Construction QA/QC

Heating Ventilation and Air Conditioning

Rev. No. Rev. Date Description of Revision Revised by Approval

00 21/April/2016 New KIA

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therefore should not be reproduced stored in a retrieval system or transmitted by any means, electronic or
otherwise, or divulged without permission of E2C.

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 CONSTRUCTION QA/QC
HEATING VENTILATION AND AIR CONDITIONING DATE: April 21, 2016

TABLE OF CONTENTS

1. Scope ............................................................................................................................. 3
2. Applicable Standards ..................................................................................................... 3
3. Installation ........................................................................................................................... 3
3.1 General Requirements ............................................................................................... 3
3.2 Air Systems ............................................................................................................... 4
3.3 Refrigeration Systems ............................................................................................... 4
3.4 Hydrostatic Testing of Chilled Water and Cooling Water Piping ............................. 5
3.5 Pre-Start Up and Commissioning .............................................................................. 5
4. Request for Inspection ................................................................................................... 6
5. Air Handling Unit .......................................................................................................... 6
6. Air Cooled Condensing Unit: ........................................................................................ 6
7 Testing, Adjusting and Balancing ................................................................................. 7
7.1 General Requirements ............................................................................................... 7
7.2 Testing Organization ................................................................................................. 8
7.3 Test Procedures ......................................................................................................... 8
7.4 Test and Balance Report ............................................................................................ 8
7.5 Instrumentation .......................................................................................................... 8
7.6 General Notes ............................................................................................................ 9
8. Commissioning .............................................................................................................. 9
8.1 Setting to work........................................................................................................... 9
8.2 Regulation. ...................................................................................................................... 10
8.3 For water flow. .......................................................................................................... 10
8.4 Performance testing. .................................................................................................. 10
8.7 Instrumentation and access. ....................................................................................... 11
9. Handover Procedure ...................................................................................................... 12

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 CONSTRUCTION QA/QC
HEATING VENTILATION AND AIR CONDITIONING DATE: April 21, 2016

1. Scope
To describe working procedures, inspection and tests plan, and responsibilities associated with
field construction and installation of Heating, Ventilation and Air Conditioning.

2. Applicable Standards
The following list is, but is not limited to, the applicable Client Engineering Standard for
Heating, Ventilation and Air Conditioning:

Design of Buildings for Petrochemical Plants

HVAC System Design Criteria
Specification for HVAC Equipment
Specification for HVAC Installation
Pressure Testing and Lay-up Procedures
Measurement Units for Use in Client Projects

3. Installation
3.1 General Requirements
Any air handlers, refrigeration condenser units, pumps, or any equipment mounted outside,
shall be mounted on a concrete housekeeping pad, at a minimum of 100 mm (4") above the
floor or a minimum of 150 mm (6”) above unpaved ground.

Equipment shall be anchored as per Equipment Manufacturers written instructions.

Roof mounting of HVAC equipment, other than in penthouse equipment room is prohibited,
unless there is no practical alternative.

Access doors shall be provided to every valve, coil, filter, damper or mechanical device for
inspection and/or adjustment and be within reachable distance. Access doors for fire dampers
shall be positioned so that dampers can be reset and fusible links replaced, if necessary.

Equipment clearance shall be provided with a minimum of 1 m clearance on each side of

equipment with openable panel or controls, unless equipment manufacturer requires greater
clearances. Adequate space shall be provided for coil removal.

Inspection requirements of HVAC systems shall include the following:

a. No work shall be covered or otherwise concealed without approval by Client

inspection.
b. Any duct work, piping, or components so covered shall be uncovered for
inspection.
c. Pre-insulated pipes and ducts may be installed only with the prior approval of
Client inspection.
Any interference between ducts, piping and/or equipment, shall be resolved by Project
Engineering and Inspection. All necessary design corrections shall be made prior to
installation of HVAC system.

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Each equipment unit shall be installed at the location indicated on the drawings and in
accordance with details of mounting, with vibration isolation as required by the Design
Specifications.

All HVAC Equipment shall be properly grounded in accordance with NFPA 70, National
Electrical Code.

A raw water hose bib with vacuum breaker shall be provided within close proximity (not to
exceed 10 feet) of HVAC equipment that require periodic washing.

