Sop Hvac 01 Central Chilled Water System

SOP-HVAC-01
CENTRAL CHILLED WATER SYSTEM

INSTALLATION
Rev: 2 Date: 01-05-2016 PAGE 1 OF 18
Contents
I................................................................................................Warning / Safety Requirements

2
a)........Fan Coil Unit / Air Handling Unit / Chiller Unit / Chilled Water Pump / Ventilation Fan
2
b).......................................................................................Chilled Water Piping / Duct Work
2
II........................................................................................................................ Pre-Installation
3
a).......Fan Coil Unit / Air Handling Unit / Chiller Unit / Chilled Water Pump / Ventilation Fan
3
b).......................................................................................Chilled Water Piping / Duct Work
3
III.................................................................................................................................. Rigging
............................................................................................................................................... 3
a).......Fan Coil Unit / Air Handling Unit / Chiller Unit / Chilled Water Pump / Ventilation Fan
3
IV............................................................................................................................. Installation
4
a)........................................................................................Fan Coil Unit / Air Handling Unit
4
b)......................................................................................................................... Chiller Unit
4
c)........................................................................................................... Chilled Water Pump
5
d)....................................................................................................Chilled Water Pipe Work
6
e).......................................................................................................................... Duct Work
7
f).................................................................................................................... Ventilation Fan
7
V................................................................................................................. Pre-Commissioning
7
7
b)......................................................................................................................... Chiller Unit
8
9
d)....................................................................................................Chilled Water Pipe Work
9
HVAC Engineer QHSE Coordinator Operations Director

Prepared by: Reviewed by: Approved by:
SOP-HVAC-01

INSTALLATION
Rev: 2 Date: 01-05-2016 PAGE 2 OF 18
e).......................................................................................................................... Duct Work

10
f).................................................................................................................... Ventilation Fan
10
VI..................................................................................................................... Commissioning
............................................................................................................................................. 11
11
b)......................................................................................................................... Chiller Unit
11
12
d)................................................................................................................... Ventilation Fan
13
VII..............................................................................................Maintenance Recommended
13
13
b)......................................................................................................................... Chiller Unit
14
c)............................................................................................................ Chilled water Pump
14
d)................................................................................................................... Ventilation Fan
15
VIII....................................................................................Tools & Equipment Requirements
........................................................................................................................................... 15
a)...................................................................Fan Coil Unit / Air Handling Unit / Chiller Unit
........................................................................................................................................ 15
b)...........................................................................................................Chilled Water Pump
15
c)........................................................................................................... Chilled Water Piping
16
d).......................................................................................................................... Duct Work
16
e)................................................................................................................... Ventilation Fan
16
I.

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INSTALLATION
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II. Warning / Safety Requirements
a) Fan Coil Unit / Air Handling Unit / Chiller Unit / Chilled Water Pump / Ventilation
Fan
 During pre-installation: Use PPE

 During rigging:
 Obtain ‘permit to work’.
 Use PPE
 During installation:
 Switch off the main power before installing the unit.
 Lock out and tag with a suitable warning.
 Use PPE
 Do not vent refrigerant to atmosphere (for Chiller).
 Ensure fire extinguishers and other fire control devices are readily available at
site.
 During pre-commissioning:
 Switch off the main power after the completion of pre-commissioning check.
 Lock out and tag with a suitable warning if the unit is switched off.
 Use PPE
 Do not vent refrigerant to atmosphere (for Chiller).
site.
 During commissioning:
 Use PPE.
 Do not vent refrigerant to atmosphere (for Chiller)
site.
 During maintenance:
 Switch off the main power before servicing.
 Lock out and tag with a suitable warning.
 Do not vent refrigerant to atmosphere (for Chiller)
 Use PPE.
site.
 Only a qualified technician should be allowed to carry out servicing the unit.
b) Chilled Water Piping / Duct Work

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INSTALLATION
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 During pre-installation:
 Use PPE
site.
 Use PPE
site.
 Display warning while conducting pressure test.
 Use PPE.
site.
III. Pre-Installation
Fan:
 Only a qualified technician should be allowed to carry out inspection.

