KENCANA SQUARE

PLUMBING TESTING, ADJUSTING AND BALANCING

SECTION PB-490
Page 1
1.0

GENERAL

1.1

DESCRIPTION
.1

1.2

1.3

1.4

Work of this Section shall conform to the requirements of the Contract

Documents.

WORK INCLUDED
.1

Pressure testing of piping system.

.2

Preliminary and final balancing of all water systems.

.3

Temporary pipe connections, pipe caps, tees, valves, etc.

.4

Performance testing of all system.

.5

This section covers general pipe and equipment testing. Additional

specific equipment tests are covered in individual sections.

.6

Operation of systems as required for testing by other divisions of this

Specification.

.7

Cooperate with independent agent performing inspections.

QUALITY ASSURANCE
.1

During the progress of the work, make tests as specified herein and as
required by authorities having jurisdiction, including local authorities
Inspection Department or E.R. Include all qualified personnel, equipment
apparatus, and services required to perform the tests.

.2

All field test instruments to have calibration certificate not more than 6
months old and issued by a recognised independent testing authority
prior to testing and/or balancing.

SUBMITTALS
.1

Submit the following at least six (6) months prior to the execution of
testing:
.1

Complete brochure of proposed independent certified balancing

firm, listing previous installations successfully balanced, length of
time in business, names and qualifications of employees who will
be assigned to the project, and list of instruments, equipment and
elapsed time schedule to be used on the project.

.2

Procedures and recording forms for testing and balancing each

system and each item of equipment.

.3

Documentation of instrumentation calibration including date of

calibration.

KENCANA SQUARE
PLUMBING TESTING, ADJUSTING AND BALANCING
SECTION PB-490
Page 2
.2

Submit the following within (2) weeks of completion of testing and

balancing.
.1

.3

2.0

Submit six (6) certified copies of each complete testing and

balancing report to the E.R. for review and send two (2) copies of
report to the Employer. Submit individual testing and balance
reports for each individual system and each pumping system
within two (2) weeks after completion of the testing and balancing
of each system.

Inspection reports.

PRODUCTS
NOT USED

3.0

EXECUTION

3.1

GENERAL
.1

Perform all tests required by Codes, Ordinances, and as specified herein,

as well as demonstration of operation for all equipment. Each final test to
be witnessed by the E.R. Give a minimum of seven (7) days written notice
before performing tests.

.2

When directed by the E.R. and/or the authorities having jurisdiction or

when the situations of site favour tests to be carried out on complete
sections or parts as the installation work progress, such tests shall be
carried out at Contractors cost. Advance notice shall be given for such
tests.

.3

Perform preliminary tests and repair leak, damage, defects or replace.

Retest systems repaired before notifying the E.R. of final tests.

.4

A minimum of fourteen (14) days notice shall be given to the E.R. to verify
the test result at site. Should the E.R. find discrepancies between the
recorded test results and the measurement demonstrated to him, further
tests shall be repeated at no additional cost.

.5

Maintain a logbook of all tests, preliminary and final, showing dates,

personnel, observers initials, description of test, and test status. Provide
updated log to E.R. each month throughout the construction period. Initial
log submitted to include listing of all anticipated tests.

.6

Should any failure occur due to or arising from faulty materials or poor
workmanship, the E.R. shall decide if further tests will be required after
remedial works have been successfully carried out.

KENCANA SQUARE
PLUMBING TESTING, ADJUSTING AND BALANCING
SECTION PB-490
Page 3

3.2

.7

Install all temporary and permanent equipment and instruments required

for tests, as well as additional thermometer wells, gauge and instrument
connections, at no additional cost to the Employer.

.8

Furnish all fuel, water, and electricity required in performing the testing,
balancing and adjustment mechanical systems.

.9

When the final tests have been successfully carried out, two (2) copies of
all test results, shall be submitted in loose leaf bound form to the E.R.
within two weeks of completion of tests. Tests which are to be carried out
under certain atmospheric conditions may be submitted later for insertion
into the test binder. All test data shall be on A4 size sheet paper.
Manufacturers literature, apart from published drafts or tables will not be
accepted. All test data shall be tabulated with design requirements and
shall be signed and dated.

.10

Clean all piping and tanks before testing.