Exception:

Packaged rooftop units, especially manufactured for rooftop installation, may be used for
other than residential HVAC systems.

3.2 Air Systems

Air System equipment and duct work shall be installed according to the Construction
Drawings and Specifications, and Manufacturer's Installation Manual.

All air system supply and return grilles shall be furnished in accordance with drawings and
specifications, and mounted at locations shown on drawings.

Ducts shall be installed in accordance with Uniform Mechanical Code (UMC) H03-
CO1.

3.3 Refrigeration Systems

3.3.1 Field Tests

After installation, purge all refrigerant lines with dry nitrogen containing refrigerant gas
detectable with halogen-sensitive electronic leak detector.
Blow out all lines with dry nitrogen prior to testing and charging.
After installation, all field-erected refrigerant piping, regardless of the quantity of refrigerant
charge, shall be pressure-tested in accordance with the requirements of the
ASME B31.5,Chapter VI. The required test pressure shall be maintained for a minimum of 10
minutes. Testing and Balancing Procedures shall be performed on each system in accordance
with AABC national standards, NEBB procedural standards or SMACNA testing, adjusting
and balancing procedures.

Exemption:

Factory charged and sealed refrigerant tubing.

After installation, dehydrate system by placing a vacuum of 1.7 kPa (0.5 in. Hg) absolute
pressure. Hold vacuum for 24 hours or cycle vacuum and dry nitrogen purge according to
manufacturer’s recommendations. Charge system with quantity and type of refrigerant as per
manufacturers' requirements.

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Leak testing of existing HVAC refrigeration systems shall be performed as follows:

a. A mixture of a trace quantity of non-CFC refrigerant with dry nitrogen shall be

injected into the refrigeration system.
b. At 350 kPa (50 psig) all joints, seals, or connections shall be checked for leakage
by an approved method.

3.3.2 Condensers

Air cooled condenser unit shall be mounted level. Vertical air-cooled condensers shall be
provided with wind deflectors.

3.3.3 Evaporator Sections

Evaporators of air handling units shall be mounted a minimum of 150 mm (6 inch) off the
floor, to allow room for condensate trap.

3.3.4 Drain pan

a. A corrosion resistant drain pan shall be provided under each evaporator coil.
b. The evaporator drain pan shall have a trapped drain pipe, attached to the bottom or
to the side of the drain pan, flush with the bottom plate.
c. The drain pan shall slope towards the drain outlet.
d. The drain pipe trap shall have a water seal height equal to or larger than the fan's
External Static Pressure (ESP) but not less than 50 mm (7).
e. The drain pipe shall discharge to the nearest floor drain, in accordance with the
requirements of ASHRAE Equipment Handbook.
Exception:

HVAC units installed outside of buildings may discharge condensate onto the ground or roof,
but not onto walkways.

3.4 Hydrostatic Testing of Chilled Water and Cooling Water Piping

Chilled water and cooling water piping shall be subjected to a hydrostatic test at a minimum
test pressure of 1.5 times the design pressure, in accordance with the procedures described in
section 937.3 of ANSI B31.9; Building Services Piping.

3.5 Pre-Start Up and Commissioning

Commissioning shall comply with "Mechanical Completion and Performance Acceptance" of
each air conditioning system or component, as per Client Standards. This document covers
the acceptance and turning over of plants and equipment.

In addition, each HVAC system shall be inspected in accordance with the HVAC Inspection
Requirements’ prior to start-up.

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4. Request for Inspection

Request for inspection shall be issued to Contractor/ Client Project inspection 24 hour in
advance on week days and 48 hours in advance for week ends and holidays, for hold points.
RFI form shall be used.

5. Air Handling Unit

5.1 AHUs casings shall be manufactured, pre-painted backed enamel finish, double wall
construction. Casings panels should be fabricated with a minimum of G-90 galvanized steel.
Casing panels should be insulated with 50mm (2 inch) minimum thickness of fire, water
resistant material with a density of not less than 48 kg/M3 (3. 0 1 blft3). Insulation should be
secured with 100% coverage of waterproof of adhesive.

5.2 Outside air / return air mixing plenum should have opposed blade dampers for the
return and outside air streams.

5.3 Mixing plenum should include baffles or other provisions to insure complete mixing of
outside and return air streams at all flow rates.

