Testing, Adjusting &

Balancing of HVAC Systems

Project:
TAB Works at Saddara Business
Complex. Jubail-KSA
 Water System
PROCEDURES
PROCEDURE OF WATER SYSTEM BALANCING

Water system testing, adjusting & balancing procedure applies to following

equipments:

S# Equipment Qty. Remarks

01 Air Handling Units 05 Detailed Data will be provided in
(DRVs) accordance with attached TAB Test
Formats.
02 Chillers 02 Detailed Data will be provided in
accordance with attached TAB Test
Formats.
03 Pumps 03 Detailed Data will be provided in
accordance with attached TAB Test
Formats.
 Testing, Adjusting & Balancing Procedures

Heating, Ventilation & Air Conditioning System

WATER SYSTEM

1. Hydronic System Inspection:

A. Hydronic Piping System

1. It shall be confirmed that the system has been hydrostatically tested and is
free of leaks.

2. The system piping shall be traced from the source (e. g. chiller, heat
exchanger) to all terminal units to determine.

A. Completeness and integrity of the installation.

B. Any variation between actual installation and design.
C. That all required valves (manual & automatic) outlined in the agenda
are open.
That accessibility is readily available for testing of all balancing devices,
flow meters, and terminal units.

3. It shall be confirmed that the system has been cleaned, flushed, filled, and a l l a i r
purged. It shall be verified that strainer baskets have been cleaned and
construction baskets (if used) have been removed. The system cleanliness during
the TAB work shall be monitored and any debris build-up may affect the final
system balance.

4. It shall be verified that the system water level and pressure are correct for
the highest terminal units.

Procedure for closed system is outlined below:

Inspect the pressure reducing valve's (PRV) for proper installation and operation.
The testing of RPV should always maintain a minimum 4 PSI static pressure at the
highest point of the system. Check the water level of the expansion or comparison
tank. Generally, 1/3 air and 2/3 water is the proper ratio of the cold expansion
tank. Please clarify if pressure relief valve / or air vent. There is no Pressure Reducing Valve installed for chilled water
system at Admin Building.

5. Proper installation of piping safety devices shall be verified. It should not be

attempted to operate any system with out backflow prevention, or with out the
proper pressure relief valves.

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 Testing, Adjusting & Balancing Procedures

Heating, Ventilation & Air Conditioning System

WATER SYSTEM

B. Pumps:

1. All required data shall be recorded on the NEBB test report forms, include
pump nameplate and motor nameplate data.
2. The nameplate data shall be compared with manufacturer’s submittal data
and design requirements. Any discrepancies will be noted.
3. It shall be verified that the pumps have been properly aligned, grouted, anchored
and lubricated.
4. If vibration isolation is used, it shall be checked for proper installation and
adjustment. All piping should be supported independent of the pump housing.
Operation of the pump with out the proper support may result in damage to volute
casing.
5. It shall be confirmed that the drive guards are in place.
6. It shall be verified that access has been provided for accurate pressure drop
readings.
7. The cleanliness of any strainer (s) serving the pump shall be verified.
8. All air shall be purged from the volute casing. Operation the pump with air
may cause cavitations resulting in damage to impeller and volute casing.
9. The electrical starter, disconnect switches, and main circuit breaker for the
pumps shall be located and verified. It shall be confirmed that thermal overload
protection is installed and of the proper size.
10. It shall be confirmed that electrical power is available for start-up and that
the voltage equipment needs are compatible.
11. The motor shall be “bumped” for rotation check. It should be ensured that
the pump is completely full of water if mechanical seals are used. Operation of a
dry pump with mechanical seals, including “Bumping” will result in seal damage.
If a packing gland is used. It should be adjusted for proper shaft lubrication.

C. Coils/Terminal Units:

1. It shall be verified that the units are piped correctly including required valves,
vents and safety devices.
2. It shall be confirmed that provisions are available for making the required
temperature and pressure measurements.
O & M to assure that all pressure gauge and thermometer are at good working condition prior to water balancing.

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 Testing, Adjusting & Balancing Procedures

Heating, Ventilation & Air Conditioning System

WATER SYSTEM
BMS shall be operational and all field device and sensors are calibrated for validation of readings from water balancing
activites.

