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Method Statement for ACMV Testing & Commissioning

Contents: -

INTRODUCTION

INSTRUMENTATION

PRELIMINARY PROCEDURES

PRE-COMMISSIONING & SETTING TO WORK

GENERAL PROCEDURES FOR COMMISSIONING OF WATER & AIR SYSTEMS

DOCUMENTATION

COMMISSIONING GUIDE

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Method Statement for ACMV Testing & Commissioning
INTRODUCTION This document has been prepared as a guide to the approach we will be taking when carrying out the Commissioning and Testing of the Air and Water systems installed at Location to be mention For ease of reading we have broken it down into sections as follows: -

Instruments

A list of proposed instruments to be used and a brief outline of their function. Outlines the activities to be carried out prior to commencing Pre-Commissioning activities. Details necessary activities to be carried out to minimize risk of damage or injury during initial start of plant. Details the methods we are proposing to adopt to carry out the balancing of the Air and Water systems. Displays sample test sheets we are proposing to use.

Preliminary Procedures

Pre-commissioning/Setting to Work

General Procedures for Balancing

Documentation

It should be noted that this document is intended to be used as a guide only, and that where necessary a more detailed account of the commissioning tasks should be sought from NEBB-The Procedural Standards For Testing, Adjusting and Balancing of HVAC Systems 1991.

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Method Statement for ACMV Testing & Commissioning
INSTRUMENTATION An adequate supply of the necessary instrumentation will be supplied to site prior to commencing Commissioning activities. Where applicable these will be provided with up to date calibration certificates. The instruments we are proposing to use are as follows: Air Systems: Electronic Micromanometer Incline Manometer Pitot Tubes Direct Reading Flowhood/Balometer Electronic Rotating Vane Anemometer Water Systems: Mercury Manometer Fluoro-carbon Manometer Computerized Balancing Instrument Bourdon Gauge Drive Speeds: Contact Tachometer Optical Tachometer Electrical Measurement: Clamp Induction Ammeter Multimeter Temperature Measurement: Electronic Thermometer Sling Psychrometer R.S. Components Castell R.S. Components / APPA R.S. Components / APPA Smiths Industries R.S. Components Perflow / Poddy Perflow / Poddy Crane Badotherm / Wika Air Neotronics / Airflow Airflow Airflow Airflow / Alnor Airflow

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Method Statement for ACMV Testing & Commissioning
A record of all instruments on site will be kept indicating calibration dates and when recalibration is due, thus ensuring adequate replacements can be provided in time when recalibration is taking place. Any instrument damaged during the course of works will be rechecked for calibration after repair even if re-calibration is not due and adjusted as necessary. All members of the commissioning team will be trained to be aware of what instrument is used for each activity. They will also be able to adequately operate the instrument and record the data, as well as maintaining the instrument in good working order. Listed below are the details of the most commonly used commissioning instruments: AIR SYSTEM: Pressure Measurement Pressure reading instruments are used for measuring: a. Total, static and velocity pressures in a ductwork system when used with a Pitot tube b. Static pressures in ductwork by the use of sidewall connections c. Differential pressures between one space and another

Manometers The instruments most commonly used for pressure measurement are the Electronic Micro Manometer and the Inclined Manometer. The electronic micromanometer can commonly measure pressures on two ranges: 0 - 199.9 Pa 0 - 1999.9 Pa It also incorporates a transducer such that when used in conjunction with a Pitot tube can convert velocity pressure directly into a velocity reading in metres/sec. The Inclined Manometer is filled with an oil-based fluid. This instrument has four pressure ranges: 0000125 Pa 250 Pa 500 Pa 2,500 Pa

It also uses a scale to convert velocity pressure to a velocity reading this operates on two ranges: 0 - 14.0 m/s 0 - 28.0 m/s

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Method Statement for ACMV Testing & Commissioning
Pitot Tube The standard Pitot tube, which is used in conjunction with a suitable manometer, provides a simple method of determining air velocity in a duct. The Pitot tube is of double concentric tube construction, consisting of 3.2mm inner tube, which is concentrically located inside of an 8.0mm outer tube. Pitot tubes are used to measure total, static and velocity pressures in ductwork. When used with a calibrated Manometer its use is the preferred method of measuring of air velocity and pressure.