.11

Use calibrated test gauges with at least 100mm diameter dial. Gauge
range not to be more than three (3) times test pressure.

.12

Provide and demonstrate operation of all test equipment and apparatus

required for the complete testing and inspection of all systems at such
time and locations as may be directed by the E.R. and/or by the
authorities having jurisdiction.

.13

All tests shall be successfully completed and approved prior to the

application of insulation and prior to the concealment of any portion of the
system being tested.

.14

In the event of any dispute with regard to scope of testing, adjusting and
balancing, the decision of the E.R. shall be taken as correct and final.

TESTING
.1

General
.1

.2

All systems shall be tested to confirm that they perform in

accordance with the intent of the Specification. Should such tests
prove unsatisfactory, remedial work shall be repeated to the
satisfaction of the E.R.

Factory Assembled Equipment

.1

All factory assembled equipment shall be factory manufactured

and tested to conform to the relevant specifications.

.2

The design data and test certification of any factory assembled

equipment shall be submitted to the E.R. if requested to do so at
no additional cost.

KENCANA SQUARE
PLUMBING TESTING, ADJUSTING AND BALANCING
SECTION PB-490
Page 4
.3

.3

Inspection and Testing by Authorities

.1

.4

.5

.1

Pipework and fittings shall be hydraulically pressure tested to one

and a half (1 ) times the working pressure, or 10 bar (150 psig)
minimum whichever is greater. The pressure shall be recorded
over a minimum period of 24 hours and extended, if necessary,
until a satisfactory result has been obtained. The test pressure
shall not drop more than 3% over a period of 24 hours.

.2

Special care shall be taken during pressure testing to ensure that

the controls, safety devices, meters, etc. whose operating
pressure ranges are below the test pressure, are not damaged or
have their accuracy impaired.

Vibration Test
Take vibration and alignment field measurements on every pump.
Readings shall include shaft alignment, equipment vibration,
bearing housing vibration and foundation vibration. Readings shall
be made using portable IRD (or as approved) equipment capable
of filtering out various unwanted frequencies. Maximum vibration
at any point listed above, or where specified, shall not exceed 2
mils on pumps, unless otherwise specified. Equipment
manufacturers shall certify in writing that the field readings, which
do not exceed the maximum specified, are acceptable.

Water Tank Test

.1

.7

All necessary arrangements must be made for the inspection and

testing of the installation by the relevant authorities inclusive of
obtaining all necessary certificates/clearances and the expenses
incurred must be inclusive in the tender price.

Pipework Test

.1

.6

Failure to supply the design data and test certification of the

equipment if so required may result in the rejection of the
equipment.

Tank shall be filled up with water and checked for leaks at panel
joints. Check sides and edges of sectional tank for any distortion.

Pumps Tests
.1

Pumps
Adjust each pump for design flow and record flow, head and
power absorbed. Check alignment before putting them in
operation.

KENCANA SQUARE
PLUMBING TESTING, ADJUSTING AND BALANCING
SECTION PB-490
Page 5
.2

Motors
Test for quietness and correct operation. Adjust all controls to
maintain designed condition. Check direction of rotation of all
motors. Check actual current being drawn.

.3

.4

.5

Record the following design requirements for pumps and pump

motors from the Drawings and reviewed shop drawings.
.1

Manufacturer, model and size.

.2

Water quantity (litre/sec)

.3

Total head (m)

.4

Pump speed (revolutions per minute)

.5

Impeller size

.6

Net positive suction head

.7

Motor kW and brake kW.

.8

Voltage, supply frequency, and amperage (V, Hz, A)

Record the following data from pumps and pump motors installed:
.1

Manufacturer, model and size.

.2

Impeller size.

.3

Motor kW, service factor and revolutions per minute.

.4

Volts, hertz and full load amperes.

.5

Motor starter and heater size.

.6

Equipment location.

Record the following data for pumps and pump motors installed at
final balanced conditions :
.1

Pump speed-revolutions per minute.

.2

Total head at shutoff or dead-end discharge in m. (Plot this

value on pump curve as a verification of impeller size).

.3

Suction, discharge and total head at final adjusted flow in

m.

.4

Calculate brake kW and show on pump curve.