3. Proper installation and operation of automatic temperature control devices

shall be confirmed.
4. All air shall be purged from the terminal units on Hydronic system.
5. The proper water flow direction.
6. The coils on both sides should be inspected for fin damage, cleanliness and
straightness of the fins. Condenser and AHU evaporator deformed fins shall be combed to make it straight for optimum
equipment performance.
7. It shall be confirmed that the condensate drains from the cooling coil drain
pans have been provided and that they are properly trapped and functioning.
Improper drains trap are a common cause of leakage, flooding and moisture
carry-over.

2. Safety Tagging:

Before touching any equipment, it will be determined that it is safely locked

out while being checked. The electrical disconnect switch will be OFF and tagged
of locked.

3. Hydronic System Phase—2

1. preparation

Upon completion of air system balancing, proceed with the following:

A. All previously prepared paper work, etc., for the system to be balanced
shall be assembled and studied.
B. It shall be verified that the preliminary system checks and procedures have
been performed.
C. Safety precautions shall be observed prior to starting any equipment related to
the operation of hydronic systems i.e. pumps, chillers, etc.

2. Pump Start Up

Prior to pump start-up the TAB Engineer shall ensure that the system is filled
with water, all air is purged from the system, the

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 Testing, Adjusting & Balancing Procedures

Heating, Ventilation & Air Conditioning System

WATER SYSTEM

make-up water system is with water, all air is purged from the system, the make-
up water system is operational, and that all strainers are clean. He shall also check
that all valves are in there normal operating position, and that all control valves are
open to full flow through the coils and equipment served by the system. All
automatic controls shall be checked for correct position.
B. Pump rotation shall be verified by “bumping” the motor i.e. the motor is
energized for a fraction of a second and the pump shaft is observed to determine
rotation direction. If the rotation is incorrect, it will be noted and the electrician
responsible for the HVAC equipment shall be advised to correct the fault. The
electrician, eliminate the possibility of the TAB technician being held responsible
for any possible damage to the motor or equipment will do this.
C. If the rotation is correct, the pump will be started. Amperage and voltage of
the motor will be measured. Amperage measurement shall be taken when the
motor is operating at full speed. Voltage should be within 10percent of the motor
nameplate rating, and there should be a very little difference of voltage and
amperage between each leg on three phase motors. Amperage should not exceed
the nameplate rating if the amperage is high, the pump will be start immediately.

3. Pump Test Reports:

The following shall apply to all water pumps:

A. Prior to testing the pump for flow rate, it shall be tested in a no flow condition.
Placing the pump in operation will do this and gradually closing the discharge
valve until the valve is fully closed and no water flow occurs. After the valve is
fully closed, a differential pressure reading will be obtained and plotted on the
manufacturer’s pump curve for the particular pump being tested. This will verify
the shutoff head and in turn verify from the curve, the actual size of the impeller
installed and establish the actual performance curve. After measurement of no
flow differential, the discharge valve shall be opened to the full open position.

O & M to provide chilled water pump 's pump curve to be obtain from the archive at library.

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 Testing, Adjusting & Balancing Procedures

Heating, Ventilation & Air Conditioning System

WATER SYSTEM

Balancing shall only be obtained by means of the proper balancing valves and
automatic flow control valves. Service valves will only be used where they are
equipped with memory stop.
After balancing flow through the coils, all 3-way valves shall be reset for flow to
by-pass and the by-pass balancing valves adjusted to equal the pressure drop
across the coil during full flow.
Upon completion of all adjustments, all balancing valves shall be marked to
indicate the final set point.
D. After completion of all adjustments, the flows, pressure and amperage of the
pumps shall be rechecked and recorded.
E. Calibrated test gauges shall be used to measure the final pressure drop across each
component after balancing is complete. All final measured flow rates, pressure
drops, etc. shall be recorded on the relevant NEBB Test Report Form.
Note: Be sure to take the final readings for the pumps and chillers after the balancing.
Record the final VFD setting & differential pressure close to DPT.

4. Certified Reports:

Upon completion of the aforementioned test, three (3) copies of the certified reports
will be submitted to the client prior to final tests and inspection. All reports shall
contain all relevant data obtained during the testing of the systems.

The report will conspicuously identify items not conforming from contract require-
ments, and obvious mal-operation and/or design. This will be noted on the Tests
Report if after notifications, no satisfactory response is obtained. We proudly used
NEBB BALPRO Software to generate TAB reports.

