7.2 Installation Qualification Protocol For Air Handling Unit

Page 1 of 37
INSTALLATION QUALIFICATION
PROTOCOL FOR
HVAC SYSTEM OF AHU-01
CUSTOMER:
PROJECT:
SUBMITTED BY:
PHARMA ENGINEERS
PLO T N O. 1 1 3 / A / 1 , L A NE 8 , P HA SE I I,
I DA C HE RLA PA LL I, H YD ERA BA D - 5 0 0 0 5 1 .
Te l N o.9 1 - 4 0 2 7 2 6 1 1 1 3 , 2 7 2 6 1 1 1 4
Page 2 of 37
INSTALLATION QUALIFICATION PROTOCOL APPROVAL
This document is prepared by the documentation team of M/S. PHARMA ENGINEERS

for
AHU TAG Number :
PLANT /PROJECT :
CLIENT :
Hence this document before being effective shall be approved by M/s Client / Customer
M/s. PHARMA ENGINEERS:
Name Designation Signature Date
Prepared By
Reviewed By
CLIENT / CUSTOMER
Name Designation Signature Date
Reviewed By
Approved By
Client:
Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD
Equipment: HVAC SYSTEM FOR AHU-01

Page 3 of 37
INSTALLATION QUALIFICATION (IQ)
TABLE OF CONTENT
1. OBJECTIVE ...............................................................................................................................4
2. RESPONSIBILITIES ...............................................................................................................4
3. SCOPE OF SUPPLY OF COMPONENTS: ..........................................................................5
4. VERIFICATION OF LEAKAGE IN DUCTING ...............................................................30
5. VERIFICATION OF MANIFOLD LEAK TEST (HYDRO TEST) .................................33
6. VERIFICATION OF CALIBRATION OF INSTRUMENTS: .........................................35
7. LIST OF DOCUMENTS ENCLOSED ................................................................................36

Client:

Page 4 of 37
1. OBJECTIVE
The objective of this document is to verify that the HVAC system (AHU Tag
No: _____________________) is installed with due considerations as specified in
DQ of HVAC System (AHU Tag No: _____________________).
2. RESPONSIBILITIES
M/s. Pharma Engineers:
1. To install the system as per the specifications.

2. To provide the necessary test certificates as per technical specifications
specified in DQ.
3. To Complete the hvac system qualification.
4. To perform the duct leak test (for classified areas only) as per SMACNA
Standard 2012.
Client:

Page 5 of 37
3. SCOPE OF SUPPLY OF COMPONENTS:
PURPOSE
This test is to verify that the AHU dimensions, position and sizes of utility
connections are in compliance with the design qualification and also with
as-built drawing.
PRE-REQUISITES
1. As built drawing
2. Measuring tape
3. Approved Design Qualification Document
TEST METHOD
1. Physically check the dimension of the AHU in length, width, and height
and confirm with design document.
2. Physically check and confirm the supply and return air duct sizes right
from the AHU up to terminal point for every room.
3. Physically check and confirm that the dampers are marked with air flow
direction and marking was mentioned for the quantity adjustment.
4. Physically check and confirm that required indications are mentioned on
the AHU like cable entry, safety indication, supply air, return air and
exhaust air location.
5. Physically check and confirm the condensate piping and slope being
maintained.
6. Physically check and confirm the location of fire/ smoke detectors and
confirm the good practice of installation.
7. Deviations or remarks may be documented along with summary of all test
results
Client:

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COMPONENT VERICATION:
AHU (SUPPLY UNIT) / AHU (RETURN UNIT) / EXHAUST UNIT / AHU CUM
DEHUMIDIFIER
CRITERIA
SPECIFICATIONS AS PER DESIGN
SR.NO DESCRIPTION FULFILLED
QUALIFICATION
(YES/NO)
CONSTRUCTIONAL DETAILS:
AHU TAG Number
Unit Serial Number
Manufacturers name M/S PHARMA ENGINEERS
Qty 01 No.
Unit Model AHU-01
Capacity (CFM) 6000 CFM
Static Pressure (MM) 220 mm of WC
Process Blower Make KRUGER / NICOTRA GEBHARDT
Process Blower Model RLO-51-4550-D38
Process Blower Speed (RPM) 2850 RPM
Reactivation Blower Make NICOTRA GEBHARDT
Reactivation Blower Model RLO-11-2528-D19
1. Process Motor Make CROMPTON GREAVES/SIEMENS
Process Motor Capacity (K.W/ 11 KW / 15 HP
HP)
Process Motor Speed (RPM) 2900 RPM
Reactivation Motor Make CROMPTON GREAVES/SIEMENS
Reactivation Motor Capacity 0.75 KW/1.0 HP
(K.W/ HP)
Motor Make BB/CG
Motor Capacity (K.W) 5.5
Poles 4 Pole / 2 Pole
Motor Speed(RPM) 2900 RPM / 1440 RPM
M.O.C of Drain Tray SS 304
M.O.C of Frame work Aluminum Extruded Profile
M.O.C of Base of the unit 14G G.S Sheet Plain
CENTRIFUGAL FAN:
2. Serial Number
Make KRUGER / NICOTRA GEBHARDT
Client:

Page 7 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Model BNB-P400
Air Flow 3000 CFM
Static Pressure 210 mm of WC
Type PLUG FAN / DIDW
Fan Pulley
V- Belt
R.P.M 3103 RPM
MOTOR:
Serial Number
Make BB/CG/SIEMENS
3. K. W 5.5
Motor Pulley
RPM 2900 RPM / 1440 RPM
Type Flame Proof / Non-Flame Proof
DEHUMIDIFIER BED CONSTRUCTIONAL DETAILS:
Manufacturers name BryAir / Air Pack
Unit Serial Number
4.
Air flow handling capacity of
2000 CFM
dehumidifier
Revolution per Hour 20
BED MOTOR
Serial Number
Make T.W.T.
5.
Type Induction motor
Power 90W/440V
RPM 3
REACTIVATION BLOWER
Type Backward
6.
Blower Model RLO-315
Air Flow 667 CFM
REACTIVATION MOTOR
7. Serial Number
Make Crompton Greaves
Client:

Page 8 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Type Tefc Sq cage Induction flange mounted
Rating 1.5 HP
RPM 2880
FILTRATION SCHEME WITH IN AHU & ACD
FILTRATION IN ACD
REACTIVATION FILTER
Make THERMODYNE / AAF
Type of filter Flange type
Filter Media Synthetic
Compatibility of water wash Yes
Filter Test method EN 779
Filter classification as per EN
G-3
779
Average arrestance of synthetic
80 ≤ Am <90
dust
Equivalent particle size in terms
8. 20 micron-Un authenticated data
of market language
I.P.D of Filter (Approximate) 55 ± 10 Pa
F.P.D of Filter (Approximate) 250 Pa
Size of Filter / Rated Air flow 610 x 610 x 50 / 2000 CFM
Qty
Serial Number
Qty
Serial Number
Qty
NOTE: I.P.D & F.P.D values change based on AIRFLOW; hence customer should set the
limits after commissioning.
FILTRATION AHU
FIRST STAGE FILTRATION IN AHU
Make of Filter THERMODYNE / AAF
9. Type of filter Flange type
Client:

Page 9 of 37
CRITERIA
QUALIFICATION
(YES/NO)
G-3
779
Average arrestance of synthetic
80 ≤ Am <90
dust
20 micron-Un authenticated data
of market language
Qty
Serial Number
Qty
Serial Number
Qty
Serial Number
FIRST STAGE FILTRATION IN AHU
G-4
779
10. Average arrestance of synthetic
90 ≤ Am
dust
of market language
Qty
Serial Number
Client:

Page 10 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Qty
Serial Number
Qty
Serial Number
NOTE: I.P.D & F.P.D values change based on AIRFLOW; hence customer
should set the limits after commissioning.
SECOND STAGE FILTRATION IN AHU
M-5
779
Average efficiency at 0.4 micron 40 ≤ Em < 60
of market language
I.P.D of Filter for 150 mm thick 90 ± 10 Pa
(Approximate)
11. (Approximate)
Qty
Serial Number
Qty
Serial Number
Qty
Serial Number
Qty
Serial Number
Client:

Page 11 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Qty
Serial Number
Qty
Serial Number
M-6
779
of market language
(Approximate)
12. I.P.D of Filter for 300 mm thick 90 ± 10 Pa
(Approximate)
Qty
Serial Number
Qty
Serial Number
Qty
Serial Number
Qty
Client:

Page 12 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Serial Number
Qty
Serial Number
Qty
Serial Number
F-7
779
of market language
I.P.D of Filter for 150 mm thick
160 ± 10 Pa
(Approximate)
13. I.P.D of Filter for 300 mm thick
120 ± 10 Pa
(Approximate)
Qty
Serial Number
Qty
Serial Number
Qty
Serial Number
Qty
Client:

Page 13 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Serial Number
Qty
Serial Number
Qty
Serial Number
THIRD STAGE FILTRATION IN AHU
Filter Media Micro Fiber Glass
Compatibility of water wash No
F-9
779
Average efficiency at 0.4 micron 95 ≤ Em
of market language
120 ± 10 Pa
(Approximate)
180 ± 10 Pa
(Approximate)
Size of Filter / Rated Air flow 610 x 610 x 150 / 1000 CFM @ 1.25 m/s
Qty
Serial Number
Qty
Serial Number
Qty
Serial Number
Qty
Client:

Page 14 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Serial Number
Qty
Serial Number
Qty
Serial Number
TERMINAL STAGE FILTRATION IN AHU (PLENUM)
H-13
779
Average Efficiency at MPPS 99.95%
0.3 micron-Un authenticated data
of market language
350 ± 10 Pa
(Approximate)
350 ± 10 Pa
(Approximate)
Qty
Serial Number
Qty
Serial Number
Qty
Serial Number
Qty
Client:

Page 15 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Serial Number
Qty
Serial Number
Qty
Serial Number
TERMINAL STAGE FILTRATION IN AHU (PLENUM)
H-14
779
of market language
350 ± 10 Pa
(Approximate)
350 ± 10 Pa
(Approximate)
Qty
Serial Number
Qty
Serial Number
Qty
Serial Number
Qty
Client:

Page 16 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Serial Number
Qty
Serial Number
Qty
Serial Number
FRESH AIR FILTRATION IN AHU / PRECOOLING
Make of Filter
Type of filter
Filter Media
Compatibility of water wash
Filter Test method
17. 779
Average efficiency at 0.4 micron
of market language
Size of Filter / Rated Air flow
Qty
Serial Number
BLEED AIR FILTRATION IN AHU

Make of Filter
Type of filter
Filter Media
Compatibility of water wash
Filter Test method
18.
779
Average efficiency at 0.4 micron
of market language
Size of Filter / Rated Air flow
Client:

Page 17 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Qty
Serial Number
COOLING, HEATING WITH IN AHU / ACD
COOLING COIL IN TFA
M/s. Flakt Woods (India) Pvt. Ltd.
Manufacturers name
Hyderabad Coils Pvt Ltd
Quantity 1 No.
19. Fluid Chilled water
Coil size (fin ht. x fin Length) 635 x 860 mm
No. of Rows 6
Tube MOC Copper
Tube Diameter 1/2”
Fins MOC Aluminum
COOLING COIL IN AHU
Manufacturers name
Quantity 1 No.
Fluid Chilled water
20.
No. of Rows 6
Tube MOC Copper
Fins MOC Aluminum
HEATING COIL IN AHU
Manufacturers name
Quantity 1 No.
Fluid Hot water
21.
No. of Rows 2
Tube MOC Copper
Fins MOC Aluminum
STEAM COIL IN ACD
22. M/s. Flakt Woods (India) Pvt. Ltd.
Manufacturers name
Client:

Page 18 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Quantity 1 No.
Fluid Steam
No. of Rows 6
Tube MOC Copper
Fins MOC Aluminum
DETAILS OF VOLUME CONTROL DAMPERS FOR AHU:
Make M/s. System Air
M/s. Pharma Engineers
23. MOC Aluminum extruded aero foil design
Supply Air 325x550 mm–1 No.
Return Air 325x550 mm–1 No..
Fresh Air 300x600 mm– 1 No.
Bleed Air 300x300 mm– 1 No.
DETAILS OF FUSIBLE LINK FIRE DAMPERS FOR AHU:
M/s. System Air
Make
Multi-blade low leakage with opposed
Type
blade
Blades & Casing 1.6mm thick GSS / 1.6 mm thick GI sheet
24. Fire Rating @ IP555 120min Fire Rating
Melting point of fusible link 74 deg. C
Limit switch Mounted on frame of damper
Supply Duct 550x325 mm
Return Duct 550x325 mm
Exhaust Duct 550x325 mm
DETAILS OF MOTORIZED FIRE DAMPERS FOR AHU:
M/s. System Air
Make
25.
MOC GI
Thickness 16G
Rating @ IP 555 120min Fire Rated
Client:

Page 19 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Supply Duct 550x325 mm
Return Duct 550x325 mm
Exhaust Duct 550x325 mm
ACTUATOR FOR FIRE DAMPER:
Make M/S. Belimo
26.
Model NFA-S2
Location Return Air Duct, Supply Duct
PIPPING & MANIFOLD DETAILS
CHILLED WATER MANIFOLD:
27.
Pipe Size 32 mm
Pipe Material MS
PIPE INSULATION
Make kflex
Material Elastomeric Nitrile rubber
Fire performance Class ‘O’ (FM APPROVED)
28.
Thickness 25 mm
Temperature range
105°C & -40°C
(maximum& minimum)
Thermal conductivity at 20°C 0.036 w/m degK
3Way Valve with Actuator
Make Honeywell / Siemens
Valve Model Number V5013P1010
29.
Actuator model number ML74208088-E
Size 25 mm
Qty 1no.
Ball Valves
Make L&T or its equivalent
30.
Size 32 mm
Qty 6 Nos.
Balancing Valves
Make Advance or its equivalent
31.
Size 32 mm
Qty 1No.
Client:

Page 20 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Strainer
Make Creative/Zoloto or its equivalent
32.
Size 32 mm
Qty 1No.
Drain Valve
Make Zoloto/L&T or its equivalent
33. Size 20 mm
Qty 1No.
Air Vent Valve
34. Make Anergy or its equivalent
Size 15 mm
Test port
Size 8mm
HOT WATER MANIFOLD:
36. Pipe Size 25 mm
Pipe Material MS
PIPE INSULATION
Make kflex
Material Elastomeric Nitrile rubber
Fire performance Class ‘O’ (FM APPROVED)
37.
Thickness 25 mm
Temperature range
105°C & -40°C
(maximum& minimum)
Thermal conductivity at 20°C 0.036 w/m degK
2 WAY VALVE WITH ACTUATOR
Make Honeywell /Siemens
Model Number V5011P1004
38.
Actuator model number ML74208088-E
Size 25 mm
Qty 1no.
Ball Valves
39. Make L&T or its equivalent
Size 25 mm
Client:

Page 21 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Qty 5 Nos.
Balancing Valves
Make Advance or its equivalent
40.
Size 25 mm
Qty 1No.
Strainer
Make Creative /Zoloto or its equivalent
41.
Size 25 mm
Qty 1No.
Drain Valve
Make Zoloto/L&T or its equivalent
42.
Size 20 mm
Qty 1No.
Air Vent Valve
Size 15 mm
Test port
Size 8mm
PRE-COOLIG COIL MANIFOLD
Manufacturers name M/s. Hyderabad Coils
Serving to AHU- FRESH AIR
No. of Rows 4
Coil size (fin Width. X fin
24” X 24”
height)
Fins/ Inch 12 FPI
Fins MOC Aluminum
45.
Size of manifold 40 NB
Pipe Material of manifold MS or its equivalent
Make of Ball Valves L&T
Qty 2 Nos
Make of Strainer Marck or its equivalent
Size 40 mm
Qty 01 No’s
Make of Balancing Valve Advance
Client:

Page 22 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Size 40 mm
Qty 01 No’s
POST HEATING COIL MANIFOLD
Manufacturers name M/s. Hyderabad Coils
Serving to AHU- FRESH AIR
No. of Rows 2
Coil size (fin Width. X fin
24” X 24”
height)
Fins/ Inch 12 FPI
Fins MOC Aluminum
46. Size of manifold 40 NB
Pipe Material of manifold MS
Make of Ball Valves L&T or its equivalent
Qty 2 Nos
Make of Strainer Marck or its equivalent
Size 40 mm
Qty 01 No’s
Make of Balancing Valve Advance or its equivalent
Size 40 mm
Qty 01 No’s
HEATERS
Make
47.
Type
Capacity
THYRISTOR HEATING MODULE
Make M/s Pharma Engineers
Unit Serial Number
Qty 01 No’s
Type Double Skin Thermal Break Type
48. Model TH-45
Location At service floor
Overall dimensions (L X W X
H) (MM)
Capacity 45 KW
Plenums Outer skin(MM) 0.8 mm PP GS sheet.
Client:

Page 23 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Plenums Inner skin(MM) 0.6 mm PP GS sheet.
Panel thickness(MM) 43±0.5 mm
HVAC ELECTRICAL PANEL (CENTRALIZED)
Make M/s. PHARMA ENGINEERS
49. Type Compartmental
Location
Cable Entry Top
HVAC ELECTRICAL PANEL (STAND ALONE)
Make M/s. PHARMA ENGINEERS
50. Type
Location
Cable Entry Top
VARIABLE FREQUENCY DRIVE
Make Danfoss
Serial Number
51. Model VLT HVAC basic Drive FC101

VFD Capacity (KW) for supply
3.7 K. W
unit
VFD Capacity (KW) for return
3.7 K. W
unit
INSTRUMENTATION DETAILS
MAGNEHELIC GAUGES
Make Dwyer, U.S.A.
Location AHU prefilter
Range 0-25mm
52.
Qty 1 No’s
Serial Number
Location AHU fine filter
Range 0-50mm
Qty 1 No’s
Client:

Page 24 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Serial Number
Location AHU plenum HEPA Filter
Range 0-50mm
Qty 1 No’s
Serial Number
Location Rooms
Range 0-60 Pa
Qty 5 No’s
Serial Number
SENSOR DETAILS
TEMPERATURE & RH SENSOR
Make
53. Model
Location
Qty
Serial Number
DPT SENSOR
Make
Model
54.
Location
Qty
Serial Number
VELOCITY SENSOR
Make
Model
55.
Location
Qty
Serial number
56. DUCTING:
Client:

Page 25 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Material Galvanized steel sheet
Manufacturer JINDAL / TATA/SAIL/UTTAM/ESSAR
Fabrication standard/Year IS 655/2012
Duct leak test standard (only for
SMACNA 2012
Classified AHU’s)
Duct seal class C
Duct leak testing pressure 2” W.G
Up to 750 mm - 24 G
Thickness of Galvanized sheet 751 to 1520 mm - 22 G