KENCANA SQUARE
PLUMBING TESTING, ADJUSTING AND BALANCING
SECTION PB-490
Page 6

.8

.5

Motor amperage and voltage on each phase at operating

conditions.

.6

In conjunction with pump manufacturer for multiple pump,

pumping systems, construct and submit system curves
indicating operating point with one pump operating, two
pumps operating, three pumps operating, etc.

Electrical Test
.1

As-built power and control diagrams shall be submitted to the E.R.

if there are modifications to or deviations from the original
drawings that have been approved by the E.R. These as-built
diagrams shall be submitted two (2) weeks in advance of the test.

.2

The system control, safety devices, etc., shall be fully tested, the
latter by stimulation of faults.

.3

The whole electrical works shall be tested as required and as

prescribed by the Local Authorities.

.4

The testing of the installation shall comply in all respects with

th
Section E of the 16 Edition of the IEE Regulations and shall be
carried out wholly or in part at the discretion of the E.R. These
shall include but shall not be limited to the following:.1

Insulation resistance

.2

Verification of polarity.

.3

Earth continuity path.

.4

Effectiveness of earth.

.5

Tests to prove correct operation of interlocks, tripping and

closing circuits, indications, etc.

.6

Operation of all protective gear circuits by primary injection

and system fault tests to check sensitivity and stability.

.7

Protective gear timing tests as may be necessary.

.8

Test operation of alarm devices.

.9

Rotational tests on all motors.

.10

Polarity tests to verify that single pole switches are

installed in the phase or live conductor of each circuit, and
not in the neutral conductor.

.11

A test to verify the continuity of all conductors in every ring

circuit, correct connections to terminals or all sockets.

KENCANA SQUARE
PLUMBING TESTING, ADJUSTING AND BALANCING
SECTION PB-490
Page 7

.5

3.3

.12

Insulation resistance test to earth and between conductors

before and after fitting of lamps.

.13

Insulation resistance tests on any electrical plant,

equipment, machine and apparatus before and after
connecting such plant equipment, machine and apparatus
to the power supply.

.14

Earth continuity tests for each final sub-circuit and the

completed installation.

.15

Full load test, which shall be sustained for at least one

hour to ensure that all motors are operating as intended
and that all circuits are protected correctly.

Electrical systems shall be adjusted and recorded as follows:

.1

Adjust each thermal overload to 10% above the actual load

on each motor on a hot day and not more than the rated
full load amps of the motor.

.2

Record the nameplate rating, the measured current drawn

on each phase and the thermal overload setting for each
motor and electric heater.

.3

Where thermistors are used, the operation of the

thermistor, and the calibration of the thermistor relay shall
be checked.

.6

Motor starter over-load relay setting shall be 10% above the actual
load current but shall not exceed the rated full load current of the
motor.

.7

Where the motor is protected with thermistors the motor starter

over-load relay shall be so adjusted that the thermistors function
only as a back-up over-load cut-out.

BALANCING
.1

After the entire installation has been completed, make required

adjustments to balance valves, air vents, automatic controls, pumps, etc.,
until performance requirements are met. Make these adjustments with
equipment operating.

.2

Permanently mark the balanced position of each balancing valve on the

pipe with indelible paint or marker.

KENCANA SQUARE
PLUMBING TESTING, ADJUSTING AND BALANCING
SECTION PB-490
Page 8

3.4

.3

Before any hydronic balancing work is done, install clean strainers, check
proper pump rotation, proper control valve installation and operation.
Verify that each system is adequately bled and vented, proper system
static pressure is available to assure a full system, flow meter and check
valve is properly installed. Maintain throttling devices and control valves
open at this time as required and appropriate.

.4

After piping systems have been installed, tested, cleaned and flushed,
complete with all pumps, piping, valves, and other items as herein
specified, make adjustments as required to deliver the water volumes at
each piece of equipment to within 5% of design flow as shown on the
Drawings, or as required to properly balanced the load throughout the
areas.

.5

Do not perform balancing until the entire system has been pressure
tested, flushed and cleaned.

FINAL REPORT
.1

Demonstrate to the E.R. that all systems and/or equipment have been
balanced and adjusted properly, and that the system and/or equipment is
in compliance with the Contract Documents.

END OF SECTION PB-490