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 Testing, Adjusting & Balancing Procedures

Heating, Ventilation & Air Conditioning System

WATER SYSTEM

Final Test, Inspection and Acceptance.

All final test and inspection required for acceptance of the aforementioned work
shall be done and rechecked in the pressure of the client’s representative at random
selection of data recorded on the reports.
All final tests and required for acceptance of the aforementioned work shall be
preformed in strict compliance with project specification.

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 Testing, Adjusting & Balancing Procedures

Heating, Ventilation & Air Conditioning System

WATER SYSTEM

Chiller Test & Balance

Operation:
Chillers must be in operation before the test and balance technician begins the
procedure. All controls are to be installed, calibrated, and fully operational.

Inspection:
1. Inspect the system to determine if it is complete and operable. If not, then end the
procedure, list any deficiencies, and proceed when they are corrected.
2. Verify that the chiller is running at the maximum load available and at a normal water
temperature setting.
3. Verify that the condenser water temperatures are correct and the cooling tower
operates properly.
4. Verify that the chilled water pumps and condenser water pumps are lined up correctly
and operate properly.
5. Verify that the flow meters are installed in chilled water piping and in condenser
piping. Flow meters are required for this rest. Provide operating manual for ultra sonic flow meters and
calibration certificate.
6. Verify that the thermometer wells and test thermometers are installed properly in
chilled water and condenser water piping according to the Basic Temperature Testing
Measurements procedure.
Condenser water not applicable. Verify chiller condenser fan working conditions in line with compressor
performance on same refrigeration circuit.
Procedures:
1. Balance and set the chilled and condenser water flow through the chiller.
2. Measure and record the entering and leaving vessel pressure on the cooler and con-
denser, and compare to the manufacturer’s submittal data, if available.
3. Load the chiller to the maximum obtainable load until an equilibrium steady state is
reached in the chilled and condenser water temperatures.
4. Log the entering and leaving condenser and chilled water temperature every five min-
utes for a one-hour duration (12 readings).
5. Log the compressor motor input kw and verify water flow and vessel pressure drop
every 15 mintues (four readings) during temperature log time.
6. Average each station reading.
7. Calculate the cooler (evaporator) capacity in tons.
8. Calculate the condenser capacity in tons.
9. Calculate the compressor motor input kw in tons.
10. Add the cooler tonnage to the compressor motor kw tonnage. This sum should equal
the condenser tonnage within 10% for a valid heat balance and acceptable field test.
 Testing, Adjusting & Balancing Procedures

Heating, Ventilation & Air Conditioning System

WATER SYSTEM

11. Upon completion of the test record the following data on report forms.
1. Factory and actual data of the installed chiller.
2. Water flow gpm for chilled and condenser water, include flow meter data, if
installed.
3. All water vessel pressure drops.
4. Final average temperatures of cooler and condenser measured to 0,10°F.
5. KW power readings, including amperage and voltage.
6. Cooler tons, condenser tons, kw tons, and heat balance equation results.

Report:
1. Include all test data on a chiller capacity data sheet.
2. List conditions at the time of the test and the results.
3. List any uncorrected deficiencies that affected the test results on the deficiency report
form.
4. Include required data from the Report Contents procedure.

Compliance:
1. Compliance with this procedure requires completion of all of the above steps with all
data recorded on the report forms.
2. All deficiencies that affect the test must be resolved by the installing contractors or in-
cluded in that deficiency report.
3. Instrumentation must be accurate and suitable for this type of testing. Test accuracy
should be within 5%.
Checklist Prior To
Start TAB Works
 Checklists Prior To Start TAB Works

Contractor shall verify that systems are operable before commencing

work and ensure the following conditions:

S# Description Remarks
1 Systems are started and operating in a safe and
normal condition.
2 Temperature control systems are installed
complete and operable.
3 Proper thermal overload protection is in place for
electrical equipment.
4 Final filters are clean and in place. If required,
install temporary media in addition to final filters.
5 Duct systems are clean of debris.
6 Fans are rotating correctly.
7 Fire and volume dampers are in place and open.
8 Air coil fins are cleaned and combed.
9 Access doors are closed and duct end caps are in
place.
10 Air outlets are Installed and connected.
11 Duct system leakage is minimized.

Please send these checklists back to us after verification.

Regards,

SHAN International Est.

Page 1 of 4
Construction Team Responsibilities:
1. Provide the TAB firm with a conformed set of contract documents
(drawings, specifications, and approved submittal), including all
current approved change orders and contract modifications.
2. Develop a project schedule, with the input of TAB firm, that
coordinates the work of other disciplines and provides adequate
time in the construction process to allow successful completion of
the TAB.
3. Notify the TAB Firm of all schedule changes.
4. Ensure that the building enclosure is complete, including but not
limited to, all structural components, windows and doors installed,
door hardware complete, ceilings complete, stair, elevator and
mechanical shafts complete, roof systems complete, all plenums
sealed, etc.
5. Ensure that all necessary mechanical and HVAC work is complete
and is safe to operate. This includes, but is not limited to, duct
leakage testing and hydrostatic testing. The piping systems should
be flushed, filled, vented, and chemically treated. All strainers
should be cleaned and the correct screens installed. The duct
systems and all related equipment should be cleaned and the
specified clean air filters installed. For additional requirements see
the Pre-TAB checklist (attached).
6. Complete the installation of permanent electrical power systems
serving the HVAC equipment and systems. Such electrical systems
shall be properly installed in accordance with all applicable codes
to ensure the safety of all construction personnel.
7. Perform start up of all HVAC equipment and systems in accordance
with manufacturers’ recommendations.
8. Complete the installation, programming (including design
parameters and graphics), calibration, and startup of all building
control systems. Verify that the building control system provider has
commissioned and documented their work before balancing
begins
9. Require that the building control system firm provide access to
hardware and software, or onsite technical support required to
assist the TAB effort. The hardware and software or the onsite
technical support shall be provided at no cost to the TAB Firm.
10. Furnish and install all drive changes as required.

Page 2 of 4
 SAMPLE PRE-TAB CHECKLIST
This is a sample checklist to be provided by the TAB Firm to the installing contractor for the contractor’s
use in verifying system readiness prior to balancing.

Project:

Ready Ready
1. HVAC Units & Built-Up Units Date Date
Yes No Yes No

a) GENERAL d) FANS

Louvers installed Rotation

Manual dampers adjusted and

Wheel clearance and balance
locked

Automatic dampers operating Bearing and motor lubricaiton

Housing construction complete Drie alignment

Access doors closed Belt tension

Condensate drain piping and pan Drive set screw tight

Free from dirt and debris Belt guard in place

Flexible duct connector alignment

b) FILTER starters and disconnect switches

Electrical service and

Type and size
connections
Number

Clean e) VIBRATION ISOLATION

Fram-leakage Spring and compression

Temporary Base level and free

c) COILS (ELECTRIC)

Sizes & construction

Airflow direction

Duct connection

Safety switches

Contactors and disconnect

switches
Electrical services and
connections
Obstruction and/or debris
 Project:

Ready Ready
2. Duct Systems Date Date
Yes No Yes No

a) GENERAL Refrigerantion Equipment

Manual dampers adjusted amd
Crankcase heaters energized
locked
Operating and safety controls
Acces door closed and tight
devices
Fire dampers open and
Valves open or set
accessible

Terminal units open or set Piping connections and flow

Register and diffusers open and

Flexible connectors
set

Turning vaes in square elbows Oil level and lubrication

Provision made for TAB

Guards in place
measurement
Ductwork sealed as required Vibration isolation

Starters, contactors and

b) ARCHITECTURAL
disconnect switches

Windows installed and closed Electrical connections

Door closed as required

Ceiling plenums installed and

Control Systems
sealed
Accees doors closed and tight Data centers operating

Air shafts and openings as

Outdoor/ return damper set
required

c) BASES Economizer controls set

Vibration isolation Static pressure control set

Grouting Space controls operating

Leveling Complete system operating

Other checks
a) Other trade or personnel
notified of TAB work requirements

b) Preliminary data complete

c) Test report forms prepared.

TAB Test Formats
 PUMP TEST REPORT
PROJECT: TAB works at Saddara Business Center-Jubail-KSA
UNIT SYSTEM
LOCATION SERVICE
UNIT DATA MOTOR DATA
MAKE MAKE
MODEL FRAME
SERIAL POWER
SEAL TYPE SERVICE FACTOR
IMPELLER DIAMETER RPM
SYSTEM OFF PRESSURE PHASE
CLOSE OFF DATA HERTZ
SUC. PRESS DIS PRESS POWER FACTOR
DIFFERENTIAL PRESSURE EFFICIENCY
FEET OF HEAD C.F.L.A.
FULL FLOW DATA FINAL FLOW DATA
TEST DATA DESIGN ACTUAL TEST DATA DESIGN ACTUAL
SUC. PRESS DIS. PRESS. SUC.PRESS. DIS. PRESS.
DIFFERENTIAL PRESSURE DIFFERENTIAL PRESSURE
FEET OF HEAD FEET OF HEAD
WATERFLOW WATERFLOW
NPSH NPSH
PUMP RPM PUMP RPM
VFD POSITION VFD POSITION
BALANCE VALVE POSITION BALANCE VALVE POSITION
FULL FLOW MOTOR DATA FINAL FLOW MOTOR DATA
BRAKE POWER BRAKE POWER
NAMEPLATE VOLTAGE NAMEPLATE VOLTAGE
NAMEPLATE AMPERES NAMEPLATE AMPERES
ACTUAL VOLTAGE ACTUAL VOL TAGE
ACTUAL AMPERES ACTUAL AMPERES
REMARKS:

NEBB TRS 23-2001 UOM: TEST DATE: READINGS BY: PAGE:

Report is not valid unless it is submitted with an accompanying NEBB Certification form stamped with a National Environment Balancing Bureau Certification Seal
 PACKAGED CHILLER TEST REPORT
PROJECT: TAB works at Saddara Business Center-Jubail-KSA
UNIT SYSTEM
LOCATION SERVICE
UNIT DATA CONDENSER DESIGN ACTUAL
MANUFACTURER PRESS. TEMP.
MODEL EWP LWP
SERIAL WATER PRESS. DIFF.
CAPACITY EWT LWT
REFRIGERANT WATER TEMP. DIFF.
STARTER WATERFLOW
OVER LOAD EVAPORATOR DESIGN ACTUAL
CHW CONTROL SETTING PRESS. TEMP.
CDW CONTROL SETTING EWP LWP
COMPRESSOR DATA WATER PRESS. DIFF.
MAKE EWT LWT
MODEL WATER TEMP. DIFF.
SERIAL WATERFLOW
SUCTION PRESSURE REFRIGERATION DATA
SUCTION TEMPERATURE OIL LEVEL CHECKED
DISCHARGE PRESSURE OIL FAILURE SWITCH DIFF.
DISCHARGE TEMPERATURE REFRIG. LEVEL CHECKED
OIL PRESSURE REFRIGERANT AMOUNT
OIL TEMPERATURE RELIEF VALVE SETTING
NAMEPLATE VOLTAGE UNLOADER SET POINTS
NAMEPLATE AMPERES % CYLINDER UNLOADED
ACTUAL VOLTAGE PURGE OPER. CHECKED
ACTUAL AMPERES BEARING TEMPERATURE
KW INPUT VANE POSITION
CRANKCASE HTR. AMPS. DEMAND LIMIT
LP.SETPNT. HP. SETPNT. LOW TEMP. CUTOUT
RERARKS:

*REFRIGETATION / COMPRESSOR DATA TO BE FURNISHED BY THE INSTALLER OF THE EQUIPMENT*

Q

NEBB TRS 18-2001 UOM: TEST DATE: READINGS BY: PAGE:

Report is not valid unless it is submitted with an accompanying NEBB Certification form stamped with a National Environment Balancing Bureau Certification Seal
 BALANCE VALVE / FLOW METER TEST REPORT
PROJECT: TAB works at Saddara Business Center-Jubail-KSA
UNIT SYSTEM
LOCATION SERVICE

LOCATION BALANCE VALVE / FLOW METER DESIGN PRELIM. FINAL

OR FLOW FLOW
ADDRESS NUMBER MAKE SIZE (gpm) (kpa) SETPOINT P.D(kpa) FLOW (gpm) %

TOTAL

REMARKS:

NEBB TRS 24-2001 UOM: TEST DATE: READINGS BY: PAGE:

Report is not valid unless it is submitted with an accompanying NEBB Certification form stamped with a National Environment Balancing Bureau Certification Seal