the motor ampere & fan rpm of all fans and shall be set to provide total air
volume within acceptable tolerances
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3. Fan speed & motor current shall not exceed the maximum allowable range set by the
manufacturer
5. Find the performance of the fan with manufacture specification and record the readings.
2. Measure the motor ampere & fan rpm of all fans and shall be set to provide total air
volume within acceptable tolerances
3. Fan speed & motor current shall not exceed the maximum allowable range set by the
manufacturer
4. Measure the velocity from discharge of the fan with the use of anemometer or velgrid.
5. Find the performance of the fan with manufacture specification and record the readings.
E. WITNESSING
After satisfactory completion of Testing, Adjusting and Balancing of the Air-
Conditioning & Ventilation system, Prime Technologies will demonstrate random
sample test results to the Consultants/Clients, provided the witnessing takes place within
a reasonable period of time after completion of testing, adjusting and balancing.
The aim of balancing is to apply a disciplined procedure of adjustment to water flow rates
throughout a system to meet the particular requirements of the design. The balancing of
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water flow rates should be carried out to specified tolerances (which may vary for
different sections of the same system).
A. SECONDARY PUMPS
1 Connect a suitable differential pressure gauge across the suction and discharge
pressure test points of the pumps.
2 Set all the supply, return valves and control valves in the system at full open
position (Cooling coil valve fully open to cooling coil, chilled water flow through
the AHU etc.).
3 With the pump on running condition, slowly close the discharge valve for a period
of less than 1 minute. Effort should be made to obtain the readings as rapidly as
possible in order to minimize the time that the pump is shut off.
4. Determine the shut-off pressure differential, check against the manufacturer data
to zero flow then slowly re-open the discharge valve.
5. Where the test results coincides with the manufacturers test data proceed
to next paragraph. Where this is not the case, draw a curve parallel to that shown
on the published data, starting at the shut-off head pressure.
6. Record the total pressure with the differential pressure gauge at full flow
rate and read the actual flow from the manufacturers data, or from the corrected
graph curve as appropriate.
With all valves are fully open, measure and record the total actual flow rate and compare
this with the total system design flow rate. Where necessary, close the main regulating
valve to provide a flow of approximately 110 % design flow rate.
1. Keep all the DRV’s & isolating valves at fully open position.
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7. Throttle the other risers proportionally to the same percentage of total flow
measured.
8. Monitor the index percentage after throttling each riser as it increases gradually.
9. By the time the last riser is complete, the flow is balanced at all risers including
the index riser.
The same method (proportional balancing) can be followed for branches & sub-branches
of the Fan Coil Units and Air Handling Units located at the various floors.
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Our Commissioning Team generally follows the following Standards and Methods for Testing
& Commissioning Activities but it follows strictly to the specified standards in particular
projects.
******
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The following are the list of instruments, which are used in testing & commissioning of HVAC
system.
1. AIRFLOW MEASUREMENT.
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SL. NAME MODEL MAKE FUNCTION OF THE QTY.
NO. INSTRUMENT
To measure the direct air 8 Nos.
volume at the grilles,
7 Flow Hood Kit 8405 Airflow diffusers and other outlets
when use with air data
multimeters
2. HYDRONIC MEASUREMENT.
SL. NAME MODEL MAKE FUNCTION OF THE Qty.
NO. INSTRUMENT
To measure the differential 6 Nos.
U-Tube PK 30 Mercury
1 Perflow pressure across DRVs,
Manometer Filled
Orifices, Heat Exchange Coils
To measure the differential 6 Nos.
U-Tube PK 30 Fluid
2 Perflow pressure across DRVs,
Manometer Filled
Orifices, Heat Exchange Coils
Advanced commissioning unit 1 No.
PSW – 2000 Crane – Per
3 Digital Meter to measure the differential
ACS Flow
pressure
3. TEMPERATURE MEASUREMENT.
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5. ELECTRICAL MEASUREMENT
6. CALIBRATION FREQUENCY
i. All the instruments are calibrated externally once in 12 months or as per the
recommendation of the Manufacturer whichever comes earlier and the records are
maintained.
ii. All are used under their allowable ranges and limits.
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iii. All equipments are stored in the service station under the suitable environmental
condition when they are not in use and verified their accuracy at regular intervals.
******
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P.O. BOX 26736, DUBAI, U.A.E. , Tel. No. 04-2695692, Fax No. 04- 2696793, E-mail : [email protected]
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The following are the list of instruments, which are used in testing & commissioning of HVAC
system.
1. AIRFLOW MEASUREMENT.
3. TEMPERATURE MEASUREMENT.
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4. OTHER INSTRUMENTS.
6. CALIBRATION FREQUENCY
v. All the instruments are calibrated externally once in 12 months or as per the
recommendation of the Manufacturer whichever comes earlier and the records are
maintained.
vi. All are used under their allowable ranges and limits.
vii. All equipments are stored in the service station under the suitable environmental
condition when they are not in use and verified their accuracy at regular intervals.
******
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PREFACE :
System testing, adjusting and balancing is the process of checking and adjusting all
includes balancing air and water distribution systems, (2) adjusting the total system to
performance of all equipment (5) verifying automatic controls, and (6) sound
conformity to design, (2) measuring and establish the fluid quantities of the system, as
required to meet design specifications and (3) recording and reporting the results.
Prime Technologies – Testing & Commissioning Division will serve you in effective and
efficient testing, adjusting and balancing with systematic, thoroughly planned procedure
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P.O. BOX 26736, DUBAI, U.A.E. , Tel. No. 04-2695692, Fax No. 04- 2696793, E-mail : [email protected]