Professional Documents
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VERSION: 1.1
ZCC-01-201MS METHOD STATEMENT
REVISION: 00
HVAC SYSTEM
“AIR SYSTEMS”
ZAMIL COOLCARE
Method Statement for
NAME / DATE: HVAC TAB – Air Systems
27.10.2010
S.G.S M. A. R P.A.S
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ZCC-01-201MS METHOD STATEMENT
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APPROVED BY
NAME & DATE
SUB CONTRACTOR
MAIN CONTRACTOR
PROPONENT
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Object
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CONTENTS
1.0 Scope………………………………………………………………………………………… 5
2.0 Responsibilities……………………………………………………………………………. 5
3.0 References………………………………………………………………………………….. 6
4.0 Abbreviations………………………………………………………………………………. 6
5.0 Safety………………………………………………………………………………………... 7
6.0 Procedures ………………………………………………..………..…………………….... 7
6.1 Equipment Start Up…………………………………………………………………... 7
6.2 Testing & Balancing………………………………………………………………….. 7
7.0 Testing & Balancing Procedures………………………………………………………. 8
7.1 General Testing Procedures for Air Systems……………………………………. 8
7.2 Procedures for Constant - Volume Air Systems….…………………………….. 8
7.3 Procedures for Variable Air Volume Systems…………………………………… 10
7.4 Flow Measurements Procedures……………………………................................ 12
7.4a Procedure for Pitot Tube Traverse…………………………………………. 12
7.4b Procedure for Electrical Measurements……………….............................. 12
7.4c Procedure for Rotational Speed Measurements……............................... 13
7.4d Procedure for Static Pressure Measurements……………………………. 13
7.4e Procedure for Basic Temperature Measurements………………………. 14
8.0 Equipment Testing
8.1 Air Handling Units…………………………………………………………………… 15
8.2 Fan Coil Units………………………………………………………………………… 15
8.3 Split Units………………………………………………………………………………. 15
8.4 Fans (Fresh Air / Inline/ Exhaust)…………………………………………………. 15
8.5 VAV Terminal Units………………………………………………………………….. 15
8.6 Packaged Air Conditioning Units………………………………………………… 15
8.7 Components…………………………………………………………………………. 15
8.8 Other Measurements………………………………………………………………… 15
9.0 Instrumentation for HVAC Testing ………………………...………............................ 15
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1.0 Scope
The scope of this document is to define the method to be applied to testing & balancing for HVAC Air
systems, subsystems and related equipment and components.
2.0 Responsibilities
a. Installation Contractor to confirm the complete operational readiness of the HVAC system to
allow the commissioning to be performed.
b. Installation Contractor to verify the installation conformity to the design drawings and
specifications and approved TQs.
c. Installation Contractor to provide operation and maintenance manuals. Manual contents are
defined as the manufacturers' data on the HVAC equipment installed and must include the
following:
i. The manufacturers' method for Precommissioning, TAB and Performance Testing of
the HVAC equipment systems, subsystems and its components for correct
operation under actual load conditions.
ii. The manufacturers' recommended tolerance for maximum and minimum operating
conditions; flow, rpm, etc.; proper locations; and unit at design flow rate.
iii. The recommended correction, or A, factors, to allow adjustment of air terminals.
iv. A list of spare parts, identification numbers and diagrams of their Pressure drops for
air systems.
d. Commissioning Contractor to inspect the system after site readiness notification to determine if
the system is actually complete and ready to be started for testing.
e. TAB contractor to field verify A or K factors for applicable air terminals, if required.
f. TAB Contractor to Test & Adjust VAV boxes minimum and maximum flows.
g. TAB Contractor to make all field adjustments required for balancing and prepares certified
report.
h. TAB contractor to prepare a final TAB report and documentation of final system & components'
balance conditions.
i. Commissioning Contractor to document any deficiencies, prior to performance testing, which
prevent the system from being properly verified and any conditions caused by a deficiency and
give them to the responsible representative for correction.
j. Other responsibilities shall be as per the agreed project scope of work.
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3.0 References:
a. ASHRAE Commissioning Guidelines
b. ASHRAE Standards
c. National Environmental Balancing Bureau Procedural Standards
4.0 Abbreviations
The following are common abbreviations used in this document:
CA Commissioning Authority
CX Commissioning
MC Mechanical Contractor
EC Electrical Contractor
CC Controls Contractor
GC General Contractor
TQ Technical Queries
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5.0 Safety
Every TAB team member has a responsibility to work in a safe manner, not to interfere with anything
provided for their safety, and to report any hazardous situation, without delay, to their immediate
supervisor in the project site.
Safety is every body's responsibility. Each has a duty to the other to maintain a working environment
that is, so far as is practicable, free from hazards and risk of injury to personnel. The elimination of
injury to employees and a reduction in the amount of damage or loss to equipment or materials must
be of utmost concern to all agencies involves in the TAB process of HVAC system.
Where it is impossible to provide a hazard-free environment, TAB contractor accepts the
responsibility to provide protection, advice and information that will help combat particular hazards.
6.0 Procedures
Testing and Balancing shall be conducted after start up check by TAB agency/ Contractor. And
shall be conducted as per the following:
Latest version of NEBB procedural standards and the project specifications with approved
TQs if applicable.
NEBB 2005 Forms shall be used for data collection and test report.
Instruments used by the TAB for taking measurements shall comply specifications listed in
table enclosed with this document.
In case of any conflict between this document and NEBB procedure, precedence shall be
given to the later and agreed scope of work.
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In order to achieve the purpose of Testing & Balancing of HVAC system the above
referred method(s) shall be applied.