5.4 Casings should include doors to provide maintenance and removal access for all fans,
motors, coils, filters.

5.5 Casing should completely enclose all AHU components.

5.6 Access doors or frames should have resilient gasketing material to prevent air leakage.
Access doors should have corrosion-resistant hinges and positive latches.

5.7 Fan should be V-belt driven with drive rated at 150% of fan rated power.

5.8 Fan should be air-foil, backward-inclined, backward curved or forward-curved and

should conform to AMCA 99 and AMCA 210 requirements.

5.9 The air velocity through coils should not exceed 3 mls (600 fpm).

5.10 Coil fins spacing of evaporator and condenser coils should not be closer than 15 fins
per inch.

5.11 Numbers of rows per coil should not exceed 10 rows.

5.12. Drain pans should extend completely under the coil sections and should have minimum
1-1/4inch threaded drain connections. Drains pans should be sealed, double wall steel
construction with rigid glass fiber insulation and type 316 stainless steel inner pan. Slope drain
pans toward drain connection, because drain pans should drain completely.
6. Air Cooled Condensing Unit:
6.1 Provide factory routine Test Certificates & Test Reports of ACCU.

6.2 Condensers should be mounted on spring-type vibration isolators.

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6.3 Compressor should be mounted on spring-type vibration isolators.

6.4 Refrigerant lines to and from compressors should have suitable flexible vibration
isolation elements. Hard piped loops or bends are not acceptable for vibration isolation.

6.5 Condenser fan motors should have a separate overload relay protection. This protection
should be in addition to other built-in compressor motor protection devices.

6.6 Condensing units should have complete with all operational equipment, including
solenoid valve, sight glass with cover, and cartridge type filter on liquid lines. It
should be mounted on a base frame.

7 Testing, Adjusting and Balancing

7.1 General Requirements
All building environmental systems and components shall be checked and adjusted to produce
the design objectives. It shall include:

a. the balance of air and water distribution

b. adjustment of total system to provide design quantities
c. electrical measurement
d. verification of performance of all equipment and automatic controls, and
e. sound and vibration measurement, when required.

The above tests shall be accomplished by:

a. checking installations for conformity to design
b. measurement and establishment of the fluid quantities
c. recording and reporting the results.

A complete system test report shall be provided on air and water movement systems, including
flow rates, temperatures, pressures as follows:

a. Record data on water side and air side of all air handling units, fans, coils, water
chillers, condensers, etc. Data shall include all water and airflow, motor, starter
heaters, manufacturer, nameplate data.
b. Balance air distribution system within + 10% of air quantities shown on project
drawings and record actual readings taken.
c. Provide construction drawings, reduced to 280 x 430 mm of every duct, air outlet,
air return measured. Identify each measurement point on this construction drawing
and on record data sheets.
d. Adjust all chilled water balance valves for quantities to within 5% of values shown
on project drawings and record actual readings.
e. Check operation of all controls to insure that all actuators cycle in accordance with
the designed action of the controlling device and the sequence of operation. Check
all control element for proper "normally open" or "normally closed" positions upon
loss of power or instrument air.
f. Provide test points and plugs or covers for all openings in duct.

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7.2 Testing Organization

The contractor shall provide the Test and Balancing Contractor.

The Testing and Balancing (TAB) work for HVAC installation shall be accomplished by a
Balancing Contractor who has:

a. an organization whose regular activities include testing, adjusting and balancing

environmental systems;
b. an organization which utilized only regular employees experienced and trained
specifically in the total balancing of environmental systems; and
c. an organization which has satisfactorily balanced at least five systems of
comparable type and size.
d. an organization which is approved by Client to perform TAB of HVAC systems.

7.3 Test Procedures

The Test and Balance Organization shall perform testing, adjustment and balancing of all
equipment and systems, and publish a Testing and Balancing report using the general
procedures for testing and balancing of:

a. ASHRAE STD 111 (latest edition), Practices for Measurement, Testing, Adjusting
and Balancing of Heating, Ventilation, Air Conditioning and Refrigeration Systems
b. ASHRAE Applications Handbook (latest edition), Chapter on 'Testing, Adjusting
and Balancing’
c. SMACNA (latest edition), "HVAC Systems - Testing, Adjusting and Balancing."
d. NEBB 'Testing, Adjusting and Balancing of Environmental Systems. The system
balance contractor shall verify installation of mechanical systems and equipment in
accordance with design and construction drawings.