Direct Reading Flowhood / Balometer The flow-measuring hood is a device that covers the terminal air outlet device to facilitate taking air velocity or airflow. The conical or pyramid shaped hood can be used to collect all of the air discharged from an air terminal and guide it over flow measuring instrumentation. Hoods generally are constructed so that the outlet tapers down to an effective area of one square foot. A velocity measuring grid and calibrated manometer in the hood will read the airflow in cfm (l/s). To measure air outlet devices direction in cfm (l/s), some digital instruments have memory, averaging and printing capabilities. Rotating Vane Anemometer For the purpose of air balancing, it may be necessary to use an anemometer in conjunction with a purpose built flow hood. Guidelines for design and construction of these flow hoods shall be carried out in accordance with The Technical Memorandum No. 4 Design of Collection Hoods for Testing & Balancing, produced by the Commissioning Specialists Association (U.K.) Rotating vane anemometers will typically have up to three ranges: 0001 m/s 5 m/s 25 m/s

The balancing cone or hood will be tailored for the particular job. The large end of the cone will be sized to fit over the complete diffuser and shall have a gasket around the perimeter to prevent leakage. Care shall be taken when constructing hoods to avoid adding an excessive artificial resistance to the terminal being measured. Hood readings will be compared with a Pitot traverse reading and corrected as necessary. However, for the purpose of documentation and repeatability, in all cases a common calibrated direct volume flow-hood / balometer will be used for the final scan and witnessing. This common instrument will be presented for prior approval.

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Method Statement for ACMV Testing & Commissioning
WATER SYSTEMS: Flow Measurement There are many possible methods of measuring flow within pipe systems and most require the insertion of a flow measurement device in the pipeline. Experience has indicated that those devices based on generating a differential pressure within the pipework system, eg orifice plates, venturi-nozzles, pressure tapped fixed orifice valves, etc are the most suitable for use in the building services industry. Since the flow measurement device is part of the pipework system, the only instrument the commissioning specialist requires is one suitable for measuring the differential pressure. This can take the form of a water-over-mercury or fluorocarbon manometer, a purpose-made diaphragm pressure gauge, or a pressure differential manometer/flow meter. Mercury Manometer The most commonly used instrument for measuring differential pressure accurately in water systems is the water-over-mercury manometer, which indicates pressure by the height of a column of mercury. The instrument is simple, has no moving parts, and regular calibration is not required. Provided certain basic procedures are followed, the instrument will give reliable and reproducible readings. The mercury manometer incorporates the following features: A large mercury reservoir with means of zero adjustment; A safety chamber to reduce the risk of blowing the mercury out of the manometer if the installation pressure is greater than the range of the manometer; Interchangeable connections for use on various pipe and flow measurement device tappings; A valve chamber for purging air out of the manometer and associated pipework; A measuring range of 0 - 65 kPa.

Fluorocarbon Liquid Manometer This is almost identical in design to the mercury manometer described above, except that it has a lower differential pressure range of 0 - 4.5 kPa. This range is achieved by using a yellow fluorocarbon liquid with a specific gravity of 1.88, instead of mercury as the manometer fluid. Differential Digital Manometer/Flow Meter A water pressure transducer test set is an electronic differential pressure-measuring device, which is pre-programmed to enable the direct reading of differential pressure and flow. In

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Method Statement for ACMV Testing & Commissioning
addition, the regulating valve manufacturer's Kv factor can be keyed into the instrument on site to give calculated valve settings. A typical instrument will incorporate the following features: temperature and differential pressure measurements; direct flow measurement readings; valve hand wheel settings; automatic calibration and de-aeration.

To set and operate this instrument, the manufacturer's instructions should be carefully followed. Pressure Measurement There are various points within a water system where pressure measurement may be necessary, in addition to those required at flow devices. Some examples are listed below: Across water chillier evaporators and condensers; Across boilers; Across pump sets; Across calorifiers; Across similar terminal units connected to a single flow measurement device.

Where the pressures to be measured lie within the range of the mercury manometer, this shall be used. For single point pressure readings, the low-pressure connection to the manometer should be left open to the atmosphere. Frequently, the pressures to be measured will be outside the range of a standard manometer and a conventional pressure gauge will have to be used. The pressure gauges fitted as part of the installation should not be used for test measurements but should be replaced with calibrated test gauges. GENERAL - AIR & WATER SYSTEMS: Rotational Speed Measurement Mechanical tachometers are generally used to measure rotational speeds where the shaft of the fan or motor is accessible. Provision should be made for the insertion of the tachometer spindle through an access aperture in the guard as measurements should never be made on an unguarded drive. Where it is not possible to use a mechanical tachometer, indirect methods using instruments such as the optical tachometer can be employed.

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Method Statement for ACMV Testing & Commissioning
Mechanical Contact Tachometer These commonly have three measuring ranges and a lock to hold maximum reading. Gives a direct reading of speed in Rev/min. Optical Tachometer This instrument projects a narrow beam of light toward the rotating shaft or pulley on which a strip of reflecting tape has been fixed. The reflected light pulses from the tape are measured as frequency (rev/min) by the meter. To be effective, the meter must be held within 0.5m of the shaft or pulley. Voltage and Current Measurement Care should be taken that only competent persons carry out voltage and current measurements. Clamp Induction Ammeter It is important to check the fan and pump motor current to ensure that it is within the design range. A clamp-on-type induction ammeter is recommended for current measurements. The instruments is easy to use, it does not have to be wired into the circuit, and it has a field measurement accuracy of about 3% of the full scale range. The trigger-operated jaws of the ammeter are placed around the conductor at any convenient point and the induced current in the ammeter is indicated as the actual current in the conductor. Insulation does not affect the reading but it is important to remember that the instrument will only work on a single conductor, not a twin cable, and for AC only. In using the instrument, the following safety precautions apply: 1. Do not touch an uninsulated electrical circuit. 2. Never put your hands into a live electrical distribution box. 3. Do not attempt to force the instrument jaws into position. 4. Do not attach the instrument before starting the motor. The start-up current, which can be from three to five times the motor nameplate current, could damage the instrument. 5. Ensure that the correct instrument range is selected. If in doubt, begin with the highest range and reduce as appropriate. Temperature and Humidity Glass Tube Thermometers Mercury filled glass thermometers have a useful temperature range of from -40C to 105C. They are available in a variety of standard temperature ranges, scale graduations and lengths.

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Method Statement for ACMV Testing & Commissioning
Sling Psychrometer A sling psychrometer consists of two mercury filled thermometers, one of which has a cloth wick or sock around its bulb which in turn is fixed into a water reservoir. The two thermometers are mounted side by side on a frame fitted with a handle by which the device can be whirled with a steady motion through the surrounding air. The whirling motion is stopped periodically to take readings of the wet and dry bulb thermometers (in that order) until such time as consecutive readings become steady. Due to the evaporation, the wet bulb thermometer will indicate a lower temperature than the dry bulb thermometer, and the difference is known as the wet bulb depression. The wet bulb depression can then be used to calculate the relative humidity of the air. Electronic Thermometers and Hygrometers Electronic thermometers and hygrometers measure temperature and relative humidity. They have an added advantage over the glass tube thermometers in that they have a quicker response time and larger ranges. However they require frequent re-calibration.

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Method Statement for ACMV Testing & Commissioning
PRE-COMMISSIONING & SETTING TO WORK The final activities to be performed prior to commencing the testing, adjusting and balancing works will be the pre-commissioning and setting to work of the system. Pre-Commissioning The main objective of the pre-commissioning activity is to minimize the risk of injury and damage to personnel and equipment. With the electrical supply isolated a pre-commissioning checklist will be carried out. These checks ensure that the system is statically complete and ready to set to work. Checks carried out will include the following: Air systems: Measurement points identified and test holes drilled. Dampers installed and accessible. Fan chamber, ductwork and system components fitted and clean. Fire dampers open. Wiring complete & power available. All electrical tests completed. Fan and motor free to rotate. Bearings lubricated. Drive system correctly set.

Water system: Measurement points suitably located. System thoroughly tested and watertight. System flushed, cleaned and all strainers checked for cleanliness. System vented and make up supply operational. Wiring complete and power available. All electrical tests completed. Pump and motor free to rotate. Bearings lubricated. Drive system correctly set.

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Method Statement for ACMV Testing & Commissioning
Setting to Work Once all the applicable pre-commissioning activities have been satisfactorily ticked off, the system will be ready to set-to-work. However, this activity will also be carried out in accordance with a pre-prepared check sheet. Checks carried out will include the following: Air systems: All branch and terminal dampers open. Fan main damper 50% open. Automatic dampers set to full fresh air or full recirculation. Supply and extract fans available to run. Windows and doors closed. Direction of rotation correct. No undue noise or vibration detected. Fuses, switchgear and motor not overstressed. Running current lower than motor F.L.C. Fan pressure developed not exceeding system design.

Water Systems: All normally open valves are open and normally closed valves are closed. All automatic valves manually overridden. Pump discharge valve 50% closed to limit start current. Direction of rotation correct. No undue noise or vibration detected. Fuses, switchgear and motor not overstressed. Running current lower than motor F.L.C. Pump pressure developed not exceeding system design.

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Method Statement for ACMV Testing & Commissioning
GENERAL PROCEDURES FOR COMMISSIONING OF AIR SYSTEMS The following procedure is a brief guide, which our staff will be using to carry out the testing, adjusting and balancing of low velocity air systems. Although more than one method of approach to balancing is possible with the same final result, we favour the proportional balance method. Where necessary further reference will be sought directly from NEBB - The Procedural Standards For Testing, Adjusting and Balancing of HVAC Systems 1991. After ensuring that all pre-commissioning and setting-to-work checks have been completed satisfactorily the following steps for Commissioning will be followed. Preparation a) Confirm that every item affecting the airflow of a duct system is ready for the TAB work, such as doors and windows being closed, ceiling tiles (return air plenums) in place, etc. b) Confirm that all automatic control devices will not affect Commissioning operations. c) Establish the conditions for the maximum demand system airflow. System Start-Up a) After ensuring that the systems to be balanced are in their normal operating condition i.e. all normally open dampers open and normally closed dampers closed, have an authorized person start the necessary fans. (Main fan V.C.D's should be regulated to 50% to limit initial motor start current). Those units, which mix fresh and recirculated air, will be initially tested usually in the full recirculation air condition. The proportion of fresh air to recirculated air will be set up after the system has been balanced. b) Once fans have been run up to normal running speed check running current to ensure it is within the full load capacity of the motor. Fan developed pressure should also be measured to ensure it does not exceed the system design. c) Whilst monitoring the motor running current and system pressure open the main fan V.C.D. to its fully open position or within motor running current and system pressure tolerances. d) Repeat activities (a) to (c) for all associated fans. Fan Test a) Measure total fan duties by means of Pitot traverse of duct. This should be measured in a straight run of duct well away from any source of turbulence. Due to ductwork configuration it may not be possible to record a single reading. In which case a number of branches may need to be measured and then totalled to obtain the required reading. b) The total fan duty should be within 10% of the required system duty. If the duty is low check pressure drops across filter banks and coils etc and cross-reference to design figures for anomalies. If the duty is high it will need to be regulated by means of the main damper or pulley change. c) Repeat activities (a) and (b) for all associated fans.

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Method Statement for ACMV Testing & Commissioning
Balancing - (Proportional Method) a) Where practical make Pitot tube traverses on all main supply and major branch ducts to determine the air distribution. Investigate any branch that is very low in capacity to make sure that no blockage exists. b) Carry out an initial scan of all terminals using a direct volume Flowhood / balometer or anemometer and constructed measuring hood (if necessary) and log results on relevant test document. c) With the aid of a single line schematic and the obtained test data identify the index terminal (commonly the furthest branch from fan). d) Working back towards the fan from the index terminal, adjust each terminal damper in turn to obtain a reading in proportion with the index (ideally an overall reading of within 10% between terminals should be obtainable). e) Once all terminals on this branch are proportionally in balance with each other move onto the next nearest branch. Taking the terminal with the lowest duty compared to its design repeat the exercise described in (d) above. This activity is then repeated until all branches have individually been proportionally balanced. f) The next step is to proportionally balance the main branches. Select the index branch, this will be the branch whose tested duty is the lowest compared to its design duty. Then, working back to the fan, the other branches are adjusted by use of their main dampers until they are proportionally in balance with the index.
As measurement by Pitot traverse can be a lengthy process, as long as the test holes have been positioned downstream of the damper, balancing of the branches can be carried out using the square law relationship between static pressure and flow. Therefore only single point static pressure readings need be taken. Alternatively anemometer readings from the index terminal of each branch could be used.

g) Once all branches are in proportional balance the main fan volume should be retested. If the fan duty is outside of the design tolerances set, then it should be adjusted accordingly. This can be by means of pulley change or adjustment of the main damper. h) Once the desired duty has been obtained at the fan, carry out a final scan of all branches and terminals using only the common flow hood / balometer. Log results on relevant test document. Fan/motor speeds, running current and system pressures should also be retaken and logged.

i) Dampers should then be marked for ease of resetting in the event of tampering. j) Repeat activities (a) to (i) for all associated fans.

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Method Statement for ACMV Testing & Commissioning
GENERAL PROCEDURES FOR COMMISSIONING OF WATER SYSTEMS The following procedure is a brief guide, which our staff will be using to carry out the testing, adjusting and balancing of the chilled water system. Although more than one method of approach to balancing is possible with the same final result, we favour the proportional balance method. Where necessary further reference will be sought directly from NEBB - The Procedural Standards For Testing, Adjusting and Balancing of HVAC Systems 1991. After ensuring that all pre-commissioning and setting-to-work checks have been completed satisfactorily the following steps for Commissioning shall be followed. Preparation a) Ensure system has been flushed, refilled and properly vented. b) Confirm all automatic valves are manually overridden into the full flow condition. c) Ensure pressurization unit or F & E tank are filled and operational. System Start-Up a) Ensure that the system to be balanced is in its normal operating condition, i.e.; all normally open valves are open and normally closed valves are closed. (In cases where 3 port automatic control valves are installed they should be set to full flow through the coil and the bypass valve should be isolated). b) Have an authorized person start up the pump. regulated to 50% to limit initial motor start current). (Main discharge valve should be