 Upon receipt of the goods on site/store ensure that the components ordered
are supplied. Notify the supplier of any discrepancies.
 Check model number as well as the components of the items received against
packing list/ order.
 Examine for damage and file claim if any damage is found.
 Choose a dry storage site that is reasonably level and sturdy to prevent undue
stress and damage to the unit structure or components.
 Do not remove protective caps from duct and coil piping connections for Air
Handling Unit, cooler piping for chillers, water piping for pumps until ready to
connect piping.
 Cover entire unit with tarpaulin or heavy-duty plastic coverall. Secure cover
with adequate tie downs.
b) Chilled Water Piping / Duct Work
 Where necessary, prepare detailed layout for piping/ducting installation and

obtain customers approval.
 Refer drawings approved by the customer and identify pipe route.

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INSTALLATION
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 On survey of the pipe/duct routes, identify any changes to the drawing.

 Provide material or material specification to the customer for approval
(wherever applicable).
III Rigging
Fan:
 Only a qualified rigger should be allowed to carry out rigging.

 Check Unit weight prior to rigging.
 Use proper rigging and handling tools while rigging the unit.
 Rig the unit in accordance to manufacturer’s instruction.
 Use spreader bars to prevent damage to the unit casing.
 Keep the unit in the upright position during rigging.
 Avoid unnecessary jarring or rough handling.
 Do not lift unit by pipe connections or headers.
 Do not remove skids or protective covering until unit or section is ready for
final replacement.
IV Installation
a) Fan Coil Unit / Air Handling Unit:
 Only a qualified technician should be allowed to carry out installation.

 Where necessary, prepare detailed layout for unit installation and obtain
customers approval.
 Clean the place where the unit is to be installed.
 Install Unit (floor mounted) on a raised plinth in location. Provide vibration
isolators underneath the unit and bolt the unit frame with the foundation frame.
 Suspend unit (ceiling mounted) from the ceiling slab by using suitable fasteners.
Provide vibration isolators between the slab and unit.
 If the unit is supplied in sections, it is important that the base is perfectly flat and
horizontal so that each unit section matches accurately with the next section in line.
 If the unit is supplied in sections, follow manufacture instructions for joining.
 Use shims to align blower and motor if necessary (wherever applicable).
 Provide adequate clearance for unit service access.
 Install a trapped condense drain line at unit drain connection.
 Install wiring and necessary components in accordance with the
manufacturer recommendations and job requirements.
 Connect supply/return/ fresh air ducts with the unit. Provide flexible connector
between the unit and the ducts.

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INSTALLATION
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 Connect pipes with the unit (refer Chilled Water Piping procedure).
 Pressure test the evaporator and associated piping to 1.5 times of the design
pressure with water. Wherever necessary, provide plastic or polythene wrapping around
the motors and sensitive electrical controls while installing the unit (the same to be
removed after the completion of installation).
 Tag unit, pipes, cables, and ducts.
b) Chiller Unit

customers approval.
 Clean the area where the unit is to be installed.
 Wherever necessary, provide plastic or polythene wrapping around the motors
and sensitive electrical controls while installing the unit (the same to be removed
after the completion of installation).
 Prepare foundation to properly support unit weight.
 Open drive unit: Use shims to align compressor and motor if necessary.
 Remove shipping spacers wherever applicable.
 Install unit on the foundation frame. Provide vibration dampers underneath the
unit to suit the operating weight as required.
 Use shims to align compressor and motor if necessary (open drive compressor).
 Locate unit in a well-ventilated area. If natural ventilation is inadequate, provide
forced ventilation.
 If the unit is supplied in loose, follow manufacture instructions for assembly.
 Provide adequate clearance for unit service access
 Provide sufficient clearance for condenser tube rodding and tube replacement
(water- cooled chiller).
 Provide sufficient clearance around the condenser coil for good air circulation (air-
cooled chiller).
 Install all necessary wiring and components in accordance with the
manufacturer instructions and job requirements.
 Install a trapped condense drain line at evaporator drain connection
(wherever applicable).
 Install chilled water piping. Install shuts off valves on the chilled water lines to isolate
the unit from the piping system during unit servicing.
 Install flexible connectors on the chilled water line and condenser line
connections to reduce vibration and noise level.
 Install condenser water piping for the water-cooled chiller. Install shuts off valves on
the condenser line (water-cooled chiller).
 Leak test the chiller evaporator and associated water piping to 1.5 times of the
design pressure with water.