7.4 Test and Balance Report

The report shall include the detailed information of either:

a. AABC National Standards for Field Measurement and Instrumentation, Total

System Balance", Volume 1; or
b. NEBB "Procedural Standards for Testing, Balancing and Adjusting of
Environmental Systems."
c. The TAB report shall be reviewed and approved by the concerned HVAC
maintenance / operation organization. After which, random points should be
selected by the concerned organizations for re-measurement to verify the accuracy
of the TAB report.

7.5 Instrumentation
Testing and balancing instruments shall be of types described in NEBB or AABC manuals.
Instruments shall be calibrated every six months. Calibration shall be in accordance with
NEBB and AABC procedures.

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7.6 General Notes

Contractor, shall submit Hydrostatic Test Packages prior to conducting hydrostatic tests of
piping, pipelines and equipment for Client review and approval. The hydrostatic test shall
comply with P01-El5 The hydrostatic test package shall include but not limited to the
followings:

 Hydrostatic Test Procedure.

 Hydrostatic Test Diagram which shall include the limits of piping (including test
manifold) and equipment included in each hydrostatic test, test pressures, test
temperature, test fluid, line flushing requirements, and safety precautions.

 Relief Valve datasheet and calibration records.

 Pressures gages and recorders calibration records.

 Client Safety Instruction Sheet and Pressure Test Report Form. Copies of P & ID and
isometric drawings of the piping system to be hydrostatically tested.

 Piping Spools control sheet with NDT extent and results.

 Inspection & Test Plan signed off.

 Pre-hydrostatic test Check List.

 Re-instatement procedure and Check List. Bolting and Gasket Control Sheet.

All pressure test shall be a "HOLD POINT inspection to Client

All start of work inspection shall be also considered "HOLD POINT to Client, Start of testing
/ Balancing / Adjusting by the TAB sub-contractor shall be notified to Client as "HOLD
POINT".

8. Commissioning
8.1 Setting to work
Normally, certain specialist items of plant, such as refrigeration units, control systems,
ventilated ceilings and certain types of humidifiers, will be set to work by commissioning
engineers from the particular manufacturers.

It is important that the plant is set up to obtain fluid flow rates and temperatures as specified
by the design and to this end all this information and full details of the intended operation of
the plant should be supplied to the commissioning engineer.
In applications where temperature and humidity are to be maintained within close limits, it
may be necessary to simulate the maximum heat loads to ensure plant performance but in any
case a load of at least 50% is required when commissioning the refrigeration plant.

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8.2 Regulation
System regulation is the final stage in a sequence that starts with the design itself. If the needs
of on-site regulation are not foreseen and provided for, it may never be possible to balance the
system within the accepted limits. It is essential that the flows of fluids through a system are
correctly regulated and balanced and conform to design parameters, otherwise, the system
cannot perform as intended and the desired internal environmental conditions will not be met.
It is customary to air balance the air outlets prior to closing of suspended ceiling. In such
events the previously recorded readings may be utilized for guidance or notes.

To carry out satisfactory regulation of a system, a schematic diagram, showing all mains,
branches, valves, etc. with the required flow, pressure drop and velocity appertaining to each
run of duct or pipe, is required covering all fluid flows in the system. Also, adequate means of
measuring flow or velocity should be provided.

For air flow in ducts, velocity measurements using a pitot tube with an adjustable manometer
provides the most reliable results. It needs no calibration and is consistent. In practice, the
lower velocity limit for readability on the manometer is approximately 4 m/s to 5 m/s

Recommendations on the number and positioning of measuring locations as well as details of

holes and spacing are given in BSRIA Application Guides 1/75 and 1/77. These also present
the range of instruments available with recommendations on the measuring techniques to be
used, and also describe the techniques of proportional balancing to ensure that the designed air
flows are obtained at each terminal point. The latter technique is also detailed in the CIBS
Commissioning Code series A.

8.3 For water flow

Regulation is achieved by measuring the pressure drop across a device with a constant flow
coefficient capacity index.

Balance is obtained by varying flow across the device so that the ratio of actual pressure
difference to design pressure difference is the same across all devices. The device may be a
venturi meter, orifice plate, or pressure-tapped valve used as a form of fixed orifice when fully
open.

