Msheireb and Education City Stations (“Major Stations”)

Takeover and Completion Contract RTC/176/2016

PROCEDURE

AIR LEAKAGE & LIGHT TESTING PROCEDURE

FOR DUCT WORKS

Education City Station

Document Reference No. Rev Rev. Date Purpose of Issue

M007-RAK-MHV-PRO-00001 2.0 31.07.2017 Issued for Review

Subcontractor Prepared by Checked by Checked by Checked by Checked by Approved by

Mehboob
Name Faisal Saeed S. Burak Oral Imran Iqbal Safeer Tareen John Hadfield
Pasha
Mechanical Construction QA/ QC Project
Job Title T&C Manager HSE Manager
Engineer Manager Manager Manager

Contractor Checked by Checked by Approved by

James Moore / Uthman
Name Mohamed Khedr Johan Mitri
Hamdan
Job Title Contractor’s Representative

Signature

Date

Document Number M007-RAK-MHV-PRO-00001 Rev 2.0 Page 1 of 20 Date: 31.07.2017

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Revision History:-

Rev. Rev. Date Description or Reason for Change

1.0 4 June 2017 Issued for Approval

2.0 31 July 2017 Issued for Review, addressing the comments on the DRS

Controlled copy Issue Log:

NB: This is only applicable to copies issued outside EDMS

This document has been issued in a controlled manner to the following recipients:
(In the event of a revision, the parties listed are to be issued with the updated version)

Copy No. Company Name Representative

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 TABLE OF CONTENTS

1 DEFINITIONS & ABBREVIATIONS .................................................................................... 4

2 PURPOSE ........................................................................................................................... 5

3 SCOPE ................................................................................................................................ 5

4 STANDARDS RELEVANT TO DOCUMENT AND INFORMATION MANAGEMENT .......... 6

5 ROLES AND RESPONSIBILITIES ...................................................................................... 6

6 EQUIPMENT AND MATERIALS USED .............................................................................. 8

7 QUALITY ASSURANCE/ QUALITY CONTROL .................................................................. 8

8 INSPECTION & TEST PLANS (ITPs).................................................................................. 9

9 HEALTH, SAFETY, ENVIRONMENT .................................................................................. 9

10 JOB HAZARD ANALYSIS ................................................................................................ 13

11 LEAKAGE FROM DUCTWORK ........................................................................................ 13

12 TESTING METHODOLOGIES ........................................................................................... 15

13 TESTING FLOW CHARTS ................................................................................................ 19

APPENDIX:

Appendix 1 – Health & Safety Risk Assessment

Appendix 2 – Ductwork Classification list
Appendix 3 – Measuring Device Sketch and details.
Appendix 4 – Test Report Form

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1 DEFINITIONS & ABBREVIATIONS

1.1 ABBREVIATIONS

ARCH Project Archive

BS British Standard
CCC Consolidated Contractors Company
DVE Design Verification Engineer
HSE Health, Safety and Environment
IFC Issued for Construction
IT Information Technology
ITP Inspection and Test Plan
MS Method Statement
MSDS Material Safety Data Sheet
NCR Nonconformity Report
PD Project Director
QRIT Qatar Rail Integrated Team
PPE Personal Protective Equipment
QA / QC Quality Assurance / Quality Control
QCS Qatar Construction Specification
QMS Quality Management System
QND Qatar National Datum
QS Qatar Standard
RAK Joint Venture of Redco and Akfa Contracting
SONO Statement of No Objection
T&C Test and Commissioning

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1.2 GENERAL TERMS

 Owner is Qatar Rail who is referred also as End User.

 QRIT is Qatar Rail Integrated Team.

 Main Contractor is Consolidated Contractors Group S.A.L (CCC).

 Sub-Contractor (RAK) is Redco - Akfa Joint Venture who is a self-certification company who hired the
supervising engineer to check and approve subcontractor’s works.

 Supervising Engineer (SE) refers to Qatar Design Consortium (QDC), who is hired by the subcontractor
to check the compliance of the works with the approved shop drawing / design drawing reviewed by the
DVE and remain in place until the completion of the works. SE will carry out a comprehensive supervision
of all construction works to ensure compliance with the approved design and check with the due
professional skill and care of the construction works.

 Inspection Request (IRE) refers to a request to the SE to inspect an installation or to witness a test. This
request raised by the construction team of the subcontractor to QDC. The works must have prior
inspection and recommending approval by subcontractor’s QA/QC inspector(s) prior to submission to
QDC.

 Light Testing Light Test is usually performed to check the leakage in the HVAC Duct with Light.

 Air Leakage Testing Air Leakage Test is normally performed to check the leakage in the HVAC Duct with
Low air pressure.

2 PURPOSE
The purpose of this procedure is to demonstrate the generic approach and procedures to be followed to
execute the Sheet Metal Air Ductwork Test. The aim is to identify the leakages in air ducts in a safe manner
to an approved and controlled methodology. To determine the results in accordance with applicable
standards, codes of practice and project specifications. It also highlights dependencies on other MS’s before
the execution of the mentioned tests.
3 SCOPE
The scope of this procedure covers the leakage testing procedures of sheet metal air ducts. This MS is valid
for Metro Rail Education city Project. The installed air ducts shall be executed with determined ways below.

This document includes the followings as main body;

 Classification of ductwork from the perspective of testing

 Methodology for to execute the leakage test.
 Equipment and materials used
 Health & Safety Risk Assessment
 Test Reports

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4 STANDARDS RELEVANT TO DOCUMENT AND INFORMATION MANAGEMENT
 QCS 2014 Qatar Construction Specifications 2014
 Specification: M007-MML-MEP-SPE-00004 Rev 5.0
 Volume 6 Contractor's Requirements Design Specifications
 Volume 7 Employers Requirements Materials and Workmanship Specifications
 DW 144 Sheet Metal Ductwork
 DW 143 Duct Leakage Testing
 SMACNA Sheet Metal and Air Conditioning Contractors National Association
 NFPA 90A Installation of Air Conditioning and Ventilating Facilities
 NFPA 5000 Building Construction and Safety Code
 NFPA 130 Standard for Fixed Guide Way Transit and Passenger Rail Systems
 BS CP 352 Mechanical ventilation and air conditioning in buildings
 BS 6164Health and Safety in Tunnelling in the Construction Industry
 ITP Inspection and Test Plan for Installation of HVAC Duct Work
(M007-RAK-MHV-ITP-00006)
 MES Method Statement for Installation Of HVAC Duct Work
(M007-RAK-MHV-MES-00006)

5 ROLES AND RESPONSIBILITIES

There shall be different teams within the subcontractor who will be involved in conducting Pneumatic
and Light Test. The inspection will be offered to the Supervising Engineer, Main Contractor and QRIT.
However, the minimum teams required to participate are as follow:

5.1 TESTING AND COMMISSIONING MANAGER (T&C MANAGER)

The T&C Manager is responsible for:
 Delivering the overall testing works in a safe and timely manner, ensuring conformance with the
approved design.
 Support the team of testing engineers and guiding them in the delivery of the works.
 Verifying that testing work carried out in accordance with the requirements of the contract.
 Ensuring the quality standards set for the testing work are achieved and the working team adhere to
the QA/ QC and HSE requirements of the contract.

5.2 SAFETY SUPERVISOR / SAFETY OFFICER

1. Shall ensure that all safety requirements are complied with by all participants in Air leakage and light
testing – as listed in Risk Assessment Appendix-1
2. Shall ensure that, the work force involved in this task possesses the required competence.
3. Shall ensure that area has been cordoned off and no irrelevant person is allowed in the area when the
pressure testing is performed.
4. Shall ensure that all the workforce is briefed about the method statement and risk assessments of the
activity.

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 5. Shall ensure that all the equipment involved in testing has a valid 3rd party calibration certificate.
6. Shall ensure to stop any on-going testing activities if any on-going process in the conduct of leakage
testing is observed to be unsafe.

5.3 QC ENGINEER / QC INSPECTOR

1. Shall act on the raised IRE and shall coordinate with all teams that are required for the pneumatic and
light testing.
2. Shall ensure that all approved procedures are complied with by all participants in testing
3. Shall ensure that all required documentations are adhered to and have the correct data / information /
signatures
4. Shall reject any failing the test and re-conduct inspection after rectification.

5.4 CONSTRUCTION TEAM

(Construction Manager / Site Engineer / Site Supervisor & Foreman)
1. Shall inform the T&C Team for finished constructions and available systems for testing.

2. Shall raise inspection request (IRE) if the system or part of the system is ready for the Pneumatic/Light
testing.
3. Shall ensure that proper work permit is obtained prior to start of testing activities
4. Shall ensure that proper safety precautionary measures and proper tool box briefing were conducted
prior to the start of Pressure testing activities
5. Shall ensure that the activities shall be conducted safely and in compliance with the approved methods,
manufacturer’s recommendations, and relevant standards
6. Shall ensure the readiness of system / duct / area / tools / devices / personnel / etc. that are included
and required for the testing.
7. Shall provide the necessary manpower, supplies, lifting and shifting equipment.

8. Shall ensure that the works are being carried out in accordance with contract requirements and this
method statement.
9. Management of the site activities to ensure that the team carries out the works in time with the
delivery schedule.
10. Shall conduct rectification of works in case of unsatisfactory testing and raised a revised IRE.

5.5 SUPERVISION ENGINEER (SE)

1. Shall witness the test as per approved ITPs

2. Shall verify testing results, and sign-off the IRE’s.

3. Will stop any on-going testing activities if observed unsafe.

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6 EQUIPMENT AND MATERIALS USED
The following equipment and material are anticipated to be used in carrying out the works:

6.1 EQUIPMENT USED

6.1.1 General Equipment used for this activity:

Proper tools and instruments must be used for safe and proper Air leakage test testing. A list of
common equipment/tools to perform the tests is given below

Sr.
Tool/Equipment/Material
No.
1. Electric Light Bulb
2. Duct Leakage Test Machine
3. Magnehelic
4. Duct Cap
5. Mobile Scaffold
6. Mechanical Forklift
7. Tool Box/Hand tools
8. Line Marker / Whitener / Marker
9. Wrench

 Equipment may be substituted subject to availability and actual requirements on the day.
 The type and quantities of equipment are subject to change to suit the site requirements and to meet the
construction program.

6.2 ACCESS
1. Clearly designated walkways must be established to allow persons to access the site safely
2. Walkways must be maintained free from obstruction and any debris.
3. Adequate illumination must be provided for access routes and walkways.
4. Signs must be displayed to indicate the routes to be taken by persons, changes in routes must be
clearly communicated.

7 QUALITY ASSURANCE/ QUALITY CONTROL

1. The Inspection and Test Plan (ITP) for this Method Statement state the testing elements to be checked.
2. T&C Manager is responsible of pre-working control and shall provide specific resource to the work to
be performed and have to determinate the verification, validation, monitoring, inspection to the test
work as well as criteria for product acceptance and quality record needed.
3. Items which are a part of, or intended to be used permanently on, any of the systems of the project
shall not be used as an element of the testing setups for the purposes of testing.

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 4. The concerned T&C Site Engineer or General Foreman will be responsible to ensure compliance for
these operations and the site QA / QC Engineer will carry out quality control checks and report the
inspection results.
5. The Test Form for this work is attached in Appendix-3.

8 INSPECTION & TEST PLANS (ITPs)

Refer to Checklist No. M007-RAK-MHV-ITP-00006
9 HEALTH, SAFETY, ENVIRONMENT
The Health and Safety Plan (M007-RAK-HMS-PLN-00001 Rev 3.0) will be strictly adhered to at all
times.

9.1 SITE INDUCTION, PERMIT AND RULES

1. All workers (Labour and Staff) will receive a site induction and be issued with PPE including a helmet
with a CCC Inducted sticker.
2. The workers (Labour and Staff), whom have been inducted are only Permitted to work.
3. Regular Tool Box talks shall be held and attendance shall be logged.
4. The Emergency Response Plan of the main contractor will be in place and will be strictly adhered to.
5. In the event of any accident the Incident Reporting Procedure will be followed at all times.
6. Always pay attention to the Emergency Telephone Numbers posted on the notice board in the site
office See the attached Sheet of Incident Reporting Procedure.
7. Specific HSE Hazards are mitigated in the Job Hazard Analysis.
8. Heat Stress Management Plan # M007-RAK-HMS-PLN-00002 shall be followed for Site Working.
9. Safety inspection is conducted by Health & Safety officer according to QCS 2014, as per the whole
process of the job to identify any hazards to be stated and recommend for rectification.
10. The result of the inspection will be communicated to all persons who will be involved for the execution
of the work.
11. Dispose all wastes, and unwanted materials must be disposed of at a designated place.

9.2 WORK PERMITS

1. Before commencement of work, a PERMIT TO WORK indicating the activities to be performed shall
be obtain from the concern authorities as per HSE policy and procedure.
2. The Site Supervisor / Site Engineer are the authorized personnel to issue and control work permits.
3. Make sure that every worker to perform the work has attended the specific safety Training before
commencing work.
4. Working in confined space (Only trained worker shell be allowed), require work permit form Site
Engineer / Site Supervisor.
5. A permit shall be required for Hot Work from Site Engineer / Site Supervisor.
6. Safety inspection is conducted by Health & Safety officer and shall identify any hazards to be stated
on the permit to work format.
7. The result of the inspection with the permit to work will be communicated to all persons who will be
involved for the execution of the work.

9.3 ELECTRICITY
Before using an electric tool, check the tool and its plug and connecting cable.

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 1. Do not use a damaged tool.
2. Do not use an electric tool unless its connecting cable is well protected.
3. Do not use an electric tool unless its metal casing is earthed and its power supply is provided with an
earth leakage circuit breaker.
4. Regular monthly inspection and regular inspection (prior to commence work) of equipment and tools
shall be conducted as required. Tag must be put to tools and equipment that have damaged to prevent
using.
5. Ensure that it has the correct inspection report for the month and report immediately any defects or
damage to your supervisor. If faulty DO NOT USE!
6. Do not repair or alter any electrical installation unless competent to do so.
7. If you meet any fault or problem, report it to your supervisor immediately.
8. Make sure that the power cables have good insulation and properly connected not causing a tripping
hazard and that they are not laid in water, working area of moving equipment, materials and areas
where they are walked on.
9. Keep cables off the ground suspend from structures where possible. It must be ensured that live cables
are not in contact with metallic surfaces.
10. Do not stand in water while using the equipment and do not allow the equipment to get wet.
11. Check the power supply connections and make sure that the equipment is properly earthed.
12. Only Trained technicians who have full knowledge on how to operate the equipment are allowed to
use.
13. Only qualified electrician must install and maintain the live electrical equipment.
14. Make sure that all equipment (If any used), cutting machine, bending machine and all other appliances
(As Specified in MS Tool & Equipment Section) brought to the Site have relevant Test Certificates /
Training.

9.4 FIRE RISK

There is always a fire risk. However, the chances of fire can be reduced, and you will know what to
do when a fire breaks out if you:
1. Always keep the workplace clean and tidy.
2. Handle machinery and tools that may generate sparks or heat carefully.
3. Do not smoke or use naked flames in any area where flammable and explosive substances are
stored.
4. Know where fire extinguishers are
5. Located and how they are used.
6. Know the place of assembly for fire evacuation.
7. Provide portable fire extinguishers nearby the working area and all persons involved must be familiar
how to operate the fire extinguisher (If Necessary or Advised by the HSE officer)
8. Rebreathes shall be provided as per CCC Safety requirements and QCS 2014 and BS 6164.

9.5 MANUAL HANDLING

1. Avoid manual handling operations as far as possible to minimize the risk of injury.
2. Estimate the weight of the load.
3. Lift an object with a correct posture.

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 4. Wear suitable protective equipment.
5. Put on gloves as far as possible to protect your hands from any cut, scratch or puncture, and wear
safety boots or shoes to prevent injury to toes by heavy falling objects.
6. Seek assistance from someone in lifting a load if necessary.
7. Manual handling of the material shall be according QCS 2014 Section 11 Part 1.2.7.

9.6 PORTABLE POWER TOOL

1. Do not use a portable power tool (such as saw, grinder and drill) unless its dangerous parts have
been effectively guarded.
2. Place the electric cable and hose of a tool at an appropriate position to avoid tripping hazards.
3. Do not operate a cartridge operated fixing tool unless you have possessed a valid certificate.
4. Wear suitable eye and ear protectors while operating a cartridge-operated fixing tool.
5. Use a cartridge-operated fixing tool with great care.

9.7 SCAFFOLD (MOBILE)

1. Do not use scaffolds unless they have been erected by trained workmen and under the supervision of
a Certified Supervisor.
2. Do not use a scaffold unless it has been inspected and certified safe (A Green Tag to visibly hoist on
the scaffolds) by a Certified Supervisor before use.
3. Strictly follow the instructions of a Certified Supervisor. Do not alter the scaffold unless authorized to
do so.
4. Do not work on an unfinished scaffold.
5. When it is necessary to work on a mobile scaffold, lock the wheels of the scaffold before you start
working.
6. Do not work on a scaffold unless it has been provided with a suitable working platform.

9.8 CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH (COSHH)

1. Products with symbols show below are classified under COSHH. They will have a label that has one
or more hazard symbols. Some examples are given below.

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 2. These products include common substances in everyday use such as paint, bleach, solvent or fillers.
3. When a product is ‘dangerous’, the supplier must provide you with a safety data sheet.
4. The COSHH Regulations requires to assess the risk due to the substances that fall under the to the
COSHH category and protect the workers who are directly involved in the related work. To do this
adequately control measures shall be taken in storing and using such items.
5. A separate Storage of Zinc Spray Paint shall be provided in consultation with HSE department rules
and regulations on Site.
6. Suitable storage will be provided.
7. Zinc Spray Paint shall be segregated form Flammable substances and LPG.
8. A Work Permit shall be obtained from the Site Engineer / Site Supervisor to do repair activity and to
use Zinc Spray Paint.
9. Task specific Training, instruction and information shall be provided to workers.
10. It shall be ensured that all workers have the Personal protective equipment accordingly to HSE
requirement obligatory onsite related to this activity.
11. Workers having the necessary skills, knowledge, experience and PPE shall be permitted to execute the
touch up (Zinc) Paint task on site.

9.9 SAFETY REQUIREMENTS

1. First Aid Kit to be provided at different locations of working areas in consultation with HSE officer.
2. Clean up work area immediately after each task; never leave an area that is cluttered with tools or
supplies that could present tripping hazard.
3. Barriers as required shall be in place wherever necessary.
4. Visible “Safety sign” shall be provided where necessary as per HSE requirements.
5. Good quality gloves are to be worn to protect your hands when using the equipment or handling
materials.
6. The basic Personal Protective Equipment for this particular job are:
7. Hard Hats (Hat Colours as specified by HSE Department)

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 8. Gloves (Must Be Task Specific)
9. Goggles (Clear for underground areas and Black for work in Sun Light)
10. Reflective Vest
11. Safety Harnesses (Third Party Certified) for working on height.
12. Always wear safety spectacles when using the equipment.
13. Safety Boots (High Ankle as per requirements of Qatar Rail)

10 JOB HAZARD ANALYSIS

The Job Hazard Analysis for this work is attached in Appendix 1.Classification

11 LEAKAGE FROM DUCTWORK

Leakage from sheet metal air ducts occurs at the seams and joints and is therefore proportional to the
total surface area of the ductwork in the system. The level of leakage is similarly related to the air pressure
in the duct system and shall be followed as per DW 144/143.

Calibrated flow measuring device shall be used with valid third-party test certificates.

11.1 SYSTEM LEAKAGE LOSS

The operating pressure will vary thought the system and as leakage is related to pressure. However, it is
generally accepted (As per DW 143 Duct work leakage testing) that in typical good quality systems the
leakage from each class of duct under operating conditions will be in the region of:

Class A Low Pressure 6% (As per DW 143 Duct work leakage testing)
Class B Medium Pressure 3%( As per DW 143 Duct work leakage testing)
Class C High Pressure 2%( As per DW 143 Duct work leakage testing)

11.2 SPECIFY AIR LEAKAGE SYSTEM

Ductwork testing activities will be handled in 4 parts

 Low Pressure Ducts
 Medium Pressure Ducts
 High Pressure Ducts

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 For every system testing following ranges will be taken into consideration.
High Pressure Ducts See Part 10.6
Medium Pressure Ducts See Part 10.5
Low Pressure Ducts See Part 10.4
Exposed Extract Systems Untested
Ceiling Void Extract Systems Untested
Secondary ducts from VAV or Fan-coil Units Untested
Flexible Duct Untested
Final Connections and Branches to grilles and diffusers Untested

For Classification of air duct see Table 1

Table-1

11.3 LOW PRESSURE DUCTS TESTING

This applies to ducts with mean velocities less than 10 m/s and static pressure 500 Pa or low
operating static pressure. In SMACNA this range is raised to 750 Pa or low operating static pressure.
Air tests for low pressure ducts are not mandatory as per DW143. When proper method of assembly and
sealing of ducts are used, visual inspection will be ordinarily sufficed for verification in some instances. For
this case of ductwork, no testing will be applied or light test will be made if required. For light testing
methodology please see Item 11.1

11.4 MEDIUM PRESSURE DUCTS TESTING

This clause applied to ductwork subject to the pressure up to 1000 Pa.

According to DW 143 , Air leakage testing of low pressure ductwork is not mandatory under this
specification. The contractor shall test 10% of the duct systems as selected as per project specs.

11.5 HIGH PRESSURE DUCTS TESTING

This applies to ductwork subject to pressures up to 2000Pa (2500Pa According to SMACNA)

For this case of duct work pressure test will be applied to ductwork. All high-pressure ductwork shall be
tested in accordance with the DW143 and SMACNA. For pressure testing methodology please see Item 11.2.

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12 TESTING METHODOLOGIES

12.1 LIGHT TESTING

The procedure set out in this section is limited to the ductworks that are specified to be light
tested in the previous parts of this document. Light testing for any pressure tested ductwork should
be considered unnecessary.
Pre-requisites of Testing:
 The following checks and confirmation prior to start the work:
 Documents required for execution of the construction work are of the latest issued shop drawings
prior to starting the work (specifications, working drawings, supplier’s drawings etc.)
 Installation of the duct system has been executed in accordance with approved shop drawings &
approved material which shall be approved before the works proceed.
 Skilled manpower required for carrying out test.
 Mobilization of equipment and materials which are required for the air duct leak testing
 Before and during the installation works, study of the shop drawings & specifications must be
done. The subcontractor shall carry out a survey of the site related to the area of the installation
works. This shall include a dimensional survey, recording the construction of the building, the
detail and nature of the existing obstruction and future installations, in order to fully coordinate
the work to be done.
 Proper marking to be done prior to commencement of installation works.
 Plan ahead and make sure that all containment to be accessible for future maintenance purpose.

Preparations:
 Ensure that all tools/equipment to be used in testing are in good working conditions
 The working area shall be delimited by a ribbon along and around the working area during test
 Place safety warnings at all points where personnel may pass through within the vicinity of testing.

Requirements of Testing:
 Test Conditions: Performance requirement sufficient to find possible leaks
 Test Pressure: No Pressure
 Duration: 15-30 Minutes. for Inspection
 Monitoring: Visual Checks
 Satisfactory: At the end of 15-30 minutes Duration, there should not be any remarkable light beam
leaking outside of duct.

Method of Testing:
 Make available a highlighted drawing of area intended for testing. Drawings to be attached and
testing area should be marked in the drawing.
 Duct prepared – all openings to be closed.
 To be provided temporary earthing protection for the duct;
 To provide the light source – inside the duct – can be simple bulb 100-200W, portable with
protection. Also stronger lighting could be used for intended tests. (See Figure-1)
 Scaffolding will be provided to access the ducts.

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 Figure-1
 After all preparations finished the lights inside the room where testing to be carried out shall be
switch off at the time of test.
 Total darkness or Dim Lit shall be maintained at the environment during test. (See Figure 2)

Figure-2
 Check at every joint – The light from outside shall not be visible.
 If any defects found, the points shall be marked and then rectified/sealed after finishing the test.
 After rectification, the test to be repeated;
 The above procedure shall be repeated for a re-test to take place once all the leaked joints are
repaired. Till the successful results recommended in “Requirements of Satisfactory” part provided.
 Test report shall be prepared and signed off by the concerned

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12.2 PRESSURE TESTING
The procedure set out in this section is limited to the ductworks that are specified to be pressure
tested in the previous parts of this document.
Pre-requisites of Testing:
 The following checks and confirmation prior to start the work:
 Documents required for execution of the construction work are of the latest issued shop drawings
prior to starting the work (specifications, working drawings, supplier’s drawings etc.)
 Installation of the duct system has been executed in accordance with approved shop drawings &
approved material which shall be approved before the works proceed.
 Skilled manpower required for carrying out test.
 Mobilization of equipment and materials which are required for the air duct leak testing
 Before and during the installation works, study of the shop drawings & specifications must be
done. The subcontractor shall carry out a survey of the site related to the area of the installation
works. This shall include a dimensional survey, recording the construction of the building, the
detail and nature of the existing obstruction and future installations, in order to fully coordinate
the work to be done.
 Proper marking to be done prior to commencement of installation works.
 Plan ahead and make sure that all containment to be accessible for future maintenance purpose.

Preparations:
 Ensure that all tools/equipment to be used in testing are in good working conditions
 Magnehelic are calibrated.
 The working area shall be delimited by a ribbon along and around the working area during test
 Place safety warnings at all points where personnel may pass through within the vicinity of testing.

Requirements of Satisfactory:
 Test Conditions: Performance requirement sufficient to find possible leaks
 Test Pressure: Mentioned in Table 1
 Duration: App. 15 min (Stability of required test pressure should be sustained)
 Monitoring: By calibrated magnetic differential pressure gauges and/or calibrated air leakage
testing device.
 Satisfactory: At the end of test determined leakage results shall not be lower than accepted leakage
limits. For accepted leakage limits see Table 1
Method of Testing:
 The duct to be tested shall be isolated from system and all open parts should be caped.

 One side of the flexible to be connected to adaptor, other side to the air leakage testing machine.
(See Figure 3)
 According to the type of the Class (Class A, B, C) of Duct maximum allowable leakage
amount will be determined. (See Table 2)

Document Number: M007-RAK-MHV-PRO-00001 Rev 2.0 Page 17 of 20 Date: 31.07.2017

Uncontrolled if printed, refer to EDMS for current version
 Figure-3
 Air leakage testing device switched on and duct shall be pressurized.
 It shall be working for app. 15 min (Stability of required test pressure should be
sustained)
 Pressure loss should be noted after stabile pressure provided.
 Measured leakage amount should be less then maximum allowable leakage amount for
Satisfactory. (In some cases Air leakage testing device provides pass/fail indication. This
option could be used for calibrated and certified devices.)

If satisfactory not obtained:

 Measured Leakage points should be inspected by hand by the help of scaffolding.
 If any defects found, the points shall be marked.
 After finishing the test all marked points should be rectified/sealed.
 The above procedure shall be repeated for a re-test to take place once all the leaked
joints are repaired. Till the successful results recommended in “Requirements of
Satisfactory” part provided.
 Test report shall be prepared and signed off by the concerned.

12.3 RECTIFICATION ACTIONS FOR THE DUCTS IN CASE OF FAILING THE LIGHT/PRESSURE
TESTING
 All rectification action shall be taken as per related installation method statement.
 Alignment of duct shall be checked properly.
 Duct support shall be levelled.
 If the joints of the duct Leaks, apply sealant properly from each periphery of the duct
made for repairing of duct over the hole or gap.
 Check the gasket properly.
 Assembly of ducts to be tightened i.e. gasket, clamps etc.
 Visual inspection to be carried out before re test the system.
 Re -test the duct assemble.
 Repeat rectification process if needed.

Document Number: M007-RAK-MHV-PRO-00001 Rev 2.0 Page 18 of 20 Date: 31.07.2017

Uncontrolled if printed, refer to EDMS for current version
13 TESTING FLOW CHARTS

 Flow Chart for Light Test

Area Define

Visual Inspection

Close Open Ends of Duct

Isolate Duct from the Equipment’s

Place Light Source Inside The Duct

Apply Light Inside The Duct

Rectification/Re-Test

Leakage Detection

Pass Fail

Document Number: M007-RAK-MHV-PRO-00001 Rev 2.0 Page 19 of 20 Date: 31.07.2017

Uncontrolled if printed, refer to EDMS for current version
  Flow Chart for Pressure Duct Leakage Test

Area Define

Visual Inspection

Close the Ends of Duct

Isolate Duct from the Equipment’s

Fittings of Test Apparatus

Supply Air Pressure

Rectification /Re-Test

Leakage Detection

Pass Fail

Document Number: M007-RAK-MHV-PRO-00001 Rev 2.0 Page 20 of 20 Date: 31.07.2017

Uncontrolled if printed, refer to EDMS for current version
 APPENDIX 1
Health and Safety Risk Assessment

Document Number: M007-RAK-MHV-PRO-00001 Rev 2.0

Uncontrolled if printed, refer to EDMS for current version
RISK ASSESSMENT FOR AIR LEAKAGE & LIGHT TESTING PROCEDURE
EDUCATION CITY STATION

RISK ASSESSMENT FOR AIR LEAKAGE & LIGHT TESTING PROCEDURE

INVENTORY OF WORK ACTIVITIES

Company: RAK JV
No. Process/Location  Area Preparation barricading etc.
 Provision of Electricity.
 Provision of Water.
 Work At Height.
 Air Leakage and Hydrostatic Pressure Testing.
 Drainage of Water.
 Completion of Activity.

Assessed by Reviewed by Reviewed by Approved by

Name: Faisal Murad Awan Name: Mahaboob Pasha Name: Muhammad Safeer Tareen Name: John Hadfield

Designation: HSE Supervisor Designation: Construction Manager Designation: HSE Manager Designation: Project Manager

Date: Date: Date: Date:

Signature: Signature: Signature: Signature:

RISK ASSESSMENT FORM - AIR LEAKAGE & LIGHT TESTING PROCEDURE

Company RAK JV Work Activities

Conducted by:
Faisal Saeed – Mechanical Engineer
Worksite Education City Mahaboob Pasha- Construction Manager

Process/ Location: EDU Station

Next Review Date: When change in
Method or Incident happening or
increase in manpower
AIR LEAKAGE & LIGHT
Work Scope:
TESTING PROCEDURE

Checked by (Tech M):

Construction Manager Date of Review:

Kamran Akhoonzada Work Commencement date: TBC

Doc. No. : M007-RAK-MHV-PRO-00001, Rev. 2.0 2/5

Printed copy is uncontrolled and only valid at the time of printing. Always refer to the electronic copy as the latest version.
RISK ASSESSMENT FOR AIR LEAKAGE & LIGHT TESTING PROCEDURE
EDUCATION CITY STATION

1. Hazard Identification 2. Risk Evaluation 3. Risk Control

1a 1b 1c 1d 2a 2b 2c 2d 3a 3b 3c 3d 3e
Possible Accident / Action Officer

Severit

Severit
Level

Level
likely

likely
Work Existing Risk Additional Risk

hood

hood
Risk

Risk
No. Hazard Health & Persons at (Designation) (Follow-

y
Activity Control (if Any) Control
Risk up date)

1.Hazard Identification 2.Risk evaluation 3.Risk Control

1a 1b 1c 1d 2a 2b 2c 2d 3a 3b 3c 3d 3e
 Electrocution  Personnel Injury  All equipment’s under test has been  Unauthorized entry restricted.
 Fire / Flash over  Property Damage correctly installed and inspected and issued  TBT must be conducted for all the
 Short Circuit  Fatality with a safety clearance certificate. activities.
 Noise / Vibration  48 Hrs. notice to CCC/sub cones prior to  Magnehelic must be calibrated and
 Unauthorized Entry the testing. certificates must be available.
 Slip, trip and fall  Commissioning procedure must be  Only qualified workers assigned for the
 Negligence and lack of available and same must be followed. job.
awareness  Ensure air compressor is operating  Worn out, damaged and make-shift
 Wrong identification of accordance with the Manual. tools not to be used at site.
valve.  Follow PTW System  Stand by person must be near to the
 Unfamiliar to the  Authorized Switching persons shall be Fan/Compressor.
equipment available to perform necessary switching  Ensure adequate lighting is provided at
 Inadequate access/egress. during testing. work location.
 Improper Coordination  LOTO procedure and Emergency response  Emergency procedure must be
Air Leakage & Commissioning Team, HSE Officers,
1 procedures are established and 5 3 15 conveyed to all the workmen before 5 1 5
Light Testing Commissioning Engineer/ Supervisor
communicated. starting the testing and commissioning
 Supervisor to ensure that electrical systems works.
are in safe condition for test and  Close Supervision must be available
commissioning. during testing and commissioning.
 All area must be barricaded with warning  Egress and Access must be clear from
tape and safety cones and appropriate sign obstruction.
boards must be available wherever
applicable.
 Appropriate PPEs to be used.
 Appropriate Fire Extinguisher must be
available.
 First-Aider with sufficient medical aids
must be available.
 Emergency vehicle must be available.
 Improper cable  Death or serious  Proper cable management, Ensure proper  Daily visual inspection of electrical
management injuries to personal earthing. equipment.
 Burns/Electric shock working for the  Use of ELCB’s in distribution boards,  Regular inspection of distribution
Provision of  Electrocution specific task and  PAT Test should be conduct and kept network and equipment lose
2 electricity at  Fire, trip, fall other co employees. record for tracking. 5 3 15 connections. 5 1 5 Electrical Supervisor
working area  Training of workers for safe use of
electrical equipment.
 Use of Proper Nonconductor Cable
Hangers
 Fall from height collapse  Death or serious  Adequate Supervision to ensure  Certified Scaffolding.
of scaffolding, Injury to workers good housekeeping of the area  Inspection (Daily & weekly basis),
 Material fall, collision / at scaffold and  Proper/Less stacking of materials Tag, Supervision,
unauthorized use MEWP,  No employee will be at the scaffold  PPE (Suitable Fall Protection),
 Collapse / over- turning  other workers, when Movement of mobile scaffold is  Training and Tool Box Talk. Skilled
Work at height  Faulty outriggers  supervisor, needed. Workers.
3 (Scaffolding,  Unstable Ground  engineer 5 3 15  Task briefing on ergonomics 5 1 5 HSE Supervisor, Site Engineer
MEWP) conditions  In case of Collapse Nurses and Crane
 Person hanging with FBH will be used to Rescue of victim by
may face suspension Rescue basket/ Stretcher. Call 999 (as
Trauma. advised by main contractor)
 In case of an emergency Rescue Plan
of Main contractor will be followed.

Doc. No. : M007-RAK-MHV-PRO-00001, Rev. 2.0 3/5

Printed copy is uncontrolled and only valid at the time of printing. Always refer to the electronic copy as the latest version.
RISK ASSESSMENT FOR AIR LEAKAGE & LIGHT TESTING PROCEDURE
EDUCATION CITY STATION

 MEWP will be operated by certified

operator,
 Area will be barricaded to stop
unauthorized entry.
 First aid measures will be deployed
 Implement the main contractor’s
rescue plan
 If crews at the scene do not have full
rescue capability, call for additional
resources
 Request the attendance of the
Ambulance Service (if not already in
attendance)
 A casualty who is experiencing pre-
syncopal symptoms or who is
unconscious whilst suspended in a
harness, should be rescued (10 mints)
by nearby scissor lift, MEWP or as
soon as is safely possible to avoid
suspension trauma.
 Risk of exposure to  Personal Injury  Strict Supervision by competent staff.  Adequate Supervision
injury  Trained on ergonomics and manual  Training and guidance by a
Incompetent  Damage of material and handling safety competent personnel.
personnel tools  Competency training will be arrange for all  Knowledge of hazards and HSE Supervisor, Supervisors,
4 3 2 6 method statements will be 3 1 3
assigned for personnel before start the activity. Engineers
the job.  Site safety induction will be compulsory convey by the competent
for all workers, supervisory staff, supervisors.
management, and visitors.

Doc. No. : M007-RAK-MHV-PRO-00001, Rev. 2.0 4/5

Printed copy is uncontrolled and only valid at the time of printing. Always refer to the electronic copy as the latest version.
RISK ASSESSMENT FOR AIR LEAKAGE & LIGHT TESTING PROCEDURE
EDUCATION CITY STATION

Table I: Accident Severity categories

Catastrophic 5  Single or multiply loss of life from injury or occupational disease, immediately or delayed: and/or
 Loss of whole production for greater than 3 man days and /or
 Total loss in excess of S$ 1 million
Moderate 4  Hospital care over 72 man hours.
 Broken/fractured bones, loss of sight, major burns.
 Total loss in excess of QR 0.5 million but up to QR 1 million
Major 3  Causing Major Injuries (e.g. unconsciousness, heat stroke)
 Hospital care in excess of 24 hours
 Damage to works or plant causing delay of up to 1 man-days: and /or
 Total loss in excess of QR250,000 but up to QR 0.5 million
Serious 2  Causing significant injuries (e.g. Cuts requiring stitches, laceration, burn) Hospital care for less than 24 hours
Minor 1  Minor injury, no lost time or person involved returns to work during the shift
 Minor damage to works or plant does not cause significant delays.

Table II: Risk Index Matrix

Accident Severity Category

(5) (4) (3) (2) (1)
Catastrophic Moderate Major Serious Minor
(5) Frequent 25 20 15 10 5
(4) Probable 20 16 12 8 4
(3) Occasional 15 12 9 6 3
(2) Remote 10 8 6 4 2
(1) Improbable 5 4 3 2 1

Likelihood Rating Description

Frequent 5 Likely to occur repeatedly
Probable 4 Likely to occur more than once
Occasional 3 Could possibly occur
Remote 2 Unlikely to occur
Improbable 1 Extremely unlikely to occur based on judgment and where possible, supported by industry
experience

Table III: Definition of Risk Index

Risk Index Description Definition

1-5 Acceptable Further action may not be necessary
6-10 Moderately Acceptable Further action is to taken where reasonably practicable to do so.
12-16 Not Acceptable Management attention is required.
A careful evaluation of the hazards should be carried out to ensure that the risk level is
reduced to as low as is practicable within a defined period of time.
Interim risk control measures, such as administrative controls may be implemented.
20-25 Strictly Not acceptable Immediate management intervention is required before work commences.
Very high risk level must be reduced to at least Medium Risk before work commences.
There should not be any interim risk control measures and should not be overly dependent on
personal protective equipment or appliances. If need be, the hazard should be eliminated
before work commences.

Doc. No. : M007-RAK-MHV-PRO-00001, Rev. 2.0 5/5

Printed copy is uncontrolled and only valid at the time of printing. Always refer to the electronic copy as the latest version.
 APPENDIX 2
List of Duct Work

Document Number: M007-RAK-MHV-PRO-00001 Rev 2.0

Uncontrolled if printed, refer to EDMS for current version
 MEP Testing and Commissioning
Prepared By
MEP Testing and Commissioning Department
Department
Date 19/7/2017

MAJOR STATION EDUCATION CITY STATION MEP WORKS DUCT LEAKAGE TEST CLASSIFICATION
Static
Pressure Static Pressure
Project
S/No
Code
Unit Tag Discipline (positive Supply Duct Pressure Classification Leakage Test Condition (positive or Extract Duct Pressure Classification Leakage Test Condition Remarks
or negative)
negative)

AHU IN EDUCATION CITY STATION

%10 Pressure Leakage Testing Recommended
1 M007 M007-EDU-VAC-AHU -MX-01 HVAC Positive 750 Pa Medium Pressure Duct (500<x<1000 Pa) N/A N/A N/A N/A
(may be light tested)

%10 Pressure Leakage Testing Recommended

2 M007 M007-EDU-VAC-AHU -MX-02 HVAC Positive 750 Pa Medium Pressure Duct (500<x<1000 Pa) N/A N/A N/A N/A
(may be light tested)

%10 Pressure Leakage Testing Recommended

3 M007 M007-EDU-VAC-AHU -MX-03 HVAC Positive 750 Pa Medium Pressure Duct (500<x<1000 Pa) N/A N/A N/A N/A
(may be light tested)

%10 Pressure Leakage Testing Recommended

4 M007 M007-EDU-VAC-AHU -MX-04 HVAC Positive 750 Pa Medium Pressure Duct (500<x<1000 Pa) N/A N/A N/A N/A
(may be light tested)

%10 Pressure Leakage Testing Recommended

5 M007 M007-EDU-VAC-AHU -MX-05 HVAC Positive 650 Pa Medium Pressure Duct (500<x<1000 Pa) N/A N/A N/A N/A
(may be light tested)

%10 Pressure Leakage Testing Recommended

6 M007 M007-EDU-VAC-AHU -MX-07 HVAC Positive 650 Pa Medium Pressure Duct (500<x<1000 Pa) N/A N/A N/A N/A
(may be light tested)

%10 Pressure Leakage Testing Recommended

7 M007 M007-EDU-VAC-AHU -MX-08 HVAC Positive 950 Pa Medium Pressure Duct (500<x<1000 Pa) N/A N/A N/A N/A
(may be light tested)

8 M007 M007-EDU-VAC-AHU -CL-01 HVAC Positive 350 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) N/A N/A N/A N/A

9 M007 M007-EDU-VAC-AHU -CL-03 HVAC Positive 500 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) N/A N/A N/A N/A

10 M007 M007-EDU-VAC-AHU -CL-04 HVAC Positive 500 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) N/A N/A N/A N/A

11 M007 M007-EDU-VAC-AHU -CL-05 HVAC Positive 350 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) N/A N/A N/A N/A

12 M007 M007-EDU-VAC-AHU -CL-06 HVAC Positive 350 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) N/A N/A N/A N/A

13 M007 M007-EDU-VAC-AHU -AG-01 HVAC Positive 450 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) N/A N/A N/A N/A

14 M007 M007-EDU-VAC-AHU -AG-02 HVAC Positive 450 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) N/A N/A N/A N/A

15 M007 M007-EDU-VAC-AHU -AG-03 HVAC Positive 350 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) N/A N/A N/A N/A

16 M007 M007-EDU-VAC-ERU-AG-01 HVAC Positive 400 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) Negative 350 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

17 M007 M007-EDU-VAC-ERU-AG-02 HVAC Positive 400 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) Negative 350 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

18 M007 M007-EDU-VAC-ERU-AG-03 HVAC Positive 600 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) Negative 450 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

19 M007 M007-EDU-VAC-ERU-AG-04 HVAC Positive 400 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested) Negative 350 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)
SMOKE FAN IN Education City STATION
1 M007 M007-EDU-VAC-SF-AG-01 HVAC N/A N/A N/A N/A Negative 300 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

SPECIAL VENTILATION FAN IN Education City STATION

Medium Pressure Duct %10 Pressure Leakage Testing
1 M007 M007-EDU-VAC-SEF-MX-01 TO 03 HVAC N/A N/A N/A N/A Negative 850 Pa
(500<x<1000 Pa) Recommended (may be light tested)
Medium Pressure Duct %10 Pressure Leakage Testing
2 M007 M007-EDU-VAC-SEF-MX-04 & 05 HVAC N/A N/A N/A N/A Negative 850 Pa
(500<x<1000 Pa) Recommended (may be light tested)
Medium Pressure Duct %10 Pressure Leakage Testing
3 M007 M007-EDU-VAC-PRF-AG-01 TO 03 HVAC N/A N/A N/A N/A Negative 550 Pa
(500<x<1000 Pa) Recommended (may be light tested)
Medium Pressure Duct %10 Pressure Leakage Testing
4 M007 M007-EDU-VAC-PRF-AG-04 TO 06 HVAC N/A N/A N/A N/A Negative 800 Pa
(500<x<1000 Pa) Recommended (may be light tested)
%10 Pressure Leakage Testing
5 M007 M007-EDU-VAC-PRF-AG-07 & 08 HVAC N/A N/A N/A N/A Negative 250 Pa Low Pressure Duct (x<500 Pa)
Recommended (may be light tested)
%10 Pressure Leakage Testing
6 M007 M007-EDU-VAC-PRF-AG-09 & 10 HVAC N/A N/A N/A N/A Negative 400 Pa Low Pressure Duct (x<500 Pa)
Recommended (may be light tested)

OTE DUCT IN Education City STATION

%10 Pressure Leakage Testing
1 M007 OTE Duct HVAC N/A N/A N/A N/A TBA TBA TBA
Recommended (may be light tested)
%100 Light Test Recommended
2 M007 OTE Duct (in Actual Fire Zone) HVAC N/A N/A N/A N/A TBA TBA TBA
Pressure Tested if Required

Other FANS IN Education City STATION

1 M007 M007-EDU-VAC-EF-AG-01 & 02 HVAC N/A N/A N/A N/A Negative 250 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

2 M007 M007-EDU-VAC-EF-AG-03 & 04 HVAC N/A N/A N/A N/A Negative 250 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

3 M007 M007-EDU-VAC-EF-MX-01 HVAC N/A N/A N/A N/A Negative 250 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

4 M007 M007-EDU-VAC-EF-CL-01 HVAC N/A N/A N/A N/A Negative 200 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

5 M007 M007-EDU-VAC-EF-CL-02 HVAC N/A N/A N/A N/A Negative 200 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

6 M007 M007-EDU-VAC-EF-CL-03 & 04 HVAC N/A N/A N/A N/A Negative 250 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

7 M007 M007-EDU-VAC-EF-CL-05 HVAC N/A N/A N/A N/A Negative 200 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

8 M007 M007-EDU-VAC-EF-CL-06 HVAC N/A N/A N/A N/A Negative 200 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

9 M007 M007-EDU-VAC-EF-CL-07 HVAC N/A N/A N/A N/A Negative 250 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

10 M007 M007-EDU-VAC-EF-CL-08 & 09 HVAC N/A N/A N/A N/A Negative 250 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)

11 M007 M007-EDU-VAC-EF-AG-05 HVAC N/A N/A N/A N/A Negative 100 Pa Low Pressure Duct (x<500 Pa) Test not Mandatory (may be light tested)
 APPENDIX 3
Sketch & Details of Measuring Device

Document Number: M007-RAK-MHV-PRO-00001 Rev 2.0

Uncontrolled if printed, refer to EDMS for current version
 Du ct Lea kag e Te ster s

Positive and Negative Duct

Accreditation (PANDA) System
Airflow Instruments
Model PAN341 Series
(PANDA Light)

Operation and Service Manual

 CONTENTS

CHAPTER 1 UNPACKING AND PARTS IDENTIFICATION ............. 1

CHAPTER 2 PREPARING PAN341 SYSTEM FOR AIR DUCT
LEAK TESTING ................................................................................... 5
CHAPTER 3 PERFORMING A DUCT LEAKAGE TEST ................ 11
Measuring Duct Static Pressure ................................................... 11
Measuring Duct Leakage Flow ..................................................... 12
Turning on the PAN341 Duct Leakage Tester.............................. 12
Using Leakage Test Application in the Model TA465-P ............... 12
Troubleshooting Guide ................................................................. 16
APPENDIX A SPECIFICATIONS ..................................................... 17
APPENDIX B LEAKAGE TESTING STANDARDS HIGHLIGHTS.. 21
Standards Supported .................................................................... 21
EU Standards ............................................................................... 22
US Standards ............................................................................... 25
APPENDIX C TYPICAL SETUP....................................................... 29

iii
Chapter 1

Unpacking and Parts Identification

Carefully unpack the PANDA system and instrument cases from the
shipping container. Check the individual parts against the list of
components below. If anything is missing or damaged, notify TSI
immediately.

The PANDA system consists of the following:

Qty Description Part Number Reference Picture

1 Low flow nozzle 6002598

1 Primary duct adapter 6002638

spigot plus rubber bung
(to fit to test duct)

1 Cam lock primary spigot 6002607

(to connect flexi-duct to
PANDA)

2 Ø4-in. (100-mm) 6002683

adjustable over lock
straps

1 13-ft (4-m) long 6002667

Ø4-in. (100-mm) plastic
flexible duct

2 20-in. (500-mm) silicone AFL9020004

tubes (red)

1
Qty Description Part Number Reference Picture
2 20-in. (500-mm) silicone AFL9020005
tubes (blue)

1 16-ft (5-m) silicone tube AFL9020005

(blue)

1 K-type thermocouple AFL82859201

probe
3 Instrument adapter AFL82859401

1 Instrument Box 6006490

1 Flex Duct Carry Tube 6006491

1 Operation and Service 6006694

manual

2 Chapter 1
The following two instruments should be used in conjunction with the
PANDA unit:

TA465-P Multi-function Refer to TA465 Operation and

Instrument Service Manual supplied with the
instrument for additional parts
supplied as standard.

PVM610 Refer to PVM610 Operation and

Micromanometer Service Manual supplied with the
instrument for additional parts
supplied as standard.

(continued on next page)

3
 IMPORTANT—
Read Before Using the PANDA for the First Time
It is IMPORTANT that the 110V PANDA (yellow power socket) be
connected only to 110V to 120V supplies. Connecting it to a higher
voltage supply will permanently damage the inverter.
The 220V/240V PANDA (blue power socket) should only be
connected to 200V to 240V power supplies.
When storing the PANDA in a vertical position, please ensure that the
straps holding the instrument box are in place and tightened first.
The PANDA is designed so that the Instrument box and duct carry
tube are removable to lighten the load when lifting.

Panda Models

Model Description
PAN315 220/240v, Instruments not included
PAN315-110 110/120v, Instruments not included
PAN341 PAN315 with instruments
PAN341-110 PAN315-110 with instruments

4 Chapter 1
Chapter 2

Preparing PAN341 System for Air Duct Leak

Testing
Carefully follow the procedures below to achieve safe and accurate
leakage testing:

Successfully completing a duct leakage test requires compiling

certain information prior to starting the test. Refer to
Appendix B for a discussion of standards relating to duct
leakage testing. The list below indicates the information
required:
• Type of leakage test to be performed (Positive or
negative).
• Leakage standard to be followed.
• Air tightness/leakage class to be achieved
• Amount of ductwork to be tested, such as the complete
system or a statistical sample.

1. Select the section of the ductwork to be tested.

2. Calculate the surface area of the ductwork of the section to
be tested.
3. Temporarily seal all the openings of the ductwork except one,
which will be connected to the PAN341 duct leakage tester.
4. Position the PAN341 unit as close to the remaining opening in the
ductwork as possible to minimize the flexible tubing needed.
Minimize bends in the flexible tubing to reduce the pressure loss,
giving the best performance.
5. Make sure the Fan Run/Stop Switch on the Fan Speed Controller
is in the Stop position and the multi-turn Fan Speed Control
potentiometer is fully turned counter-clockwise using the picture
of the VFD in Figure 1 as a reference. Plug the cord into the
PANDA unit as shown in Figure 2 and Figure 3. Then connect the
other end of the cord to a suitable electrical supply.

CAUTION
Remove the power cord from the PANDA duct leakage tester before
tilting it to the vertical position to avoid damaging the cord.

5
 Fan Speed Control

Fan Run/Stop Switch

Figure 1. Fan Speed Controller

Note: The settings for the inverter have been locked and cannot be
changed using the key pad.

Figure 2. Receptacle for Figure 3. Connected Power Cord

Power Cord

Note: The 110V unit has a yellow receptacle and the 230V unit has
a blue receptacle.

6 Chapter 2
6. Fit the primary duct adapter
spigot (black sheet metal with
rubber bung) to one end of the
4-in. (100-mm) diameter flexi-
tube. Make an air-tight seal
using one of the over lock
straps and lever-locking cam
provided as shown in Figure 4.
Adjust the fit of the over lock
strap with a screwdriver.
7. Securely attach the black
primary duct adapter
spigot/flexi-tube assembly to
the opening on the ductwork
to be pressure tested. Figure 4. Flex Ductwork
Connected to Primary Adapter
Spigot. Bung not shown.
8. If the static pressure tap on the
black Primary Duct Adapter is
open to the duct, connect the
16-ft (5-m) long blue silicone
tube to it as shown in Figure 5.
If the static pressure tap on the
black Primary Duct Adapter is
not open to the duct, drill a
4-mm hole in the duct and
insert about 6 inches (10 mm)
of the silicone tube into the
duct. Seal around the hole
with putty.
Figure 5. Connecting Pressure
9. Connect the other end of the Tubing to Tap on Primary Duct
4-in. (100-mm) flexi-tube to the Adapter. Bung not shown.
cam lock connector (grey cast
aluminum without nozzle). Make an airtight seal using the other
over lock strap (not shown) and lever-locking cam provided.
Adjust the fit of the over lock strap with a screwdriver.

Preparing PAN341 System for Air Duct Leak Testing 7

10. Determine if you are going to perform a high- or low-flow testing
and positive or negative testing. Set-up the duct leakage
tester by:
a. For positive pressure, high-
flow testing, remove the
low flow nozzle if it is
installed. Then, connect
the grey cast-aluminum
cam lock connector to the
outlet side of the blower
per Figure 6. Close both
cam lock arms at the same
time to ensure proper fit.
Connect the free end of the Cam Lock Fan Outlet
static pressure 16-ft (5-m) Connector
silicone tube to the positive
Figure 6. Positive Pressure,
pressure connector on the
High-Flow Setup
PVM610.
Finally, connect the FLOW GRID pressure taps marked
P1(+) and P2(-) to the appropriate connectors on the
TA465-P using the red and blue tubing.
b. For positive pressure, low- Low Flow
flow testing, add the low- Fan Inlet
Nozzle
flow nozzle to the blower
inlet if it is not installed per
Figure 7. Then, connect
the grey cast-aluminum
cam lock connector to the
outlet side of the blower
per Figure 6. Close both
cam lock arms at the same
time to ensure proper fit.
Connect the free end of the
Figure 7. Positive Pressure,
static pressure 16-ft (5-m) Low-Flow Setup
silicone tube to the positive
pressure connector on the
PVM610.
Finally connect the pressure taps marked P1(+) and P2(-) on
the nozzle to the appropriate connectors on the TA465-P
using the red and blue tubing.

8 Chapter 2
 c. For negative pressure,
high-flow testing, remove
the low flow nozzle if it is
installed. Then, connect
the grey cast aluminum
cam lock connector to the
inlet side of the blower per
Figure 8. Close both cam
lock arms at the same time
to ensure proper fit. Fan Inlet Cam Lock
Connector
Connect the free end of the
static pressure 16-ft (5-m) Figure 8. Negative Pressure,
High-Flow Setup
silicone tube to pressure
connector on the PVM610.
Finally connect the pressure taps marked P1(+) and P2(-) to
the appropriate connector on the TA465-P using the red and
blue tubing.
d. For negative pressure, low- Low-Flow Nozzle
flow testing, add the low-
flow nozzle to the blower
inlet if it is not installed.
Then, connect the grey
cast aluminum cam lock
connector to the low-flow
nozzle per Figure 9. Close
both cam lock arms at the
Fan Inlet Cam Lock
same time to ensure
Connector
proper fit.
Figure 9. Negative Pressure,
Connect the free end of the
Low-Flow Set-Up
static pressure 16-ft (5-m)
silicone tube to the positive
pressure connector to the
PVM610.
Finally connect the pressure taps marked P1(+) and P2(-) on
the nozzle to the appropriate connectors on the TA465-P
using the red and blue tubing.

Preparing PAN341 System for Air Duct Leak Testing 9

Chapter 3

Performing a Duct Leakage Test

The PAN341 duct leakage test system includes a Model PVM610

Micromanometer and a Model TA465-P Ventilation Meter. During duct
leakage testing, the Model PVM610 Micromanometer measures the
duct static pressure while the Model TA465-P Ventilation Meter
measures the airflow rate.

Refer to the Operation and Service Manuals for the Model PVM610
Micromanometer and the Model TA465-P Ventilation Meter to use
these instruments in other applications. If you do not have the
manuals, download them from TSI’s website www.tsi.com.

Measuring Duct Static Pressure

1. Turn ON the Model PVM610.
2. Zero the Model PVM610 pressure sensor with both ports open to
the atmosphere.
3. Connect the (+) port on the Model PVM610 to measure the duct
static pressure (see Figure 5).
4. Leave the (-) port on the Model PVM610 open to the atmosphere.

Note: Refer to the Model PVM610 Operation and Service

Manual for instruction on use.

11
Measuring Duct Leakage Flow
1. Turn ON Model TA465-P. P1(+) and P2(-) Flow Grid
2. Zero the Model TA465-P pressure Pressure Connections
sensor with both ports open to the
atmosphere.
3. Connect the Model TA465-P to
the PAN341 by connecting the (+)
and (-) ports on the Model TA465-
P to the P1 (+) and P2 (+) ports
located on the inside edge of the
box shelf facing the fan. See
Figure 10.
Box Shelf Thermocouple
4. Connect the thermocouple to the
Model TA465-P. Figure 10. Connecting
5. Insert the thermocouple probe Instruments to PANDA Tester
in High Flow Mode
into the blower inlet through the
hole marked TC1.

Turning on the PAN341 Duct Leakage Tester

1. Power the PANDA unit on by plugging in the power cord.
2. Position the Fan Control switch to the RUN position to energize
the fan.
3. Increase the fan to the desired speed by turning the Fan Speed
Controller clockwise. To decrease the fan speed, turn the Fan
Speed controller counter-clockwise.

Using Leakage Test Application in the Model TA465-P

CAUTION
The Model PVM610 and Model TA465-P meters must be zeroed
before entering the Leakage Test Application.

12 Chapter 4
1. Press the MENU key to access
MENU
the menu system on the
Model TA465-P. Zero Press
Display Setup
2. Use the
 keys to highlight Settings
the Applications item.
Flow Setup
3. Press the (ENTER) key to Actual/Std Setup
access the Applications menu. Data Logging
Zero CO
Applications
Calibration
Discover Printer

4. Select Leakage Test and

APPLICATIONS
press key.
Draft Rate
Heatflow
Turbulence
% Outside Air
Leakage Test

5. Select either the EN Standard

LEAKAGE TEST
or SMACNA leakage test.
EN Standard
SMACNA

Instrument Operation if EN Standard Test Protocol is Selected

1. Enter key parameters:
LEAKAGE TEST
a. Surface Area of ductwork Surface Area
section to be tested. Static Pressure
b. Static Pressure of test, as Flow Device
measured by Model Tightness Class
PVM610 micromanometer. Test Length
c. Flow Device as Nozzle or Run Test
Flow Grid.

Performing a Duct Leakage Test 13

 d. Leakage class as A, B, C, or D. Note that tests with negative
pressures must be selected as negative tests, as indicated
by -.
e. Test Length, or duration of leakage test, usually 5 minutes.
2. Increase the blower speed until
the desired static pressure is
LEAKAGE TEST
achieved. Leakage Factor x.xx
Leak Limit x.xx
3. When the static pressure has Leak Rate x.xx
stabilized, select Run Test and
press .
Status OK
Flow Device Flow Grid
4. The display will show the Baro Pressure 20.20
readings on the right. Leakage Temperature 20°C
Factor and Leak Rate will
update in real time, while other
Time 9:55
parameters will remain constant. Standard TestXXX
Sample
If the Leakage Factor and Leak 0
Rate are sufficiently stable,
press the START soft key or the
(Sample Saved 1)
key to begin the leak test.
Pressing the ESC key will exit
back to the previous screen.
5. After the leak test is complete, the Model TA465-P will prompt you
to press the SAVE or PRINT soft key. You can also press the ESC
key here to back out to the previous screen without saving the
data.

After completing leakage testing for a section of duct, you can move
onto the next section.

Instrument Operation if SMACNA Test Protocol is Selected

1. Enter key parameters:
LEAKAGE TEST
a. Surface Area of ductwork Surface Area
section to be tested. Static Pressure
b. Static Pressure of test, as Flow Device
measured by Model Leakage Class
PVM610 micromanometer. Test Length
c. Flow Device as Nozzle or Run Test
Flow Grid.

14 Chapter 4
 d. Leakage class as a number LEAKAGE TEST
from 1 to 48. Typical values Leakage Factor x.xx
are 3, 6, 12, 24, or 48. Leak Limit x.xx
e. Test Length, or duration of Leak Rate x.xx
leakage test. Status OK
2. Increase the blower speed
Flow Device Flow Grid
until the desired static pressure Baro Pressure 20.20
is achieved. Temperature 20°C
Time 9:55
3. When the static pressure has
stabilized, select Run Test and Standard TestXXX
press . Sample
0
4. The display will show the (Sample Saved 1)
readings on the right. Leakage
Factor and Leak Rate will
Stop(Save) Print
update in real time, while other
parameters will remain constant.
If the Leak Factor and Leak Rate are sufficiently stable, press the
START soft key or the key to begin the leak test. Pressing the
ESC key will exit back to the previous screen.
5. After the leak test is complete, the Model TA465-P will prompt
you to press the SAVE or PRINT soft key. You can also press the
ESC key here to back out to the previous screen without saving
the data.

After completing leakage testing for a section of duct, you can move
onto the next section.

Performing a Duct Leakage Test 15

Troubleshooting Guide
Symptom
Fan motor will not run.
Static pressure reading (on
PVM610) is zero.
Static pressure reading (on
PVM610) is too low.
Required static pressure cannot
be achieved with motor speed
control settings at the maximum.
Leak Flow (on TA465-P) shows
flashing XXX.XX.
16
Recommended Action
• Check the power connection.
• Circuit Breaker may have
tripped.
• Check the connections.
• Leakage rate is too high.
Check for leaks using soap
bubbles or smoke pallets.
Alternatively, test a smaller
section of the ductwork.
• Check the pressure tube
connections to the TA465-P
meter.
• Leak flow is too low. Use low
flow nozzle adapter.
Chapter 4
Appendix A

Specifications

Pressure Measurement (PVM610)

Range ± 3,735 Pa ±15 inwg
Resolution 0.1 Pa 0.001 inwg
Accuracy ±1% of reading ±1% of reading
±1 Pa ±0.005 inwg
Actual duct static range 2500 Pa at 0 Flow 10 inwg at 0 Flow
Volume Flow Measurement (TA465-P)
High Leakage Range 10 to 200 l/s 21 to 424 cfm
3
(Flow Grid): 36 to 720 m /hr
Low Leakage Range 1 to 13 l/s 2 to 27.5 cfm
(15 mm Low Flow Nozzle 3.6 to 46.9 m3 /hr
Adapter)
Accuracy ± 2.5% of reading ± 2.5% of reading
± 0.01 l/s ± 0.02 cfm
± 2.5% of reading
± 0.04 m3 /hr
Resolution 0.01 l/s 0.01 cfm
3
0.01 m /hr
Temperature Measurement (TA465-P)
K Type Thermo Couple Probe To EN60584 (IEC 584)
Barometric Pressure Measurement (TA465-P)
Range 690 to 1,241 hPa 20.36 to
36.648 in Hg
517.5 to
930.87 mm Hg
Accuracy ±2% of reading ±2% of reading
Weight
Carry Weight 45 Kg 99 lbs
Total Weight 55 Kg 121 lbs
Dimensions (LxWxH)
1,130 mm x 660 44.5 in x 26 in x
mm x 600 mm 23.5 in
Power Requirements
230V Version 220 to 240 V, 1 Phase, 50/60 Hz 10A
110V Version 110 to 120 V, 1 Phase, 50/60 Hz 16A
TA465-P and PVM610
See specification sheets for details on
individual instruments
(Specifications are subject to change without notice.)

17
 Panda Fan Performance Graph (metric units)

3000

2500

2000

.a
P
e
r
u
ss
e
r 1500
P
ict
at
S

1000

500

0
0 50 100 150 200 250
Volume Flow l/s

18 Appendix A
 Panda Fan Performance Graph (imperial units)

11

10

7
Static Pressure ins.wg.

0
0 50 100 150 200 250 300 350 400 450 500

Volume Flow CFM

Specifications 19
Appendix B

Leakage Testing Standards Highlights

Different standards are used throughout the world to specify duct air
tightness and leakage requirements. The PAN341 duct leakage test
system has a duct leakage application to automatically compare the
actual leakage flow with the maximum allowed leakage flow for EN
and SMACNA standards. Field technicians can also use the duct
leakage application to determine actual leakage flow and manually
compare it to maximum leakage from another standard. The PAN341
duct leakage test system cannot determine the appropriate leakage
classification for a given duct.

Standards Supported
US- or
EU-
Standard Based Description
BS EN 12237:2003 EU Ventilation for buildings—
Ductwork—Strength and leakage of
circular sheet metal ducts.
BS EN 1507:2006 EU Ventilation for buildings—Sheet
metal air ducts with rectangular
section—Requirements for strength
and leakage.
DW/143 EU HVAC—A practical guide to
Ductwork leakage testing.
Eurovent 2/2 EU Air leakage rate in sheet metal air
distribution systems.
SMACNA HVAC Air US Duct construction leakage
Duct Leakage Test classification, expected leakage
manual, First edition, rates for sealed and unsealed
1985 ductwork, duct leakage test
procedures, recommendations on
use of leakage testing, types of test
apparatus and test setup and
sample leakage analysis.

TSI has made every effort to accurately reflect the standards

referenced. Please refer to the actual standards for more detailed
information and to make the best interpretation of each statement.

21
The scope of the standards listed above includes many items other
than duct leakage. This summary, however, is limited to duct
leakage testing.

EU Standards
Ductwork classification and maximum air leakage. Note that EN1507,
EN12237 Eurovent 2/2 and DW/143 all have the same formula to
determine fmax, the Air Leakage Limit, although DW/143 uses units of
2 3 2
l/s/m whereas others use m /s/m .

• EN 1507 (rectangular ductwork)

Static Pressure Limit (ps) Pa

Air Air Leakage Positive at
Tightness Limit (fmax) pressure class
3 2
Class m /s/m Negative 1 2 3
A 200 400

B 500 400 1000 2000

C 750 400 1000 2000

D* 750 400 1000 2000

* Class D ductwork is only for special apparatus

• EN12237 (circular ductwork)

Air Air leakage Static Pressure Limit (ps)

Tightness limit (fmax) Pa
3* 2
Class m /s/m Negative Positive
A 500 500

B 750 1000

C 750 2000

D* 750 2000

* Class D ductwork is only for special apparatus

22 Appendix B
• Eurovent 2/2 Air Tightness For Installed Duct Testing:

Air Tightness Air leakage limit (fmax)

3 / 2
Class m /s m
A

• DW/143: A Practical Guide to Ductwork Leakage Testing

Static Pressure Maximum

Duct Limit Air Air leakage
Pressure Positive Negative Velocity limits
2
Class Pa Pa m/s l/s/m
0.65
Low-pressure 500 500 10 0.027*pt
– Class A
0.65
Medium- 1000 750 20 0.009*pt
pressure –
Class B
0.65
High pressure 2000 750 40 0.003*pt
– Class C

Figure 11. Allowable Air Leakage Rates from DW/143

Leakage Testing Standards Highlights 23

• The measured leakage flow rates shall be corrected if the
temperature and/or barometric pressure are different from
standard conditions (+20ºC and 101 325 Pa) as follows:

where:
qv=corrected flow leakage rate
qmeasured = measured flow leakage rate
t = measured temperature (ºC)
p = measured barometric pressure (Pa)
• The test report shall give the following general information of the
test performed:
o Date and place
o Test personnel and witness
o Test equipment, including pressuring means and measuring
instruments
o Air temperature and barometric pressure during the test
o Building and project reference
o Design of installed ductwork including dimensions, thickness
of materials, types of stiffening, length, type of duct/tubes and
fittings, assembly method and distance of hangers/supports
o Required air tightness class and design operating pressure of
the installed ductwork
o Installer of ductwork
o Manufacturer of the ductwork
o Measured values of:
1. Ductwork surface area (A)
2. Total joint length (L)
3. Test pressure (ptest)
4. Leakage flow rate (qv) corrected for temperature and
barometric pressure
5. Pressurizing time
o Calculated values of
1. Leakage factor (f)
2. Air leakage limit (fmax) according to the formulas given in
table above at the measured test pressure (ptest)
o Air tightness class achieved

24 Appendix B
• For tests including several test pressures it is recommended to
plot the leakage factors as a function of test pressure in a
diagram together with the air leakage limit curve.

US Standards
Ductwork classification and maximum air leakage

Duct Class ½-, 1-, 2-inwg 3-inwg 4-, 6-, 10-inwg

Seal Class C B A
Transverse Joints, Seams
Sealing Transverse
Joints and and All Wall
Applicable Joints Only
Seams Penetrations
Leakage Class
Rectangular
24 12 6
Metal
Round
12 6 3
Metal

Maximum air leakage is then defined as

F=CLP0.65

where: F = Maximum air leakage (cfm/100 ft2)

CL = Leakage class
P = Pressure (inwg)

Figure 12. Allowable Air Duct Leakage from Round Ducts,

per SMACNA Standard

Leakage Testing Standards Highlights 25

 Figure 13. Allowable Air Duct Leakage from Rectangular Ducts,
per SMACNA Standard

• The SMACNA standard does not generally require correcting

leakage flow rates to standard conditions, unless:
1. Air temperature <40ºF or >100ºF
2. Elevation <1500 ft above sea level
3. Duct static pressure <-20 inwg or >+20 inwg
Should one of these conditions not be satisfied, then correcting
the leakage to standard conditions may be done using one of
these formulas:
1. ACFM=SCFM * (460+T)/530
where T = actual dry bulb air temperature (ºF)
moisture is negligible
pressure between -20 and +20 inwg
2. ACFM = SCFM * 0.075/d
where d = air density from psychrometric chart
3
3. ACFM=lb dry air/minute * humid volume (ft /lb dry air)

26 Appendix B
• The SMACNA standard does not specify the information to be
reported, but instead defers to project documents. However, the
SMACNA standard does include a sample test report that
includes:
o Test date and place
o Test personnel and witness
o Building and project reference
o Duct section tested
o Specified leakage class, test pressure and duct construction
pressure class
o Measurements of:

Ductwork surface area

Leakage flow and calculations required to determine
leakage flow

Leakage Testing Standards Highlights 27

Appendix C

Typical Setup

29
 APPENDIX 4
Test Report Form

Document Number: M007-RAK-MHV-PRO-00001 Rev 2.0

Uncontrolled if printed, refer to EDMS for current version
 CONSOLIDATED CONTRACTORS GROUP S.A.L (OFFSHORE) (CCC)
MAJOR STATION EDUCTION CITY

IRE No:
AIR LEAKAGE TEST REPORT
Report No:
(DUCT WORK)
Date:

Location :

Reference Drawings :

Reference Documents :

Tested Service :

Testing Medium : Test Method : PRESSURE Light

Light Test for Duct

Section of Duct to be tested : Grid :

Outside should be dark enough : YES No Leakage Test before Insulation: YES No

Check the duct from : Below Above Side

Remarks:

Pressure Test for Duct

Physical Details Test Particulars

a. Duct to be tested (Service) : a. Duct static pressure reading Pa/psi:

Grid : b. Type of flow meaning device:

c. Range of measurement of flow measuring device:

b. Surface area of duct under test m²/ft2:
Litres/Sec/cfm.

c. Test Static Pressure Pa/psi: e. Reading of flow measuring device Pa /psi:

d. Leakage Factor Litres/sec/m²/cfm/ft2: f. Interpreted air flow leakage rate Litres/Sec/cfm:

e. Maximum permitted leakage(b x d) Litres/sec/cfm: e. Duration of Test (normally 15 minutes):

Length width and depth Periphery Area

(Meter) (Millimeters) (Millimetres) (Square meters)

Attached TEST RESULT

( Pease only note either Satisfactory or Unsatisfactory )
Documents :

Redco Construction
Redco T&C Redco QA/QC CCC QA/QC Supervision Engineer
Name, Date,
Name, Date, Signature Name, Date, Signature Name, Date, Signature Name, Date, Signature
Signature

Form No.: M007-RAK-DCM-FRM-000116 Rev 1 Issue Date 17-07-2017