Method Statement – HVAC Duct Leakage Testing Procedure

CONTENTS

01. SCOPE
02. PURPOSE
03. DEFINITION & ABBREVIATIONS
04. REFERENCE DOCUMENTS
05. RESPONSIBILITIES
06. FABRICATION
07. INSTALLATION PROCEDURE
08. RESOURCES
09. HSE REQUIREMENTS ENVIRONMENT PROTECTION

1. SCOPE:
 This method statement is applicable to work related to duct air leakage inspection
and rectifying process.

2. PURPOSE:
 To see the true condition of the existing HVAC system and ensure that the
performance of the HVAC system is as designed.
 To ensure that all quality assurance / control activities are conducted in a systematic
manner, works are inspected, and conformance is verified and documented.

3. DEFINITIONS AND ABBREVIATIONS

COMPANY Al Reem Hospico
QCP Quality Control procedure
IFC/AFC Issued for Construction/Approved for Construction
RFI Request for Inspection
TRA Task Risk Assessment

4. REFERENCE DOCUMENTS
• Mechanical Specifications, Volume No.2-C, Project: Renovations and Upgrade of
HVAC System at Sheikh Khalifa General Hospital, UAQ.
• Internal Test and Balancing Report
• Certificate of Calibration Air Measuring Equipment
• Equipment Data Sheet
• ASHRAE Standard 111

5. RESPONSIBILITIES:
• Project Manager (MEP) shall be responsible for overall construction activities
inclusive of ensuring that all safety measures are implemented, and permits are
obtained from the relevant authorities connected with scope of work
• Construction Manager (MEP) shall be responsible for co-ordination with site
engineer are responsible for ensuring adequate manpower, materials and
equipment are available to carryout the works as planned, avoid delays and ensure
that all works are carried out in accordance with project specified requirements.
• QA/QC on site will be ensuring that work is done as per project Specification and
approved drawings and all safety measures are implemented.
 Method Statement – HVAC Duct Leakage Testing Procedure

• Site Engineer will be responsible for performing air measurement and air balancing
procedure.
• The implementation of the procedures mentioned in the Method Statement will be
done by concerned site engineer/site supervisor.

7. AIR LEAKAGE INSPECTION & RECTIFYING PROCESS:

7.1 PRELIMINARY CHECK-UP

a. Site Preparation
 All system must work properly (FAHU, AHU, FCU, Fans…)
 Adequate access for inspection provided
 A report on the calibration of the measuring instrument has been provided

b. Duct Connectors Inspection (on AHU, FCU, Indoor VFR unit…)

 Check the condition of each connector; damage, tearing, leakage from the side,
etc.
 Check that the duct connector is properly attached to the unit or duct.
 Replace a damaged connector or fasten a loose one

c. Flexible Duct Inspection

 Check the condition of each flexible duct; damage, tearing, leakage from the side,
etc.
 Check that the flexible duct is properly attached to the plenum box or duct.
 Replace a damaged flexible duct or fasten a loose one

d. Plenum Box Inspection

 Check the condition of each plenum box; damage, leakage from the side, etc.
 Check that the plenum box is properly attached to the diffuser.
 Check that the plenum box is sealed properly.
 Repair the damaged plenum box or seal it properly

e. GI Duct Inspection
 Check the condition of each GI duct; damage, forgotten holes (from earlier
sensors or equipment), loose flanges and noticeable air leaks.
 Close all unnecessary holes, tighten properly flanges.

f. GI Duct Inspection
 Check the condition of each GI duct; damage, forgotten holes (from earlier
sensors or equipment), loose flanges and noticeable air leaks.
 Close all unnecessary holes, tighten properly flanges.

7.2 CHECKING OF AIR SUPPLIED FROM UNIT AND DELIVERD IN EACH RELATED AIR
TERMINAL

a. Main duct air flow checking

 Follow procedure from Method Statement – Air Measurement and Air Balancing
 Method Statement – HVAC Duct Leakage Testing Procedure

b. Air terminals air flow checking

 Follow procedure from Method Statement – Air Measurement and Air Balancing

c. Comparison supply/delivery
 If the difference between supply and delivery air does not exceed 5%, the system
operates with permissible air leakage
 In the case of a difference greater than 5%, select one branch of the system and
verify that the airflow on that branch and the associated air terminal match
according to the previous criteria. In case the air flow is correct (matching the
criteria), select another branch and locate the branch with the problem.
 Physically check each duct flange, if necessary, cut the insulation in that area and
find the leak. after fixing the problem, repair the insulation.
 In case the problem cannot be located, the duct in the riser or an extremely
congested area, use another method of sealing the duct with chemicals (it is not
part of this submittal)

8.2. MANPOWER:
The services of the following workforce category are provided:
 Supervisor
 Job performer

9. HSE REQUIREMENTS:

9.1 SAFETY
 All the new members of the team shall undergo a safety induction course in order to
be aware of the work.
 All lifting tools/tackles and equipment shall have third party valid certification before
use.
 All lifting equipment shall be color coded.
 Safety officer should be available at site all the time of work.
 Workmen shall have all relevant safety helmet, shoe and coverall as necessary for
the job and others necessary PPE'S.
 Signage to be provided at site related to site & hazards conditions.
 First aid kit shall be available at site.
 A toolbox meeting shall be conducted by job performer to brief all concerned about
Dos & Don'ts. Special coverage of salient points related to the job undertaken and
risk involved, including course of action in case of emergency, shall be ensured
during the session.
 Rest area shall be provided.
 Sufficient Drinking water to be available for the workforce at all time.
 Approved emergency procedure to available at site all the time.
 Mobile scaffold towers should be used for installation of cable tray works and
erected on firm, level ground, by trained competent
 Working platforms should be fully boarded and at least 600mm wide.
 Access points such as trapdoors should be kept shut while workers are on the
working platform.
 Method Statement – HVAC Duct Leakage Testing Procedure

9.2 ENVIRONMENT PROTECTION:

 Good housekeeping shall be maintained on workplace especially at the end of each
day's work.
 Method Statement – HVAC Duct Leakage Testing Procedure

Leak Testing Method

Select a section of duct to be tested.
Select a test pressure (never in excess of the construction pressure class). Ideally the operation
pressure.
Calculate the allowable leakage using leakage factors for the duct surface area.
 Method Statement – HVAC Duct Leakage Testing Procedure

Select Leak Tasting Machine (blower and orifice) suitable for the test air flow requirements (may
need to divide the test section into subsections).
Provide temporary seals at all openings by providing fabricated GI end cap for each opening within
the duct section under air leakage test, and seal it firmly to avoid any air leakage from these
temporary connections.
If the duct opening has a flange than fix the end cap with matching flange with bolts and Drive cleat,
Clip or Clamp and seal it by Gasket and approved sealant material.

Otherwise it we be connected by lapping the GI end cap to the duct opening edge using a Gasket
between and fastening by screws or rivets than to be sealed by approved sealant material as shown
below:
 Method Statement – HVAC Duct Leakage Testing Procedure

Connect Leak Tasting Machine to the duct section as per manufacture recommendation.
Start blower at low air velocity capacity & increase till test pressure is reached.
Adjust the instrument until the designed pressure is obtained (the pressure at which to test the
ductwork will be determined by the designer and the installation contractor. The maximum
permitted leakage rates are given in DW-143.
Check the measured leakage is within the permitted range or not.
If the leakage is not in the limit, check the ductwork and mark all points on the Duct where the air is
coming out.
Sealant will be applied to the leakage joints and perform another test to maintain the leakage within
the permitted limit.
Maintain the test for 15 minutes and check that the leakage rate has not increased.
Record all the details on the test sheet and compare with the allowable leakage.
Once a satisfactory duct leak test has been completed arrangements will be made following the
request for inspection procedure of the project.