27 Saip 01

Inspection Procedure
27-SAIP-01 22 August 2009

HVAC Inspection Requirements
Document Responsibility: Inspection Engineering Standards Committee
Saudi Aramco DeskTop Standards

Table of Contents
1 Scope............................................................. 2
2 Purpose.......................................................... 2
3 General.......................................................... 2
4 References..................................................... 2
Previous Issue: 29 September 2004 Next Planned Update: TBD

Revised paragraphs are indicated in the right margin Page 1 of 12
Primary Contact: Kakpovbia, Anthony E. on 966-3-8747226
Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Inspection Engineering Standards Committee 27-SAIP-01
Issue Date: 22 August 2009
Next Planned Update: TBD HVAC Inspection Requirements
1 Scope
1.1 This SAIP covers instructions for the assigned Inspector on procedures and
items to check or verify for the installation of HVAC systems.
1.2 This SAIP covers the inspection of all aspects of HVAC systems including air-
side hydronic and electrical aspects of the systems.
1.3 This procedure shall be used in conjunction with the applicable manufacturer's
installation and maintenance instruction manual.
1.4 This SAIP is intended to establish a standardized methodology by Saudi Aramco

inspection personnel in the implementation of inspection programs within Saudi
Aramco facilities. The SAIP shall not be included in purchase order or contract
documents issued to outside agencies.
2 Purpose
2.1 The purpose of this SAIP is to highlight the main HVAC items requiring
inspection.
2.2 This procedure is to insure that the main inspection requirements are met and
that the findings and corrective actions are in standard format.
3 General
31. All inspection report forms shall be submitted to the responsible

maintenance/operations personnel or project representative. Copies shall be
retained in the Inspection Unit's field files.
3.2 The inspection report for any system shall consist of the following parts:
3.2.1 Equipment identification.
3.2.2 General requirements checklist.
3.2.3 Specific system/equipment.
3.2.4 Corrective action list.
4 References
The following Standards were used in the preparation of this procedure and should be
carefully reviewed by the Inspector prior to inspecting HVAC systems:
Page 2 of 12
4.1 Saudi Aramco References
Saudi Aramco Engineering Standards

SAES-K-001 Heating Ventilating and Air Conditioning (HVAC)
SAES-K-002 Air Conditioning Systems for Essential Operating
Facilities
SAES-K-003 Air Conditioning Systems for Communication
Buildings.
SAES-K-100 Saudi Aramco Mechanical (HVAC)
Saudi Aramco Materials System Specifications

27-SAMSS-001 Packaged Water Cooled Centrifugal Chillers for
Utility Services
27-SAMSS-002 Direct Expansion Air Conditioning Systems for
Critical Services
4.2 Industry Codes and Standards
American Society of Heating, Refrigerating and Air Conditioning Engineers

ASHRAE STD 1 Guideline for Commissioning HVAC Systems
ASHRAE Handbook 1991, Applications, Chapter 34, Testing Adjusting and
Balancing
National Fire Protection Agency

NFPA 90A Standard for the Installation of Air-Conditioning
and Ventilating Systems
National Environmental Balacing Bureau

NEBB Procedural Standards for Testing, Adjusting,
Balancing of Environmental Systems
NEBB Testing, Adjusting, Balancing Manual for
Technicians
Sheet Metal and Air Conditioning Contractors National Association, Inc.

SMACNA HVAC Duct Construction Standards - Metal and
Flexible
SMACNA HVAC Air Duct Leakage Test Manual
SMACNA HVAC Systems - Testing, Adjusting and Balancing
Page 3 of 12
SMACNA Installation Standards for Residential Heating and

Air Conditioning Systems
SMACNA Rectangular Industrial Duct Construction
Standards
SMACNA Round Industrial Duct Construction Standards
Attached:
 Inspection Reports/Checklists - for all HVAC systems ( 17 pages )
 Equipment Identification
 General Requirements
 Handling Units
 Fans
 Filters
 Ducts
 Hydronic Coils
 Electric Coils
 Humidifiers
 Pumps
 Cooling Towers
 Chillers
 Hydronic Piping
 Refrigerant Piping
 Corrective Action List
Revision Summary
22 August, 2009 Revised the "Next Planned Update". Reaffirmed the contents of the document, and
reissued with editorial changes.
Page 4 of 12
EQUIPMENT IDENTIFICATION:
1. EQUIPMENT TYPE :
2. LOCATION :
3. PLANT NO. :
4. TAG NO. :
5. MNFR. DRWG NO. :
6. MANUFACTURER :
7. MODEL :
8. SERIAL NO.:
GENERAL REQUIREMENTS:
CHECKLIST ITEM FINDINGS
All equipment installed in accordance with
1.
Manufacturer's instructions and design documents.
All equipment are clean and all debris and foreign matter
2.
are removed.
3. None of the equipment and components are damaged.
Adequate clearances are provided for service and
4. maintenance as required by Manufacturer and design
drawings.
5. All equipment are installed level.
Nameplate data of all equipment are in accordance with
6. the design documentation and certified Vendor
documents.
7. Special tools are provided where required.
Spare parts are provided in accordance with the design
8 and vendor documents, and spare parts are original and
the same as the parts they are to replace.
All safety systems and devices are in place and
9.
functional.
10. Louvers are properly installed.
All air shafts and air plenums are finished without
11.
noticeable air leakage.
Provisions are made for Testing, Adjusting and
12.
Balancing (TAB) measurements.
13. All gauges and instruments are in place and functional.
Control systems are complete as per control systems
14.
vendor documents.
Ensure pressure vessels associated with A/C Plants are
15.
given individual engineering item numbers.
Page 5 of 12
Air Handling Units

1. Unit interior and exterior is free of damage.
Field-assembled air handling unit housing does not
2.
include any noticeable air leakage.
Vibration isolators (for motor-fan or entire air handling
3.
unit, as applicable) are in place and functional.
4. Access doors and access-ways are properly sealed.
Duct flexible connections to air handling units and/or fans
5. are airtight, properly aligned and ducts are supported
independent of equipment.
Starters, disconnect switches and all other electrical
6. connection are in place, operational, and meet the
requirements of the Electrical Inspector.
Condensate drain pan is sloped properly and drain
7.
piping is provided with trap.
8. Filters are in place and clean.
Lights inside AHU, where required, are the type specified
9.
and are functional.
Fans
1. Fan rotation is correct.
2. Wheel clearance and balance checked.
3. Motor and fan bearings are properly lubricated.
4. Vee belts and drive are properly aligned.
Belt tension is correct and drive set screws are tight.
5.
Belts have been checked after run-in period.
Belt guards, drive guards and protective screens are in
6.
place where indicated.
Flexible connection to duct is provided and duct is
7.
properly aligned.
Starters, disconnect switches and all other electrical
8. connections are in place, operational, and meet the
requirements of the Electrical Inspector.
Page 6 of 12
Filters
Filter size and type conform to design and certified
1.
Vendor documents.
Filters used for testing are removed and new / clean
2.
filters are in place.
Filter frame leakage is within acceptable limits of design
3.
and certified vendor documents.
4. Access for filter replacement is provided and acceptable.
5. Orientation conforms with airflow direction.
Substitute media of chemical filters, used during testing,
6. is replaced with proper service media, as per
specification.
7. Chemical filter units are properly supported.
Ducts
Air distribution duct sizes, sheet metal gauges and duct
1
configurations conform with design drawings.
Grilles, diffusers and registers (type and sizes) conform
2.
with design.
3. Registers and diffusers are open.
Each fan has been started, prior to installation of grilles
4.
and diffusers, and all debris is blown from duct work.
Ductwork is free from damage, supported properly and
5.
tightly connected to equipment and air devices.
6. Ductwork is properly aligned with building structures.
7. Duct hanger spacing is verified.
Flexible connections are provided at each fan
8.
inlet/outlet and are not in tension.
9. All fans and connecting ducts are properly aligned.
Balancing dampers are installed in each duct branch, as
10.
required.
Flexible duct installations (type and length) conform with
11.
NFPA 90A.
All dampers (manual and automatic) are operational
12.
through the full range (0-100%).
Manual dampers are locked in position, as specified in
13.
design and/or Vendor documents.
Chains or rods are provided for in-accessible and
14.
adjustable diffusers, as required.
Page 7 of 12
Ducts (Cont.)
15. Access doors are closed and tight.
Fire dampers are open and accessible through access
16.
doors.
Fire dampers are installed in accordance with SMACNA
17.
"Fire, Smoke and Radiation Damper Installation Guide".
18. Required listing label (UL) is attached to fire dampers.
Terminal units are open, set properly and supported
19.
independently from ducts.
Turning vanes are installed and properly secured in
20.
square elbows.
21. Ductwork sealed and leak-tested as required.
Air shafts and air transfer openings in walls and ceilings
22.
are finished.
Air intakes or outlets, protruding from building structure,
23. are properly reinforced and/or supported to withstand
wind pressure.
24. Duct insulation conforms with design requirements.
Hydronic Coils
Following coil data are in accordance with the design
and certified Vendor documents: size, type,
1.
construction, number of rows, fin spacing, and
orientation
Fins are not damaged and free of debris and
2.
obstructions.
Piping connections are correct as indicated on the
3.
design and certified Vendor documents
Piping is properly connected and supported to avoid
4.
stresses on coil headers.
5. Piping valves are in proper position.
Sufficient access is provided for coil maintenance and
6.
coil-bundle removal.
Page 8 of 12
Electric Coils
1. Airflow direction across coil is correct.
The required safety interlock, cut-outs and switches are
2.
in place and operational.
3. There are no obstructions to coil and air flow.
4. Coil is clean and free of debris.
Heating elements are the required distance from any
5.
combustible material.
6. Duct connections are complete and leak tight.
7. Additional support for coil is provided where required.
8. Heater de-energizes when air handling unit is off.
All electrical connection are provided as required by
9. design documents and meet the requirements of the
Electrical Inspector.
Humidifiers
1. Humidifier capacity complies with design requirement.
Water supply and drain are properly piped, and unit is
2.
properly wired.
3. Humidistat is installed and wired.
4. Flush cycle is functional
Page 9 of 12
Pumps
1. Pump rotation is verified.
2. Motor, drive and pump alignment is verified.
Belt guards, drive guards and protective screens are in
3.
place.
4. Drive set screws are tight.
All electrical connections and devices are complete and
5.
operational.
6. All required lubrication is provided.
7. All piping connections are complete.
Strainers are installed at pump suction and baskets are
8.
cleaned/replaced since testing.
All isolation valves, flanges and/or unions are installed
9.
to permit pump removal from system.
10. Vibration isolators are installed.
In-line pump and motor assemblies are independently
11.
supported, where required.
12. Flexible electrical connections are provided.
Cooling Towers
1. All piping connections are properly installed.
All valves in the system are operational through their full
2.
range, and are properly positioned.
3. Type, size and number of spray nozzles are verified.
4. Fan and pump rotation are verified.
5. Motors/fans are properly lubricated.
6. Motor, drive and fan alignment is verified.
7. Vibration isolators are installed for fan/motor.
8. Belt and drive-guards are installed as required.
Tower basin is filled, cleaned, and water treatment
9.
system is functional.
10.
operational.
11. Anti-vibration switch is installed and functional.
Page 10 of 12
Chillers
Chiller factory performance test is complete with report
1.
submitted.
2. Chiller is set in place and is hydrostatically leak tested.
Chiller safety and protection devices are tested and
3.
report is submitted.
4. Crankcase heaters are energized.
5.
6. All piping connections are properly installed.
7. Oil level and lubrication is checked.
8. Motor, drive and fan alignment is verified.
9.
operational.
10. Vibration isolators are installed for fan/motor.
11. Belt and drive-guards are installed as required.
Chemical treatment of chilled water system is
12.
completed.
Hydronic Piping
1. Piping system is installed, as per design.
2. Piping system is pressure-tested and accepted.
3.
All required air vents and pressure relief valves are
4.
properly installed.
Piping system is flushed, filled with water and
5.
chemicals.
6. Strainers are clean.
All air is purged from system and pumps were run to
7.
eliminate air trapped in system.
8. All required piping insulation is securely installed.
Balancing, isolating and control valves are installed
9. where required and operational through their full range
(0-100%).
Page 11 of 12
Refrigerant Piping
1. Piping is insulated, as required by SAES-K-001.
System is pressure tested, dehydrated, evacuated and
2.
charged.
Sensing bulb of thermal expansion valve is tightly
3. secured to suction line at the location recommended by
Manufacturer.
Sight glass, filter-drier, solenoid and charging valves are
4.
installed, as per Manufacturer's recommendation.
CORRECTIVE ACTION REQUIRED:

CHECKLIST
ACTION REQUIRED
ITEM NO.
__________________ _____________________
INSPECTOR'S NAME DATE OF INSPECTION
Page 12 of 12

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Inspection Procedure

27-SAIP-01 22 August 2009

Saudi Aramco DeskTop Standards

Previous Issue: 29 September 2004 Next Planned Update: TBD

Copyright©Saudi Aramco 2009. All rights reserved.

1.4 This SAIP is intended to establish a standardized methodology by Saudi Aramco

31. All inspection report forms shall be submitted to the responsible

3.2.1 Equipment identification.

3.2.2 General requirements checklist.

3.2.3 Specific system/equipment.

3.2.4 Corrective action list.

4.1 Saudi Aramco References

Saudi Aramco Engineering Standards

Saudi Aramco Materials System Specifications

4.2 Industry Codes and Standards

American Society of Heating, Refrigerating and Air Conditioning Engineers

National Fire Protection Agency

National Environmental Balacing Bureau

Sheet Metal and Air Conditioning Contractors National Association, Inc.

SMACNA Installation Standards for Residential Heating and

Air Handling Units

CORRECTIVE ACTION REQUIRED:

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