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INSTALLATION
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 Leak test the condenser and associated water piping to 1.5 times of the design
pressure with water.
 Tag unit, pipes, and cables.
c) Chilled Water Pump

 Where necessary, prepare detailed layout for pump installation and obtain
customers approval.
 Clean the place where the pump is to be installed.
 Prepare foundation to properly support unit weight.
 Remove shipping spacers wherever applicable.
 Install unit on the foundation frame. Provide vibration dampers underneath the
unit to suit the operating weight as required.
 Use shims to align pump and motor if necessary.
 Install all necessary wiring and components in accordance with the
 Install a trapped condense drain line at pump drain connection (wherever applicable).
 Install water piping.
 Leak test the pump and associated water piping to 1.5 times of the design pressure
with water.
 Wherever necessary, provide plastic or polythene wrapping while installing the unit
(the same to be removed after the completion of installation).
 Tag unit, pipes, Cables.
d) Chilled Water Pipe Work
 Only qualified technicians should be allowed to carry out installation.

 Weld pipe support in steel.
 Prime supports with two coats of epoxy primer.
 Install pipe and pipe accessories with suitable fasteners as per the approved layout.
 Clean surfaces of the pipes and accessories to be braced/welded/flared.
 If the pipe material is copper, brace joints by using appropriate bracing rods. Use
flaring tool to connect threaded joints.
 If the pipe material is steel, weld joints by using appropriate welding rods.
 Electrical coil of modulating valve, bonnet of shut off valves should be removed to
avoid damage while heating the joint. Ensure the electrical power supply is
disconnected before removing the solenoid coil.
 Use pipe penetration for pipes passing through specified class approved location.
 Install air vents at the high points of the air system so that the air can be vented.

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INSTALLATION
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 Flush piping network with fresh water thoroughly to remove the foreign particles. The
equipments and the precious valves should be isolated from the system during flushing.
 Pressure test-piping network with fresh water to 1.5 times of the design pressure
and retain the test pressure in the system for 24 hours. Check joints for leakage with
soap bubble
 Check gauges for pressure drop after 24 hours.
 If any pressure loss, rectify leak and repeat the above procedure until successful.
 Fill pressure test forms for final approval by the customer.
 After conducting pressure test, the chilled water should be treated to minimize the
maintenance requirements and optimize the efficiency of the plant concerned. The
degree of water treatment depends on the impurities and hardness of the water to be
circulated in the system. Where water contains pH, alkalinity, hardness or other
contaminant values outside recommended standard limits, water treatment should be
applied to correct the undesirable water condition. Consult with a local expert for
water treatment.
 Insulate chilled water lines including valves and pumps with armaflex insulation or
equivalent and covered with 8 oz (minimum) woven glass fabric cloth /canvas cloth and
finally apply 2 coats of vapour barrier. In general, for armaflex material 19mm thick
insulation of high density is to be used, but 22mm thick insulation is recommended in the
hot areas like Engine room Liquid lines need not be insulated except in hot areas like
Engine room to minimize the heat conduction from the surrounding area. If the material
3
is rockwool/fiberglass, install 50 mm thick, 96 kg/m insulation.
 Install pipe cladding for the insulated lines with aluminum sheet /stainless steel
sheet where required.
 Marking/ tagging.
e) Duct Work
 Only qualified technicians should be allowed to carry out installation.

 Weld duct support in steel.
 Prime supports with two coats of epoxy primer.
 Install duct and accessories with suitable fasteners as per the approved layout.
 Use duct penetration for ducts passing through specified class approved location.
 Insulate duct (air-conditioning) internally with acoustic insulation as required.
 Insulate duct externally (wherever required) with fiberglass or equivalent and
covered with 8 oz (minimum) woven glass fabric cloth /canvas cloth and finally apply 2
coats of vapor barrier. In general, 25 mm thick and 24 kg/m3insulation is to be used,
but 50mm thick and 48kg/m3 insulation is recommended in the exposed areas.
 Install cladding for the insulated lines with aluminum sheet/ stainless steel
sheet wherever required.
 Marking/ tagging.

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INSTALLATION
Rev: 2 Date: 01-05-2016 PAGE 9 OF 18
f) Ventilation Fan

customers approval.
 Install the fan in the direction of airflow.
 Install fan (floor mounted) on a raised plinth in location. Provide vibration
isolators underneath the fan and bolt the fan frame with the foundation frame.
 Suspend unit (ceiling mounted) from the ceiling slab by using suitable fasteners.
Provide vibration isolators between the slab and fan.
 If the unit is supplied in sections, it is important that the base is perfectly flat and
horizontal so that each unit section matches accurately with the next section in line.
 If the unit is supplied in sections, follow manufacture instructions for joining.
 Use shims to align blower and motor if necessary (wherever applicable).
 Install a trapped condense drain line at unit drain connection (wherever applicable).
 Install wiring and necessary components in accordance with the
manufacturer recommendations and job requirements.
 Connect duct with the fan. Provide flexible connector between the fan and the
ducts. Wherever necessary, provide plastic or polythene wrapping around the motors
and sensitive electrical controls while installing the unit (the same to be removed
after the completion of installation).
 Tag fan, cables, and ducts.
V Pre-Commissioning

 Only a qualified technician should be allowed to pre-commission the unit.
 Ensure the unit has been properly installed.
 Ensure the interior of the unit is clean.
 Install filter in all filter section. Ensure that the filter media is correctly installed.
 Ensure the modulating valve is installed properly.
 Ensure the thermostat sensor is located properly.
 Remove fan and motor shipping clamps before starting the fan.
 Check that the fan, motor bearings and damper linkages are adequately lubricated.
 Hand-operate dampers and blower to check free movement.
 Check tightness of bearing setscrews or locking collars.
 Double-check the alignment and tension of the V-belts.
 Ensure the ducts have been installed in accordance with duct layout.
 Ensure the dampers are open.
 Ensure the ducts are supported properly to avoid transfer of duct weight across
flexible connections.

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INSTALLATION
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 Ensure the pipes have been installed in accordance with piping layout.
 Ensure the hand shut-off valves are open.
 Ensure the pipes are supported properly to avoid transfer of weight across the unit.
 Ensure the water filled is treated.
 Ensure the wiring is done properly.
 Ensure necessary components are installed in accordance with the
 Turn on main incomer power supply and ensure the controls are
functioning satisfactorily.
 Manually energize the evaporator blower contactors to check the fan rotation.
 Set thermostat in accordance with design.
b) Chiller Unit
 Only a qualified technician should be allowed to pre-commission the unit.
 Ensure the unit has been properly installed.
 Ensure the oil filter and suction felt sock filter of the compressor is installed correctly.
 Ensure the feeler bulb of the expansion valve is in good contact with suction pipe
and insulated to prevent erratic operation.
 Ensure relevant safety switches are available with the unit.
 Ensure the chilled water is treated.
 Ensure the water pipes are supported properly to avoid transfer of weight across
the unit.
 Ensure the strainer mesh fitted on the water lines is clean.
 Ensure the factory installed refrigerant pipes are supported properly to avoid
transfer of weight across the unit.
 Ensure all hand valves of water and refrigerant lines are in full open position.
 Top up freon.
 Open drive unit: Check tightness of bearing setscrews or locking collars. Double-
check the alignment and tension of the V-belts (belt driven unit). Ensure the coupling
alignment and the coupling guard is fitted properly.
 Ensure wiring is done properly.
 Ensure adequate lubrication oil in the compressor.
 Manually energize the condenser fan contactors to check the fan rotation (air-
cooled chiller).
 Manually energize the compressor contactors to check the motor rotation (open drive
compressor) and verify (wherever applicable) that the compressor oil pump is configured

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INSTALLATION
Rev: 2 Date: 01-05-2016 PAGE 11 OF 18
properly. (Compressor rotating direction should match the arrow indicated on the oil
pump side of the compressor body).
 Ensure adequate water flow through the evaporator.
 Ensure adequate water flow through the condenser (water-cooled chiller).
 Energize crankcase heater at least 24 hours before starting the unit.
Only a qualified technician should be allowed to carryout pre-commissioning.

Ensure the pump has been properly installed.
Ensure the interior of the pump is clean.
Remove shipping clamps before starting the pump, if any.
Check that the bearings are adequately lubricated.
Check tightness of bearing setscrews or locking collars. Double-check the alignment.
Ensure the coupling alignment and the coupling guard is fitted properly.
Ensure the wiring is done properly.
Ensure the pipes are supported properly to avoid transfer of weight across the pump.
Ensure the hand shut-off valves fitted on the piping are in full open position.
Ensure vibration eliminators are fitted on the water line connections.
Ensure the wiring is done properly.
Ensure necessary components are installed in accordance with the
manufacturer’s instructions and job requirements.
 Ensure the strainer fitted on the water line is clean.
 Ensure the pump is primed.
 Check voltage.
 Manually energize the pump motor contactors to check the pump rotation.
d) Chilled Water Pipe Work
 Only qualified technicians should be allowed to pre-commission the piping.

 Ensure the pipes are installed in accordance with the drawing and supported properly.
 Ensure the strainer mesh fitted on the water line is clean.
 Ensure flexible connectors are provided near the equipments.
 Ensure the modulating valve electrical connection is made.
 Ensure the hand shuts off valves are in open position.
 Ensure piping is flushed thoroughly and tested.
 Ensure the chilled water filled in the system is treated.
 Ensure the operation of automatic and manual valves.

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e) Duct Work
 Only qualified technicians should be allowed to pre-commission the ducting.

 Ensure the ducts are installed in accordance with the drawing and supported properly.
 Ensure flexible connectors are provided near the equipments.
 Ensure the damper electrical/ pneumatic connection is made.
 Ensure the hand shuts off dampers and electric/ pneumatic operated dampers
are in open position.
 Ensure the interiors of the ducts are clean.
 Ensure the joints are airtight.
 Ensure test holes are made as required.
f) Ventilation Fan
 Only a qualified technician should be allowed to pre-commission the fan.

 Ensure the fan has been properly installed.
 Ensure that the filter media is correctly installed (wherever applicable).
 Remove fan and motor shipping clamps before starting the fan, if any.
 Check that the fan, motor bearings and damper linkages are adequately lubricated.
 Hand-operate dampers and fan wheel to check free movement.
 Check tightness of bearing setscrews or locking collars.
 Check safety guard is installed.
 Double-check the alignment and tension of the V-belts (wherever applicable).
 Ensure the coupling guard is fitted properly (wherever applicable).
 Ensure the ducts have been installed in accordance with duct layout.
 Ensure the dampers are open.
 Ensure the ducts are supported properly to avoid transfer of duct weight across
flexible connections.
 Ensure the pipes have been installed in accordance with piping layout.
 Check voltage.
 Manually energize the fan motor contactors to check the fan rotation.

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VI Commissioning
 Only a qualified technician should be allowed to carry out commissioning.

 Turn on Unit power supply.
 Check voltage.
 Check fan speed.
 Check motor amps.
 Check airflow- supply/return/fresh.
 Set volume control dampers as per design.
 Set balancing valves (waterside) as per design.
 Check air temperature/humidity- supply/return/fresh
 Inspect visually the vibration level.
 Check air is expelled from the unit/system and the operation of the modulating
valve. Check water flow rate against the design. Check inlet and outlet water
pressure/ temperature.
 Monitor the operation of the unit at least 48 hours continuously and ensure the
unit is functioning satisfactorily.
Note:
The following should be checked after 24 hours of operation:
Belt tension
Filter sections
Foundation bolts.
Shaft bearing and drive setscrews
b) Chiller Unit

 Turn on unit power supply.
 Check voltage.
 Check compressor motor speed (wherever applicable).
 Check compressor motor amps.
 Check condenser water flow rate (water cooled chiller)
 Check condenser fan operation sequences (air-cooled chiller).
 Check condenser fan motor amps (air-cooled chiller).
 Check compressor oil level.
 Check sight glass to ensure no bubbles.
 Check expansion valve function and set in accordance with design requirements.
 Check refrigerant pressures.
 Check suction gas superheat

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 Check liquid subcool.

 Check chilled water temperature and pressure.
 Check the function of the water-regulating valve of the condenser (wherever
applicable).
 Water-cooled chiller: Check pressure and temperature of the inlet and outlet water.
 Air-cooled chiller: Check condenser entering and leaving air temperature.
 Set high and low pressure switches in accordance with design requirements.
 Check compressor capacity control function.
 Set compressor capacity control and other adjustable controllers, if any in
accordance with design requirements.
 Check oil, body and shaft seal temperature (wherever applicable).
 Set valves as required.
 Check the unit for any abnormal operation.
Note:
Remove the felt sock filter after the first 50 hours of operation.
Replace the filter cartridge after the first 100 hours of compressor operation.
Replace the lubrication oil after the first 50 hours of operation.
The following should be checked after 24 hours of operation:
Belt tension (belt drive unit)
Coupling (open drive compressor)
Foundation bolts.
Shaft bearing and drive setscrews.

 Turn pump power supply on.
 Check and ensure that the air is expelled.
 Check pump motor amps.
 Check pumps rpm.
 Check water pressure.
 Set balancing valves and globe valves as per design.
 Monitor the operation of the pump at least 48 hours continuously and ensure the
Note:
The following should be checked visually after 24 hours of operation:
Foundation bolts.

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d) Ventilation Fan

 Turn on Unit power supply.
 Check voltage.
 Check fan speed.
 Check motor amps.
 Check airflow.
 Set volume control dampers as per design.
Note:
The following should be checked after 24 hours of operation (wherever applicable):
Belt tension
Foundation bolts.
VII Maintenance Recommended
a) Fan Coil Unit / Air Handling Unit
 Check the cleanliness of the air filters every month and replace or clean as required.
 Examine the damper and linkages once in every year to ensure that it is
operating smoothly.
 Lubricate bearings every 3 months and ensure manufacturer
recommendation is followed.
 Check belts once in 3 months. When it is necessary to replace one belt in a given set
the entire set of belts must be replaced by a matched set.
 Inspect the coils for cleanliness every year. If necessary, hose the coils down with a
low- pressure water hose or low-pressure air.
 Clean the fan wheels and the drain pan annually.
 Inspect electrical contacts annually.
 Check efficiency of controls annually and calibrate, when required.
 Inspect overall condition of the unit for corrosion and operation annually.
and sensitive electrical controls while cleaning the unit.
b) Chiller Unit

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 Only a qualified technician should be allowed to carry out servicing the unit.
 Check compressor oil level. Top up oil as required and record the date and
quantity added (not applicable for hermetic compressor).
 Check oil pressure once a month.
 Check yearly for refrigerant filter clogging.
 Pump down the refrigerant before servicing compressor.
 Recover any residual refrigerant.
 After disassembly, clean all parts with solvent. Use mineral spirits, white
gasoline or naphtha.
 Before assembly, coat all parts with compressor oil and clean and inspect all
gasket surfaces. Replace all gaskets with new gaskets and lightly coat with oil.
Follow manufacturer torque values while tightening the bolts.
 After reassembly, evacuate compressor and open suction and discharge valves.
Restart compressor and adjust refrigerant charge.
 It is recommended to replace the gaskets whenever the condenser heads are
removed for tube inspection (water-cooled chiller).
 Clean condenser tubes and the water strainer periodically (water-cooled chiller).
The frequency of cleaning depends on the condenser water quality.
 Lubricate bearings every 3 months and ensure manufacturer’s
 Check belts once in 3 months. When it is necessary to replace one belt in a given
set, the entire set of belts must be replaced by a matched set (belt driven open type
compressor).
 Inspect the condenser coils for cleanliness every month. If necessary, hose down
the coils with a low-pressure water or low-pressure air (air-cooled chiller).
 Clean condenser fan annually (air-cooled chiller).
 Clean condenser tubes annually (water-cooled condenser).
 Check efficiency of controls and safety switches annually and calibrate, when required.
 Annually inspect expansion valve sensing bulb for cleanliness. Determine if the
sensing bulb is secured to the suction line tightly and insulated properly.
 Annually inspect the unit for corrosion and overall condition.
c) Chilled water Pump
 Only a qualified technician should be allowed to carry out servicing the pump.
 Close the hand valves installed on the piping. .
 Top-up grease every 3 months and ensure manufacturer recommendation is followed.
 Inspect electrical contactors annually.

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 Check efficiency of controls, safety switches annually and calibrates, when required.
 Inspect the unit for corrosion and operation annually.
d) Ventilation Fan
 Only a qualified technician should be allowed to carry out servicing the fan.
 Check the cleanliness of the air filters every month and replace or clean as required.
 Examine the damper and linkages once in every year to ensure that it is
operating smoothly.
 Lubricate bearings every 3 months and ensure manufacturer
 Check belts once in 3 months. When it is necessary to replace one belt in a given set
the entire set of belts must be replaced by a matched set (wherever applicable).
 Clean the fan wheels and the drain pan annually.
 Check efficiency of controls annually and calibrate, when required.
 Inspect overall condition of the unit for corrosion and operation annually.
and sensitive electrical controls while cleaning the fan.
VIII Tools & Equipment Requirements
a) Fan Coil Unit / Air Handling Unit / Chiller Unit
 During rigging:
Chain block, Jigs and fixtures.
Chain block, Jigs and fixtures, Bracing set, welding set, coil comb, dial gauge, and filler
gauge.
Clampmeter, megger, water flow meter, coil comb, and dial gauge.
Tachometer, Clampmeter, megger, temperature & humidity meter, and water flow meter.
Chain block, Jigs and fixtures, Bracing set, welding set, Tachometer, anemometer, pitot
tube, Clampmeter, megger, temperature& humidity meter, coil comb, Air compressor
with hose, water hose, pressure gauge, and filler gauge.
b) Chilled Water Pump

SOP-HVAC-01

INSTALLATION
Rev: 2 Date: 01-05-2016 PAGE 18 OF 18
Chain block, Jigs and fixtures, welding set, dial gauge, and filler gauge.
Tachometer, Clampmeter, megger, temperature meter, water flow meter, and dial
gauge.
Tachometer, Clampmeter, megger, and pressure gauge.
Chain block, Jigs and fixtures, welding set, Tachometer, Clampmeter, megger,
temperature meter, and pressure gauge.
c) Chilled Water Piping
Chain block, Jigs and fixtures, welding set, bracing set, spirit level, bending spring,
swaging tool, Flaring tool, Tube cutter, pressure gauge, scaffolding.
 During start up
procedure: Pressure
gauge.
d) Duct Work:
Chain block, Jigs and fixtures, welding set, spirit level, and folding.
e) Ventilation Fan
 During rigging:
Chain block, Jigs and fixtures.
Chain block, Jigs and fixtures, welding set, filler gauge, and dial gauge.
 During start up procedure:
Tachometer, Clampmeter, megger, dial gauge, and filler gauge.
 During commissioning procedure:
Tachometer, Clampmeter, megger, and dial gauge.
 During service instructions (DX and Chilled water):
Chain block, Jigs and fixtures, welding set, Tachometer, anemometer, Clampmeter,
megger, filler gauge, and dial gauge.


Sop Hvac 01 Central Chilled Water System

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SOP-HVAC-01

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 1 OF 18

I................................................................................................Warning / Safety Requirements

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 2 OF 18

e).......................................................................................................................... Duct Work

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 3 OF 18

II. Warning / Safety Requirements

 During pre-installation: Use PPE

b) Chilled Water Piping / Duct Work

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 4 OF 18

 Only a qualified technician should be allowed to carry out inspection.

b) Chilled Water Piping / Duct Work

 Where necessary, prepare detailed layout for piping/ducting installation and

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 5 OF 18

 On survey of the pipe/duct routes, identify any changes to the drawing.

 Only a qualified rigger should be allowed to carry out rigging.

a) Fan Coil Unit / Air Handling Unit:

 Only a qualified technician should be allowed to carry out installation.

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 6 OF 18

 Only a qualified technician should be allowed to carry out installation.

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 7 OF 18

c) Chilled Water Pump

 Only a qualified technician should be allowed to carry out installation.

d) Chilled Water Pipe Work

 Only qualified technicians should be allowed to carry out installation.

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 8 OF 18

 Only qualified technicians should be allowed to carry out installation.

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 9 OF 18

 Only a qualified technician should be allowed to carry out installation.

a) Fan Coil Unit / Air Handling Unit:

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 10 OF 18

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 11 OF 18

c) Chilled Water Pump

Only a qualified technician should be allowed to carryout pre-commissioning.

 Only qualified technicians should be allowed to pre-commission the piping.

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM

Rev: 2 Date: 01-05-2016 PAGE 12 OF 18

 Only qualified technicians should be allowed to pre-commission the ducting.

 Only a qualified technician should be allowed to pre-commission the fan.

HVAC Engineer QHSE Coordinator Operations Director

CENTRAL CHILLED WATER SYSTEM