1521 to 2285 mm - 20 G
Type of Gasket Rubber based gasket
Supporting Rods 8 mm G.I threaded rod
MS angle frames for Classified AHU
Duct joint
TDF for unclassified AHU
Bonding/sealant Silicone based sealant
INSULATION:
Make THERMOBREAK
Type Cross linked polyolefin foam
Thermal Conductivity ‘K’ valve, 0.032 W/mK @ 23° C
Density Kg / m3 25
57.
Temperature range -80 Deg.C to +100 Deg.C
Finishing material Aluminum foil
Fire performance Class “0”
19mm For Supply & 13 mm For Return
Thickness
Ducts
SUPPLY AIR TERMINAL MODULE
Make M/s PHARMA ENGINEERS
58. Module MOC GI POWDER COATED
Grill MOC SS 304
Thickness of sheet 1.2 mm
Damper In built with housing
TERMINAL HEPA FILTERS IN ROOM
59. Make of Filter AAF
Client:

Page 26 of 37
CRITERIA
QUALIFICATION
(YES/NO)
H-14
779
of market language
Hood Size
HEPA Filter Size / CFM
Qty
Serial Number
Room Name
HEPA Filter Size / CFM
Qty
Serial Number
SUPPLY AIR TERMINAL FOUR WAY DIFFUSERS

M/s SYSTEM AIR INDIA PVT LTD
Make
M/s PHARMA ENGINEERS
Ceiling mounted square type horizontal
Diffuser MOC
air diffusion pattern
Damper MOC Aluminum
60.
Room Name
Diffuser Size
Qty
Room Name
Diffuser Size
Qty
Client:

Page 27 of 37
CRITERIA
QUALIFICATION
(YES/NO)
SUPPLY AIR TERMINAL GRILLES (Linear Grilles)
Make
Material Of Construction Extruded Aluminum
Damper MOC Al. extruded
61. Room Name
Grill Size
Qty
Room Name
Grill Size
Qty
RETURN AIR TERMINAL MODULE
Make M/s PHARMA ENGINEERS
Module MOC GI POWDER COATED
Grill MOC SS 304
Thickness of sheet 1.2 mm
62. Room Name
Hood Size
Qty
Room Name
Hood Size
Qty
RETURN AIR TERMINAL FOUR WAY DIFFUSERS
Make
Ceiling mounted square type horizontal
Diffuser MOC
63. air diffusion pattern
Damper MOC Aluminum
Room Name
Diffuser Size
Qty
Client:

Page 28 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Room Name
Diffuser Size
Qty
RETURN AIR TERMINAL GRILLES (Linear Grilles)
Make
Material Of Construction Extruded Aluminum
Damper MOC Al. extruded
64. Room Name
Grill Size
Qty
Room Name
Grill Size
Qty
RETURN AIR RAISERS
Make M/s. Pharma engineers
Riser MOC GI Powder Coated
Damper MOC Aluminum
Riser Grill MOC SS 304
Riser Filter Make M/s Pharma Engineers
Type of filter Flange / Box
65. Compatibility of water wash Yes
Filter Test method EN-779
Filter classification as per EN G-4
779
Average arrestance of synthetic 90 ≤ Am
dust
Equivalent particle size in terms 10 micron-Un authenticated data
of market language
Room Name
Riser Size
Client:

Page 29 of 37
CRITERIA
QUALIFICATION
(YES/NO)
Filter Size / CFM
Qty
Serial Number
Room Name
Riser Size
Filter Size / CFM
Qty
Serial Number
ACCEPTANCE CRITERIA
Dimensions and supply connections of the system should comply with DQ document and as built
drawings.
However, the acceptance is up to the judgment of experts if any deviations in the readings
REMARKS (IF ANY):
Test Conducted By Test Witnessed By

Client:

Page 30 of 37
4. VERIFICATION OF LEAKAGE IN DUCTING
PURPOSE:
To ensure that the ducting was Fabricated as per IS 655/2012 and leak test for
classified AHU are performed as per SMACNA 2012
PRE-REQUISITES:
1. Full tightened nut and bolts in the flanges of the erected duct network.
2. Duct leak test machine
3. Flexible pipe
4. Dummy plate connector
TEST PROCEDURE:
1. Before starting up the test procedure all the required instruments and tools to
be arranged to the work location.
2. Fix the dummy plate connector to one end of the duct to be tested.
3. Make sure that all the flanges are tightened properly with gasket and the other
end of the duct was closed with dummy sheet.
4. Now, connect one end flexible hose pipe to the connector fixed to duct and the
other end to the test rig.
5. Now, switch on the leak tester and feed the required data in the HMI, like
date, AHU No., area of ducting, Seal class, static Pressure and leak factor etc.,
6. The test rig has two blowers, first start with one pump and increase the speed
of blower gradually until it achieves the required pressure, if not switch on the
second blower and increase the speed gradually until it achieves the required
pressure duct pressure as specified.
7. If desired pressure is not achieved check for any leakages in duct.
8. Let the system run for 2-4 minutes to stabilize.
9. Now, print the results and observe the status in the printed data and verify the
leakage falls under acceptable range and the test is passing.
Client:

Page 31 of 37
10. If the test fails, verify for any leakages at all tangential joints and tight it
properly and repeat the test again as per the above steps.
11. After completion of test, remove the hose connector piece and close the
opening with dummy piece at the duct end.
12. Repeat this test for main ducts.
13. Duct leak test report is enclosed with this document.
Duct Pressure Class / Seal Class / Air Leakage Class as per SMACNA Standards
Reprinted =Table: E-1 (HVAC AIR DUCT LEAKAGE TEST MANUAL--- 2nd Edition 2012)
Duct Pressure 1”, 2” WG. 3” WG 4”, 6” WG

Class
Seal Class C B A
Sealing All Transverse All Transverse & All Transverse Joints, Longitudinal
Requirement Joints Longitudinal Seams Seams & Wall Penetrations
Rectangular
Class 16 Class 8 Class 4
Duct
Appendix E: SMACNA -- HVAC AIR DUCT LEAKAGE TEST MANUAL

Leakage Factor “Lf” - CFM / 100 Sq. ft of Duct
Pressure (P) Leakage Class (CL)
P 0.65
In. wg Class 2 Class 4 Class 8 Class 16
1.0 1.00 2.0 4.0 8.0 16.0
2.0 1.57 3.1 6.3 12.6 25.1
3.0 2.04 4.1 8.2 16.3 32.7

4.0 2.46 4.9 9.8
5.0 2.85 5.7 11.4 F = CL (P 0.65)
6.0 3.20 6.4 12.8
Client:

Page 32 of 37
Duct Pressure class is decided based on pressure generated by terminal

filters.
As pressure of terminal filter is 50mm. Hence 2” static pressure is selected.
ACCEPTANCE CRITERIA:
Result must be ‘PASS’ it ensures that the duct fabrication is satisfactory.
This test must be completed for at least 60% to 70% of main ducts.
REMARKS (IF ANY):
Performed By Checked By
Client:

Page 33 of 37
5. VERIFICATION OF MANIFOLD LEAK TEST (HYDRO

TEST)
PURPOSE:
To ensure that the piping manifold installed to AHU is free from leakages.
PRE-REQUISITES:
1. Full welded joints.

2. Duly calibrated Pressure gauge
3. Hydraulic Pump
4. Isolation of System for performing test
TEST PROCEDURE:
1. First fill up the water distribution loop with DM/Purified water.

2. Close the return line of loop by means of Blind TC/Return line valve to
pressurize the distribution loop
3. Connect the Hydro pump at the supply line side with adequate range of
pressure gauge
4. Pressurize the distribution loop system up to 1.5 times of design pressure with
help of hydro pump
5. Observe the pressure gauge reading after achieving the required pressure in
the loop
6. Hold this pressure for minimum 30 minutes.
7. Observe for any Pressure drop/Leakage in the distribution loop
8. If at all there is any leakage in the loop, Rectify the same & Repeat the
Procedure
9. Release the pressure and put the loop in operation.
10. Test results are enclosed with this document.
ACCEPTANCE CRITERIA:
Manifold must be free from leakages it ensures that the manifold fabrication is
satisfactory.
However, the acceptance is up to the judgment of experts if any deviation in the

readings.
Client:

Page 34 of 37
TEST REPORT FOR MANIFOLD LEAKAGE (HYDRO TEST)

Purpose: To determine fluid leakage in manifold
Type of manifold Date of Test
INSTRUMENT / EQUIPMENT USED

Name of instrument /
Make
equipment
Make of Master pressure
Range
gauge
Serial number
Calibrated on Calibration Due
TEST RESULTS
PRESSURE
START END
SR.NO GAUGE
TIME TIME READING
REMARKS (IF ANY)
Performed By Checked By
Client:

Page 35 of 37
6. VERIFICATION OF CALIBRATION OF INSTRUMENTS:
Instrument Calibration
S.no. Instrument Type Location Calibrated on
Tag Number Due
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
REMARKS (IF ANY):
Submitted By Checked By
Client:

Page 36 of 37
7. LIST OF DOCUMENTS ENCLOSED
Enclosed
S.No Drawing Name
(Yes / No)
1. Testing Certificate For AHU
2. Testing Certificate For Blower
3. Testing Certificate For Motor
4. Testing Certificate For Dehumidifier Bed
5. Testing Certificate For Dehumidifier Bed Blower / Motor
6. Testing Certificate For Reactivation Blower / Motor
7. Testing Certificates For Ahu Filters
8. Testing Certificate For Chilled Water Coil
9. Testing Certificate For Hot Water Coil
10. Testing Certificate For Steam Coil
11. Testing Certificate For Volume Control Damper
12. Testing Cerrticate For Fire Damper
13. Testing Cetificate For Actuator For Fire Damper
Testing Certificate for Chilled Water Manifold and All Related Fitting And
14.
Accessories
Testing Certificate for Hot Water Manifold and All Related Fitting And
15.
Accessories
Testing Certificate For Steam Manifold And All Related Fitting And
16.
Accessories
17. Testing Certificates For Pipe Insulation
18. Testing Certificates For Actuators For Control Valves
19. Testing Certificate For Thyristor Module
20. Testing Certificates For Control Panel
21. Testing Certificate For Variable Frequency Drive
22. Calibration Certificate For Magnehelic Gauge
23. Calibration Certificate For T&RH Sensor
24. Calibration Certificate For DPT Sensor
25. Calibration Certificate For Velocity Sensor
26. Testing Certificate For Ducting
27. Testing Certificate For Duct Insulation
Client:

Page 37 of 37
28. Testing Certificate For Terminal Module

29. Testing Certificate For Terminal Filters
30. Testing Certificates For Diffusers
31. Testing Certificates For Grilles
32. Testing Certificates For Risers
33. Testing Certificate For Riser Filter
34. Duct Leak Test Report
35. Manifold Leak Test Report (Hydro Test)
REMARKS (IF ANY):
Submitted By Checked By

7.2 Installation Qualification Protocol For Air Handling Unit

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Page 1 of 37

INSTALLATION QUALIFICATION PROTOCOL APPROVAL

This document is prepared by the documentation team of M/S. PHARMA ENGINEERS

Name Designation Signature Date

Name Designation Signature Date

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

3. SCOPE OF SUPPLY OF COMPONENTS: ..........................................................................5

4. VERIFICATION OF LEAKAGE IN DUCTING ...............................................................30

5. VERIFICATION OF MANIFOLD LEAK TEST (HYDRO TEST) .................................33

6. VERIFICATION OF CALIBRATION OF INSTRUMENTS: .........................................35

7. LIST OF DOCUMENTS ENCLOSED ................................................................................36

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

M/s. Pharma Engineers:

1. To install the system as per the specifications.

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

3. SCOPE OF SUPPLY OF COMPONENTS:

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

BLEED AIR FILTRATION IN AHU

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-01

INSTALLATION QUALIFICATION (IQ)

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD