Reliance

Procedure For
Installation of HVAC Works

EPCMD-2-QM00-JEP-HV-001

01

06.06.2013

Fluor Comments
Incorporated - Issued for
Implementation

ALJ / PPP

KSS / Rick
Tucker

SNS

00

07.04.2012

Issued for Implementation

ALJ / PPP

KSS / EMK

SNS

Rev

Date

Revision

Prepared
By

Checked
By

Approved
By

Reliance
Contents
1. Purpose ..3
2. Scope ..3
3. References ..3
4. Abbreviations & Terms ..3
5. Responsibilities .3
6. Methodology ..3

EPCMD-2-QM00-JEP-HV-001, Rev:00
Confidential Reliance. All rights reserved

Page 2 of 7

Reliance
1.

Purpose
The purpose of this procedure is to define the inspection, testing method and
criteria for installation work of HVAC system to achieve mechanical completion and
ensure all materials are inspected after arrival to site prior to incorporation into
permanent work.

2.

Scope
This procedure covers the incoming inspection and tests pertaining to the
installation of the HVAC system.

3.

References
Nil

4.

5.

Abbreviations and Terms

HVAC

Heating, Ventilation and Air Conditioning

HOD

Head of the Department

QMD

Quality Management Department

DCC

Document Control Centre

Responsibilities

Construction Managers/Engineer in Charges is responsible for implementing

this procedure in their area.

HOD, QMD is responsible for maintaining this procedure.

DCC is the custodian of this document.

6.

Methodology

6.1

General Requirements

6.1.1

All Installation Construction/Testing works shall be carried out in accordance with

Safety Manual.

6.1.2

Inspection and testing shall be conducted by Contractor and Reliance Engineer

coordinated with Vendor's Representative, when applicable.
Verification of inspection checklists and tests shall be witnessed, recorded on Form
EPCMD2-QM00-FMT-HV-001 to 025 and signed by the Contractor as well as
Reliance Engineer as applicable in each individual form.

6.1.3

Test equipment shall have valid calibration certificate.

6.1.4

The checks specified in the following text are generally applicable for all the
Equipments / units listed below.
1.

Refrigeration Equipments

2.

Air handling units

3.

Electric duct heaters

4.

Electric steam humidifiers

5.

Fresh air fan units

EPCMD-2-QM00-JEP-HV-001, Rev:00
Confidential Reliance. All rights reserved

Page 3 of 7

Reliance
6.

Extract air fans

7.

Ductwork System

8.

Volume dampers

9.

Fire dampers

10.

Air terminals

11.

Louvers/Sand trap louvers

12.

HVAC controls

13.

Insulation

14.

Chilled water pipes

15.

Pressurization skid

16.

Chilled water pump

17.

Test record for low voltage motors.

18.

Low voltage and control cable check list.

19.

Material Discrepancy Report.

6.2

Equipment Inspection Storage and Preservation.

6.2.1

Every shipment of HVAC material received on site shall be inspected immediately

upon arrival by Contractor & Reliance Engineer.

6.2.2

All name plates or identification of HVAC materials on site shall be checked against
the equipment and material date sheets to confirm conformity.

6.2.3

Any material found to be non-conforming i.e. does not meet specification,

certification missing etc. shall be reported to Client.

6.2.4

Materials with minor discrepancies such as paint scratches, small dents i.e. any
damage that can easily rectified on site shall be documented on a Discrepancy
Report.

6.2.5

All materials arriving on site shall be stored as recommended by the manufacturer.

6.2.6

All HVAC material arriving on site shall be preserved as per manufacturers

recommendations.

6.3

Installation Inspection

6.3.1

Prior to installation, the following will be observed and checked, as applicable,

against Vendor drawings:

Equipment foundations will be checked for cleanliness and level. Dimensions

will be verified. Location of the equipment fixing points on the foundations
will be verified.
Location of anchoring points of equipment will be verified.
Location of pipe sleeves will be checked.
Location of ductwork penetration through walls will be checked.
Location of cable ducts and tray penetrations through walls will be checked to
ensure that they will not clash with ductwork.
Location of equipment electrical isolation switches to be checked.
Electrical panels will be opened up and inspected for cleanliness and to
ensure no foreign bodies are present. Dust will be removed using an
appropriate method.

EPCMD-2-QM00-JEP-HV-001, Rev:00
Confidential Reliance. All rights reserved

Page 4 of 7

Reliance
6.3.2

During and after installation, the following procedure will be observed:

A. Equipment
-

Inspect visually anti-vibration mountings and anchors, as applicable.

Check visually for damage.

Ensure that drive belt guards are securely fitted.

B. Ducting
-

Ductwork should be checked internally by means of the access doors to

assure that it is free of obstructions such as construction debris, scrap, etc.
which is to include the checking of fire dampers for obstruction. When this
has been determined, the door shall be closed and sealed with an acceptance
tag, in a manner that will require the tag to be broken to gain access. Use of
the tag seal is intended to provide protection against unauthorized access to
the ducts.

Inspect visually duct reinforcement, hangers and rods.

Check duct size and sheet thickness.

Check visually the connection tightness, gaskets and seals.

Check for cracks at duct corners.

Check visually the ducting route.

Verify that any internal field-installed accessories, such as dampers, are in

place. Inspections prior to release for testing shall verify that openings in the
ductwork are closed or fitted with temporary blank-offs as required to
establish the pressure boundaries for leak testing.

Check in particular for proper application of heavy mastic type sealants for
application as a fillet in grooves or between flanges. Mastics must have
excellent adhesion and elasticity. Oil base caulking and glassing compounds
should not be used.

Check for proper application of gaskets in flanged joints. Gaskets should be of

durable materials, such as soft elastomer butyl or other suitable materials.

For ease of application, gaskets should have adhesive backing or otherwise

be tacky enough to adhere to the metal while assembling the joint.

C. Piping
-

Inspect visually piping supports, hangers and rods.

Check pipe size and material.

Check that pipe connection by soldering/welding/threading is performed in

accordance with acceptable practice.

Ensure that valves, accessories and sight glasses are readily accessible.

Check that equipment drain is routed to floor drains and discharges directly
in the floor drains.

Check floor drains serving equipment are located close to the equipment
base.

Check that dissimilar pipe materials are not directly connected.

EPCMD-2-QM00-JEP-HV-001, Rev:00
Confidential Reliance. All rights reserved

Page 5 of 7

Reliance
D. Insulation
-

Inspect visually the material and thickness.

Confirm insulation density comparing to samples obtained during material

approval stage.

Check visually for damage.

Check continuity of vapor barrier and other protective coatings on insulation

surface as well as at connections.

Check for firm adherence of insulation around piping and ducting (no air gaps
between pipe and insulation).

E. Control Panels
-

Insulation will be witnessed to ensure the equipment is vertical and fixing

bolts tightened. Where equipment consists of a number of panel sections, the
assembly shall commence from the center section. Sections on either side of
the center shall be alternated, leveled and shimmed as necessary.

The complete assembly will be checked to ensure alignment and level after
tightening of the bolts.

The control equipment arrangement will be inspected and checked against

the relevant layout and general arrangement drawings.

The panel shall be inspected to ensure all identifying labels and tags are
installed in accordance with schedule.

Interconnecting wiring of the panel sections shall be checked against the

detailed wiring diagram.

The inspection results shall be recorded on Form EPCMD-2-QM00-FMT-HV012 and 024.

F. Cabling, Wiring
-

Installation of electrical cables and wires from HVAC control

panel to the
various HVAC equipment (air cooled condensing units, fans, actuators of
motorized dampers, temperature and humidity controllers) and connections
of field located controls with their respective controllers will be inspected and
tested as follows:

Meggering Voltage for cables are as follows:

0

600 Volt cables

megger at 500 Volts

600

1000 Volt cables

megger at 1000 Volts for 1 min.

The continuity of each core shall be checked & recorded on Form EPCMD-2QM00-FMT-HV-017 and EPCMD-2-QM00-FMT-HV-023.

After completion of the tests the ends of the cables shall be sealed to prevent
the ingress of moisture.

6.4

Testing

6.4.1

Piping
Leakage Test

EPCMD-2-QM00-JEP-HV-001, Rev:00
Confidential Reliance. All rights reserved

Page 6 of 7

Reliance
After completion of a piping system and prior to painting, insulating or
concealment of the whole system or part thereof, the piping system will be subject
to hydrostatic, pneumatic or hydraulic pressure test as applicable.
6.4.1.1 Any modification made in piping system after a successful test shall necessitate retesting of such affected portion of piping system.
6.4.1.2 Defective material or defects in workmanship that were developed during tests
shall be remedied and subject to re-testing.
6.4.1.3 Equipment or other piping system components whose pressure is below the test
pressure shall be isolated from the system during testing.
6.4.2

Test Method
A1

Hydraulic Pressure Test

Piping system shall allow no pressure drop during the test.

Even though gauge pressure has not fallen after specified holding time, every
connection shall be visually inspected. For executing a hydraulic pressure test, a
suitable manual pump set with water reservoir, pressure gauge and non-return
valve shall be used.
Result will be recorded on Form No. EPCMD-2-QM00-FMT-HV-013.
6.4.3

Motor installation and test

-

The motor installation will be carried out by the sub-contractor.

The insulation resistance of the windings shall be tested as follows using a

500 Volt megger for low Voltage motors (up to 440 Volt)

Where only three connections are brought out to the motor terminal block,
these shall be connected together and the insulation resistance checked
between this point and earth

For motors with wound rotors, the three leads shall be connected together
and insulation resistance checked between this point and earth.

Insulation resistance values lower than those specified may indicate the
ingress. The degree of ingress shall be as follows.

The motor terminal box shall be opened up and the terminal block dried out
by applying a fan heater or placing an electric lamp or heater in the terminal
box.

The insulation resistance test shall be repeated and any improvement in the
test results noted. Where improvement is noted, the source of contamination
shall be investigated and corrected.

If no improvement is noted, this will indicate that the motor winding are
contaminated and should be "dried out" by the vendor.

The motor shaft will be rotated to ensure there is no restriction and the
lubrication of bearings checked.

After connections of the cables, the terminal box will be checked to ensure
proper Glanding and that there is no damage to sealing gasket of terminal
box cover.

The results shall be recorded on form EPCMD-2-QM00-FMT-HV-016.

EPCMD-2-QM00-JEP-HV-001, Rev:00
Confidential Reliance. All rights reserved

Page 7 of 7