TEKTON TCX Test Forms

TEKTON STRONG BUILDERS
CORP.
TE CONNECTIVITY
MANUFACTURING PHILIPPINES
INC.
TESTING AND COMMISSIONING

REPORT
Project: TE CONNECTIVITY MANUFACTURING PHILIPPINES INC.

General Contractor: AQUAGEN TECHNOLOGIES INC.
Commissioning Team: TEKTON STRONG BUILDERS CORP.
Tab Supervisor:
Approved By:
Date
PRELIMINARY CHECKS
FOR AIR HANDLING SYSTEM
System Cleanliness
Check
Check List Mark Remarks
Check the following for cleanliness:
1 Air intake filter
2 Fan & other equipment chamber
3 Floor drains & drainage traps
5 Cooler batteries
6 Cooling coil trays
7 Dampers
8 Ducting
10 Machine room
TESTED BY: WITNESSED BY: DATE:

PRELIMINARY CHECKS
Initial Start of Fans

And
Air Handling Units
Check
Check List Remarks
Mark
On activating the motor starter check
1 Direction of rotation of motor shaft

2 Motor, drive and fan free from
vibration or undue noise
3 Motor starting current for sequence

timing adjustment
4 Motor running current on all phases

5 That there is no sparking at commutator
or slip rings
6 That there is no over heating of motor

7 That there is no seepage of lubricant
from housing
8 That there is no over heating of

bearings

PRELIMINARY CHECKS
Air Regulation Devices
Check
Check List Remarks
Mark
Check that the following are fitted and
1 not damaged:
Tuning vanes
Straigntening vanes
Themal insulation
Sensing elements
check that cooler batteries are installed
2 correctly in relation to air flow
check that filters are correctly installed
3 in relation to air flow
4 check that test holes for measurement
of air flow are provided
5 check that test holes are provided with
plugs

Mechanical Checks
Check List Check Remarks

Mark
1 External cleanliness
2 All components, bolts, fixings are
secured
3 Impeller secured and free to rotate

4 Axial flow type fan installed for correct
air flow direction
5 Level and plumb of fan and motor shaft

and slide rails
6 Anti vibration mounting for correct

deflection
7 Static balance of unit

8 Correct drive fitted
12 Fresh & correct grade of lubricant

AIR HANDLING UNIT 1
SHEET 1 0F 2
REF. NO.: TONNAGE:
LOCATION: POWER:
DATE:
Check List Check Measured Testing Remarks

Mark Value Procedure Check (Compare
Mark with design
values)
Check body for physical damage
Check thickness of panels
Free floating vibration isolators
Belt guard with tachometer opening
Thermal & acoustical lining
Centrifugal fan
Prelubricated ball bearings
Coil air vent
Coil drain plug
Coil face area
Drain pan
Drain connections with seal trap
Drain valve with hose and adapter
F/A and return damper
1" cleanable filter & bag filters
Filter access doors
Check vibration and noise
Check proper motor rotation
Check belt tightness
Measure motor rpm
Measure fan rpm
Measure total air quantity
Measure total air velocity
Measure fresh air quantity
Measure return air quantity

AIR HANDLING UNIT 2
SHEET 1 0F 2
REF. NO.: TONNAGE:
LOCATION: POWER:
DATE:
Check List Check Mark Measured Value Testing Remarks

Procedure Check (Compare with
Mark design values)
Centrifugal fan
Coil air vent
Coil drain plug
Coil face area
Drain pan
Filter access doors
Measure motor rpm
Measure fan rpm

SHEET 2 OF 2
REF. NO.: TONNAGE:
LOCATION: POWER:
DATE:
Measure filter face velocity
Measure motor current (each phase)
Measure motor voltage
Check leaks and starter
Check internal lights
Check duct flexible connectors
Measure static pressure
Measure coil face velocity
Outside air dry & wet bulb temp.
Return air dry & wet bulb temp.
Mixed air dry and wet bulb
supply air dry & wet bulb temp.
Measure water flow rate
Measure water pressure drop
Measure water temp. in
Measure water temp. out
Outside air damper position

AIR HANDLING UNIT 3
SHEET 1 0F 2
REF. NO.: TONNAGE
:
LOCATION: POWER:
DATE:

Mark Value Procedure Chec (Compar
k e with
Mark design
values)
Centrifugal fan
Coil air vent
Coil drain plug
Coil face area
Drain pan
Filter access doors
Measure motor rpm
Measure fan rpm

SHEET 2 OF 2
REF. NO.: TONNAGE:
LOCATION: POWER:
DATE:
Measure filter face velocity
Check leaks and starter
Check internal lights
Check duct flexible connectors
Measure static pressure
Outside air dry & wet bulb temp.
Return air dry & wet bulb temp.
Mixed air dry and wet bulb
supply air dry & wet bulb temp.
Measure water pressure drop
Measure water temp. in
Measure water temp. out
Outside air damper position

PRELIMINARY CHECKS
FOR CHILLED WATER SYSTEM
State of System
Check List Check Mark Remarks

Check:
1 That pressure tests have been completed
throughout
2 That the system has been flushed and cleaning
chemicals have been added
3 That permanent water connections have been
made
PRELIMINARY CHECKS
Check of System Before Filling
Check that:
1 Probes, pockets, pressure gauges, orifice plates
and air vents are installed
2 Drains and overflows are connected and free
from blockage
3 Connections to cooler batteries are correct in
relation to the design water flow directions
4 Control and non return valves are installed the
right way round
5 Relief valve outlets are piped away to suitable
drain points
6 Strainer mesh is of the correct grade and
material
7 Tanks are cleaned
8 Drain valves are closed and other valves left
open or closed according to the plant for filling
9 Pipe work and fittings are adequately supported

PRELIMINARY CHECKS
Mechanical Checks For Pumps

Mark
1 The external cleanliness of the pump
2 That the flow direction is correct
3 That all components, bolts, fixings are
secured
4 That the impeller is free to rotate
5 The level and plumb of pump and motor
shaft
6 The anti vibration mountings for correct
deflection
7 That the pipe work imposes no strain at
the pump connections
8 The securing and alignment of couplings
9 The bearing cleanliness
10 That the lubricant is fresh and of the
correct grade
11 That the drive guards are fitted
12 Pressure gauges are installed & are
functioning correctly.
13 All valves are installed according to plant
drawings

PRELIMINARY CHECKS
Mechanical Checks for Motorized Valves & Float Switches

Mark
2 That the valve spindles are free to move
3 For free movement
4 For freedom from excessive lost motion
5 The fit of pins
6 The rigidity of the mountings
7 For stiffness of the linkage
8 The tightness of locking device
9 The bearing lubrication
10 For accessibility for maintenance

PRELIMINARY CHECKS
Initial Start of Pump
Mark
1 That the direction and speed of
rotation of the motor shaft are
correct
2 That the motor, pump and drive are
free from vibration and undue noise
3 The motor starting correct for
sequence timing adjustment
4 The motor running current on all
phases to ensure that they are
balanced between phases
5 That there is no sparking at the
commutator or slip ring
6 That there is no overheating of the
motor
7 That there is no seepage of lubricant
from the housing
8 That there is no over heating of the
bearings
9 That the water flow to water cooled
bearings is sufficient

REFRIGERATING SYSTEM
PRELIMINARY CHECKS
System Cleanliness

Mark
1 External cleanliness
2 External condenser surface
3 Condenser fan chamber
4 Sensing elements
5 Compressor
6 Safety and control devices

PRELIMINARY CHECKS
Mechanical Checks

A. Compressor:
A.1 Compressor cleanliness
A.2 All components, bolts, fixings are secured
A.3 Level & plumb of compressor
A.4 Anti vibration mountings of correct deflection
A.5 Correct oil level in compressor
B. Condenser fan check:
B.1 External cleanliness
B.2 All components, bolts, fixings are secured
B.3 Securing and alignment of pulleys
B.4 Belt tension and match
B.5 Bearing cleanliness
B.6 Fresh and correct grade of lubricant
B.7 Static balance
C. Safety and control devices are fitted:
- Low pressure cut-out
C.1
C.2 - High pressure cut-out
C.4 - Chilled water low temp. thermostat
C.5 - Low water flow safety device
D. Liquid line strainer, isolating valves as specified,
sight glass and drier fitted
E. Thermostatic expansion valve fitted and thermal
bulb correctly fitted and secured
F. Suction, discharge and oil pressure gauges fitted
and isolated from the system
G. Purging and charging connections fitted

System Check Before Starting

1 Check that refrigerant pressure controls are set
in accordance with manufacturer's instructions
2 Check the setting of freeze protection
thermostat
3 Check that all sequence and safety interlocks
are operating correctly and that compressor
will be locked out if items essential to its
operation stop for any reason
4 Check condensing system to ensure design air
quantities at required temperature are available
5 Prior to commencing a continuous test run on
the refrigeration system
Check
5.1 All refrigerant circuit shut off valves in open
position
5.2 All chilled water valves in correct position
5.3 Compressor suction and discharge valves open
5.4 Oil, suction and discharge pressure gauge
throttling valves open
5.5 Lubricating oil visible in sight glass on
compressor sump
5.6 That electrical supply has been available to the
crank case heater and that the heater has been
operated
5.7 Reset buttons on refrigerant pressure controls,
oil pressure control and freeze protection
thermostat and/or freeze protection pressure
switch are depressed

PACKAGED CHILLER
Test Report
REF. NO.:
Check List Design Actual
Evaporator pressure / temp.
Evaporator entering / leaving water pressure
Evaporator entering / leaving water temp.
Evaporator flow rate
Condenser pressure / temp.
Condenser entering / leaving water pressure
Condenser entering / leaving water temp.
Condenser flow rate
Compressor suction pressure / temp.
Compressor discharge pressure / temp.
Voltage
Current (all phases)
KW input
Crank case heater amps.
CHW control setting
Condenser water control setting
Low pressure cutout setting
High pressure cutout setting

WATER CHILLERS

Mark Values Procedure
No.
Check vibration & noise
Check leaks
Compressor motor temperature cut-out
Check starter
Test high Cut-out Comp. 1, 2, 3, 4
pressure (psi) Cut-in Comp. 1, 2, 3, 4
Test low Cut-out Circuit 1, 2
pressure (psi) Cut-in Circuit. 1, 2
Test return water Comp. No. 1
temperature Comp. No. 2
control (deg. F)
Comp. No. 3
Comp. No. 4
Voltage at MDB (RY, YB, RB)
Voltage at Not operating
chillers
Disconnect Operating
switch
Main FLA (R, Y, B)
FLA circuit No. 1 (each phase)
FLA circuit No. 2 (each phase)
Part winding Comp. No. 1
FLA (R, Y, B) Comp. No. 2
Comp. No. 3
Comp. No. 4
Check FLA for each compressor (each
phase)

WATER CHILLERS
Check List Check Measured Value Testing Procedure Remarks

Mark No.
FLA – fan No. 1

motor (R, Y, B)
FLA – fan No. 2
motor (R, Y, B)
Chilled water
temp. in (deg. F)
Chilled water
temp. out (deg.
F)
Chilled water
pressure in (psi)
Chilled water
pressure out
(psi)

WATER COOLED CHILLER
REF. NO.: TYPE: TONNAGE:

LOCATION: POWER:

Mark Value Procedure Check
Mark
Compressor shut-off valves
Suction refrigerant pressure gauge
Discharge refrigerant pressure gauge
Low pressure cut-out
High pressure cut-out
Thermostatic expansion valve
Freeze protection low limit
thermostat
Thermometer for refrigerant gas
Dial pressure gauge for refrigerant
CHW inlet & outlet thermometers
CHW inlet & outlet pressure gauges
CHW inlet & outlet valves
CHW inlet & outlet plugged tee for
cleaning
Drain valve on the CHW return line
Thermostatic bulb
Solenoid valve on the liquid line
Flow switches
Differential pressure controller
Factory chiller insulation
Check leaks
Compressor motor temp. cut-out
Check bearings with stethoscope
Check starter
Test high pressure cut-out
Test low pressure cut-out

COOLING TOWER
REF. NO.:
LOCATION: CAPACITY:
Check List Check Test Values Remarks

Mark Measured Designed
Condenser water flow to
each cell
Entering water temp.
Leaving water temp.
Entering water pressure
Leaving water pressure
Entering air dry bulb
temp.
Entering air wet bulb
temp.
Leaving air dry bulb
temp.
Leaving air wet bulb
temp.
Condenser water flow rate
Cooling Tower pump
discharge pressure
Feed rate of make-up
water
No. of fans
Fan RPM (each fan)
Voltage
Current (Each phase at
each fan)

BOILER
REF. NO.:
LOCATION:
DESIGN OUTPUT
CAPACITY:

Mark Value Procedure Check
Mark
Check flame failure
Check photocell operation
Check spark
Check low water cut-off
Check prepurge timing (sec.)
Check timing (sec.)
Check flame
Check fuel oil pump pressure
(PSI)
Check flow switch interlock
Check temp. on boiler start
(deg. F)
Check temp. on boiler stop
(deg. F)
Measure stack temp. (deg. F)
Measure entering water temp.
Measure leaving water temp.
Measure operating pressure
Measure operating temp.
High Limit setting
High fire set point
Low fire set point
Voltage
Current (each phase)

HEAT EXCHANGER
Test Report
REF. NO.:
LOCATION: RATING:
Check List Design Measured Remarks

Value Value
Primary Water:
DELTA P
Leaving water temp.
DELTA T
Flow rate
Secondary Water:
DELTA P
Leaving water temp.
DELTA T
Flow rate

FAN COIL UNITS
REF. NO.: CAPACITY:

LOCATION: POWER:

Mark Value Procedure Check (Compare with
Mark design values)
Check supports
Check that FCU is level & plumb.
Decorative enclosure for vertical unit
Removable panel for access
1" thick fiberglass acoustical lining
Coper tubes & fins
No. of rows
Insulated drain pan with drain
connection & seal trap
Acoustical treated fan
Coil face area
Coil air vent and drain
CHW inlet and outlet valves
CHW inlet strainer
3 speed/off fan switch
Vibration isolators for motor
Thermal overload protection
Measure motor rpm
Measure fan rpm
Measure air quantity
Measure motor current at medium
speed
Check leaks
Check the purge air vent
Check fin spacings
Check pressure-test points
Measure CHW pressure drop
Measure space temp.
Measure outlet temp.
Measure system static pressure

PUMP TEST SHEET
REF. NO.: DESIGN VOLTAGE:

LOCATION: POWER:

Mark Value
Procedure Check
Mark
Check flexible connectors
Concrete isolator base
Pump and motor alignment
Pump secured to base with anchor bolts
Pump test report
Pump operating characteristics
Check packing and seal
Check bearings
Check pump shaft
Check valves and air vents
Check strainer
Check pressure gauges
Measure motor current all phases
Check leaks
Check starter
Check interlocks
Shut-off pressure priming
Measure suction pressure
Measure discharge pressure
DELTA P
Flow rate
Measure motor RPM
Measure pump RPM

CENTRIFUGAL FANS
Test Report
REF. NO.:
LOCATION:
Check List Design Actual
Make & size

R.P.M.
S.P. Total (in WG)
S.P. Suction (in WG)
S.P. Discharge (in WG)
Discharge C.F.M
Position of vortex damper
Sheave size & make
Sheave bore size
Sheave keyway size
Number of belts, make & size
Centers between pulleys
Motor frame & MFG
Motor H.P.
Motor voltage
Full load amps (for each phase)
Motor R.P.M.
Sheave size & make
Sheave bore size
Sheave keyway size
Base type
Belt guard
Vibration mounts

AIR COOLED DUCTED UNIT SPLIT
SHEET 1 OF 2
REF. NO.: TONNAGE:
LOCATION: POWER:

Mark Value
Procedure Check
Mark
Check fan guard
Compressor shut-off valves
Suction refrigerant pressure gauge
Discharge refrigerant pressure gauge
Low pressure cut-out
High pressure cut-out
Liquid line shut-off valves
Thermostatic expansion valve
Thermometer for refrigerant gas
Filter drier on the liquid line
Compressor motor temperature cut-out
Check leaks
Check starter
Measure high pressure cut-out
Measure low pressure cut-out
Measure entering air DB temp.
Measure leaving air DB temp.
Measure KW inputs
Measure crankcase heater amps.
Measure refrigerant suction pressure.
Measure refrigerant suction temp.
Needle valve on the refrigerant liquid
line.
Needle valve on the refrigerant suction
line
AIR COOLED DUCTED UNIT SPLIT
SHEET 2 OF 2
REF. NO.: TONNAGE:
LOCATION: POWER:
Evaporator:
Measure duct inlet / outlet S.P
Measure fan RPM
Measure F.A flow rate
Measure R.A flow rate
Measure total air flow rate
Measure outlet air velocity
No. of fins & spacing
Coil face area
Measure DELTA T across the coil
Drain fan

EXPANSION TANK
REF. NO.:
LOCATION:

Mark Value
Procedure Check
Mark
Gauge glass
Combination of pressure
regulator & relief valve
Pressure gauge
Check valve

COLD WATER PUMP SET
REF. NO.:
LOCATION:
Check List Check Design Measured Remarks

Mark
Cold water line pressure

tested
Low level cut out switch
installed
pump-motor alignment
Isolating springs
Tightness of electrical
connections
Free rotation of impeller
Pressure vessel properly
charged
Control wiring properly done
Voltage
Current (each phase)
Measure motor RPM
Cut-in pressure
Cut-out pressure
Auto change-over

BALANCING VALVE / FLOW METER
REF. NO.: SYSTEM:
LOCATION:
Designation Size Design Actual Actual Actual Remarks

Flow Valve Set Valve Flow
Rate Point P.D. Rate
(Degree)

WATER BALANCING
REF. NO.: SYSTEM:
LOCATION:
Location of Metering Type Metering Size of Metering Design Design Test Result
Station Station Station Flow ∆P
Initial Final
Valve
∆P Flow % Design ∆P Flow % Design
Position

OUTLET TEST REPORT
(CONSTANT VOLUME)
SYSTEM NO.:
AREA SERVED:
NO. SIZE FACTOR DESIGN DESIGN TEST TEST TEST ACTUAL ACTUAL REMARKS
C.F.M VEL. OR NO. 1 NO. 2 NO. 3 FINAL FINAL &
S.P. VEL. VEL. VEL. VEL. OR C.F.M % OF
OR S.P. OR S.P. OR S.P. S.P. DESIGN
TOTAL:
JOB NO.: JOB NAME:
DATE:
TESTED BY: ADDRESS:

VAV AIR OUTLET
Test Report
REF. NO. SYSTEM NO.:

LOCATION:
NO. SIZE MAXIMUM DESIGN MAXIMUM FINAL MINIMUM

Vel. Flow Rate Vel. Flow Rate Design Air Air Flow
Flow

AIR BALANCING TEST SHEET SYSTEM:
(MAIN PLANT)
LOCATION:
PROJECT DESIGN DUTY:
FAN MAKE: ITEM DESIGN TEST
TYPE/REF.:
MOTOR MAKE: FAN SPEED
TYPE/REF.:
MOTOR SPEED
HP/KW:
PULLEY DIA FAN: MOTOR FLC
MOTOR: (OVERLOAD
SETTING)
REF LOCATION DUCT DUCT DESIGN DESIGN MEASURED MEASURED %

SIZE AREA VOL. VEL. VEL VOL. DESIGN
1
TOTAL VOL.
STATIC PRESSURE:
BEFORE FAN:
FAN MEASURED DUTY
AFTER FAN:
TOTAL ACROSS FAN:

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TEKTON STRONG BUILDERS

TESTING AND COMMISSIONING

Project: TE CONNECTIVITY MANUFACTURING PHILIPPINES INC.

FOR AIR HANDLING SYSTEM

Check the following for cleanliness:

1 Air intake filter

2 Fan & other equipment chamber

3 Floor drains & drainage traps

6 Cooling coil trays

TESTED BY: WITNESSED BY: DATE:

Initial Start of Fans

1 Direction of rotation of motor shaft

3 Motor starting current for sequence

4 Motor running current on all phases

6 That there is no over heating of motor

8 That there is no over heating of

TESTED BY: WITNESSED BY: DATE:

Air Regulation Devices

TESTED BY: WITNESSED BY: DATE:

Check List Check Remarks

3 Impeller secured and free to rotate

5 Level and plumb of fan and motor shaft

6 Anti vibration mounting for correct

7 Static balance of unit

TESTED BY: WITNESSED BY: DATE:

Check List Check Measured Testing Remarks

TESTED BY: WITNESSED BY: DATE:

Check List Check Mark Measured Value Testing Remarks

TESTED BY: WITNESSED BY: DATE:

REF. NO.: TONNAGE:

Measure filter face velocity

Measure motor current (each phase)

Measure motor voltage

Check leaks and starter

Check internal lights

Check duct flexible connectors

Measure static pressure

Measure coil face velocity

Outside air dry & wet bulb temp.

Return air dry & wet bulb temp.

Mixed air dry and wet bulb

supply air dry & wet bulb temp.

Measure water flow rate

Measure water pressure drop

Measure water temp. in

Measure water temp. out

Outside air damper position

TESTED BY: WITNESSED BY: DATE:

Check List Check Measured Testing Remarks

Check thickness of panels

Free floating vibration isolators

Belt guard with tachometer opening

Thermal & acoustical lining

Prelubricated ball bearings

Coil air vent

Coil drain plug

Coil face area

Drain connections with seal trap

Drain valve with hose and adapter

F/A and return damper

1" cleanable filter & bag filters

Filter access doors