All instruments need to be calibrated at intervals of not more than six months and each
instrument should carry a calibration record.

It is not possible to achieve a high degree of accuracy on balancing a system.

Once the system has been regulated, it is important that the setting of all balancing dampers,
valves, etc. is clearly marked and that they are locked in position.
8.4 Performance testing
Performance testing is the evaluation of the performance of a commissioned installation. If the
installation is to perform as required by the designer, test outlined below should be carried out
under actual operating conditions, usually after the building has settled down and been
occupied.

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It is necessary to distinguish between the two main types of tests associated with mechanical
and electrical services. One is to ascertain that the specified rated outputs of the various
systems are achieved and forms part of commission testing, the other is to ascertain whether
the installation will satisfy the design intentions and forms part of performance testing.

Since there is as yet no standard practice for performance testing, the following method and
tests are suggested:

Suggested analysis for assessment of the installation to provide adequate internal comfort
conditions.

8.4.1 Air patterns. Outlet grilles should give sufficient throw and adequate entrainment, should
counteract convection currents and should be sufficiently flexible to cope with both heating
and cooling loads where applicable.

8.4.2 Noise and sound control. Measurements should be taken with a sound level meter either
using the ‘A’ weighing scale or to draw up a noise criteria curve.

8.5 Measurements should be taken in the following locations:

a. Plant rooms;
b. occupied rooms adjacent to plant rooms;
c. Outside plant rooms facing air intakes and exhausts and condenser discharge to
assess possible nuisance to adjacent accommodation; if the adjacent
accommodation is a private residential building, tests may be required at night.
d. In the space served by the first grille or diffuser after a fan outlet;
e. In at least two of the spaces served by fan coil units or high velocity system
terminal units (where applicable);
f. In any space where, by the addition of special silencing material or techniques, or
by classification of use (e.g. lecture hall), a low level of noise is clearly required.

8.6 Measuring the in situ performance to assess the ability of an installation to operate at
design conditions. For a continuously occupied building, e.g. a hospital, design conditions are
reached when the installation has to operate at the design weather conditions. For an
intermittently occupied building, e.g. an office block, supermarket, etc. design conditions are
reached when the installation has to achieve preheating in a specified time.
Tests should be devised to relate the variables upon which the performance of the installation
depends; a schematic layout can be conveniently used. Variables should be chosen to enable a
linear (i.e. straight line) relationship to be constructed from in situ measurements. The
resulting relationship should then be used to infer the performance at design conditions.
Suitable relationships could be:
a. Heating capacity to satisfy total energy demand for humidifying and heating load;
b. Zone heater/cooler capacity to meet space heating/ cooling loads;
c. Cooling capacity to satisfy total energy demand for dehumidification and cooling
load.
8.7 Instrumentation and access
Ideally, instrumentation for performance testing should be considered during the design stage,
so as to enable adequate access for operators during normal operation.

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9. Handover Procedure
Handover documentation should contain all information that the user needs to enable the
installation and equipment to be efficiently and economically operated and maintained. It
should also provide a record of the outcome of any site testing, balancing and regulation
carried out prior to handover. Some of these documents will be prepared by the system
designer, whilst others will be produced by the suppliers or by the contractor who erects the
installation.

The documentation required should be specifically stated in the contract so that the
responsibility for ensuring that all relevant information is provided rests clearly with the air-
conditioning contractor.

All the requisite information should be available at the time of handover. It is advisable for the
client's representative to meet the air conditioning contractor and designer some time before
the anticipated handover date and review the progress of documentation and arrange any
necessary training and familiarization.

Handover documentation should include the following:

a. The designer's description of the installation, including simplified line flow and
balance diagrams for the complete installation;
b. As fitted' installation (as-built) drawings and the designer's operational instructions;
c. Operation and maintenance instructions for equipment, manufacturer's service of
maintenance manuals, manufacturer's spare parts lists and spares ordering
instructions;
d. Schedule of electrical equipment;
e. Schedule of mechanical equipment;
f. Test results and test certificates as called for under the contract, including any
insurance or statutory inspection authority certificate;
g. Copies of guarantee certificates for plant and equipment;
h. List of keys, tools and spare parts that are handed over;
i. List of consumable items required.

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