c) Once pumps have run up to normal operating speed, check motor running current to ensure it is within the full load capacity of the motor. Pump developed pressure should be measured to ensure it does not exceed the system design. d) Whilst monitoring the motor running current and system pressure open the main valve to its fully open position or within motor running current and system pressure tolerances.

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Pump Test a) With pump running, gradually close main discharge valve fully and record suction and discharge pressures. b) Using shut-off head, determine and verify actual pump operating curve and the size of impeller. Compare this data with the submitted data curves. If the test point falls on the design curve, proceed to the next step; if not, plot a new curve parallel with other curves on the chart, from zero flow to maximum flow. Make sure the test readings were taken correctly before plotting a new curve. Preferably one gauge should be used to read differential pressure. c) Open the discharge balancing valve slowly to the fully open position; record the discharge pressure, suction pressure and total head. Using the total head, read the system water flow from the corrected pump curve established in step b. d) If flow meters or calibrated balancing valves are installed, which would allow the flow rate of the pump circuit(s) to be measured, perform the necessary work and record the data. Compare this to the reading recorded from the pump curve. e) The total pump flow rate should be within 10% of the design requirement. If it is low check pressure drops across coils, heat exchanges, strainers etc and cross-reference to design figures for anomalies. If the duty is high it will need to be regulated on the main balancing valve. Balancing - (Proportional Method) a) Carry out an initial scan of all balancing valves and log results on relevant test document. Investigate any abnormally low reading for blockage or air lock. b) With the aid of a single line schematic and the obtained test data identify the index valve (commonly the furthest valve from pump). c) Whilst monitoring the reading on the index valve work back towards the pump adjusting each valve on the respective branch in turn until readings are proportionally balanced. (Ideally an overall reading of 10% between valves should be obtainable). d) Activity (c) should be carried out on all terminal valves until each individual branch is proportionally balanced. At this stage you will generally find some branches higher than the pump % duty and some lower. e) Connect a manometer to the index branch and take a reading. Whilst monitoring this reading, work back towards the pump adjusting each branch valve in turn until they are all in proportional balance with the index. f) If the system has more than one riser the next step would be to work back from the index riser carrying out the same exercise as detailed in (d) & (e). g) Once all terminal, branch and riser valves are in balance the bypass valves on the 3 port valve arrangements can be set. These should be regulated to pose an identical resistance through the bypass pipe as that of the coil. (Bypass valves can be set at any stage of the balancing procedure, as they will not affect the overall balance) h) Pressure drops across AHU coils, heat exchangers, condensers, evaporators etc should be taken where possible and logged as necessary. i) Valve settings should then be recorded and the valve handles locked in position.

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Method Statement for ACMV Testing & Commissioning
ENVIRONMENTAL EVALUATION/FINE TUNING Fine-tuning of the systems can be carried out at this stage to improve the environmental condition of the space. This final tuning will usually be in the form of adjustments to the controls system rather than the physical system. If it is found necessary to make any major adjustments to air or water flow, it should be brought to the attention of the design team prior to making such adjustments. The commissioning team relies on the data given to them by the design team who will have carried out all the load calculations. Therefore if the system has been set to the desired duties but then does not perform as intended this is not the responsibility of the commissioning specialists. DOCUMENTATION The importance of accurate, well presented documentation cannot be overemphasized. It forms the only physical evidence of the completion of the commissioning activity, as well as being of vital importance to the operation and maintenance teams. It can save many maintenance man hours during fault finding by being a base line check for all areas of a system. Test results will be documented in the T & C Forms. COMMISSIONING GUIDE This document has been prepared in relation to the following procedural standards and commissioning guides. Relevant excerpts have been attached for ease of reference. 1. NATIONAL ENVIRONMENTAL BALANCING BUREAU PROCEDURAL STANDARDS FOR TESTING, ADJUSTING AND BALANCING OF HVAC SYSTEMS - 1991 2. COMMISSIONING SPECIALISTS ASSOCIATION (U.K.) TECHNICAL MEMORANDUM NO. 4 DESIGN OF COLLECTION HOODS FOR TESTING & BALANCING

End of T & C Zainal Mohd Salleh. MSc. Mtrls. Sc

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