To ensure that basic procedures are followed in TAB Processes, the following
general procedures are described:
i. Adjust fans to deliver total indicated airflows within the maximum allowable fan
speed listed by fan manufacturer.
ii. Where sufficient space in ducts is unavailable for Pitot-tube traverse measurements,
measure airflow at terminal outlets and inlets and calculate the total airflow.
iii. Measure outlet static pressure as far downstream from the fan as practical and
upstream from restrictions in ducts such as elbows and transitions.
iv. Measure static pressure directly at the fan outlet or through the flexible connection.
v. Measure inlet static pressure of single-inlet fans in the inlet duct as near the fan as
possible, upstream from the flexible connection, and downstream from duct
restrictions.
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vi. Measure inlet static pressure of double-inlet fans through the wall of the plenum that
houses the fan.
vii. Measure static pressure across each component that makes up an air handling unit,
rooftop unit, and other air-handling and -treating equipment.
viii. Report the cleanliness status of filters and the time static pressures are measured.
ix. Measure static pressures entering and leaving other devices, such as sound traps,
heat-recovery equipment, and air washers, under final balanced conditions.
x. Do not make fan-speed adjustments that result in motor overload. Consult
equipment manufacturers about fan-speed safety factors. Modulate dampers and
measure fan-motor amperage to ensure that no overload will occur. Measure
amperage in full-cooling, full-heating, economizer, and any other operating mode to
determine the maximum required brake horsepower.
xi. Adjust volume dampers for main duct, sub main ducts, and major branch ducts to
indicated airflows within specified tolerances.
xii. Where sufficient space in sub main and branch ducts is unavailable for Pitot-tube
traverse measurements, measure airflow at terminal outlets and inlets and calculate
the total airflow for that zone.
xiii. Measure static pressure at a point downstream from the balancing damper, and
adjust volume dampers until the proper static pressure is achieved.
xiv. Remeasure each sub main and branch duct after all have been adjusted. Continue
to adjust sub main and branch ducts to indicated airflows within specified
tolerances.
xv. Measure terminal outlets using a direct-reading hood or outlet manufacturer's written
instructions and calculating factors.
xvi. Adjust air outlets and inlets for each space to indicated airflows within specified
tolerances of indicated values. Make adjustments using branch volume dampers
rather than collar dampers.
xvii. Adjust each outlet in same room or space to within specified tolerances of indicated
quantities without generating noise levels above the limitations prescribed by the
Contract Documents.
xviii. Adjust patterns of adjustable outlets for proper distribution without drafts.
xix. Measure the sound levels in all rooms in dBa.
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Compensating for Diversity: When the total airflow of all terminal units is more than the
indicated airflow of the fan, place a selected number of terminal units at a minimum set point
airflow with the remainder at maximum-airflow condition until the total airflow of the terminal
units equals the indicated airflow of the fan. Select the reduced-airflow terminal units so they
are distributed evenly among the branch ducts.
Note:
After the fan systems have been adjusted, adjust the variable-air-volume systems as
follows:
1. Set outdoor-air dampers at minimum, and set return- and exhaust-air dampers at a
position that simulates full-cooling load.
i. Select the terminal unit that is most critical to the supply-fan airflow and static
pressure. Measure static pressure. Adjust system static pressure so the entering
static pressure for the critical terminal unit is not less than the sum of the terminal-
unit manufacturer's recommended minimum inlet static pressure plus the static
pressure needed to overcome terminal-unit discharge system losses.
ii. Measure total system airflow. Adjust to within indicated airflow.
iii. Set terminal units at maximum airflow and adjust controller or regulator to deliver the
designed maximum airflow. Use terminal-unit manufacturer's written instructions to
make this adjustment. When total airflow is correct, balance the air outlets
downstream from terminal units the same as described for constant-volume air
systems.
iv. Set terminal units at minimum airflow and adjust controller or regulator to deliver the
designed minimum airflow. Check air outlets for a proportional reduction in airflow
the same as described for constant volume air systems.
v. If air outlets are out of balance at minimum airflow, report the condition but leave
outlets balanced for maximum airflow.
2. Remeasure the return airflow to the fan while operating at maximum return airflow and
minimum outdoor airflow.
i. Adjust the fan and balance the return-air ducts and inlets the same as described for
constant-volume air systems.
3. Measure static pressure at the most critical terminal unit and adjust the static pressure
controller at the main supply-air sensing station to ensure that adequate static pressure
is maintained at the most critical unit.
4. Record final fan-performance data.
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v. For static controlled systems, measure and record the static pressure at the control
static pressure sensor location.
vi. Compare and review static pressure measurements against the manufacturer's
submittal data for differences that could affect the system performance.
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COMMISSIONING
TESTING AND BALANCING
VERSION: 1.0
GEN-ZCC-01-301MS METHOD STATEMENT
REVISION: 00
HVAC EQUIPMENT
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GEN-ZCC-01-301MS METHOD STATEMENT
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APPROVED BY
SUBCONTRACTOR
COMPANY NAME:
Object
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CONTENTS
1 Scope………………………………………………………………………………………… 5
2 Responsibilities……………………………………………………………………………. 5
3 References………………………………………………………………………………….. 5
4 Abbreviations………………………………………………………………………………. 6
5 Safety………………………………………………………………………………………... 6
6 Procedures…………………………………………………………..……………………... 7
6.1 Pre Commissioning…………………………………………………………………... 7
6.1.1 Pre-Inspection Check List……………………………………………………. 7
6.1.2 Equipment Start Up…………………………………………………………… 7
6.1.3 Solo Run Test…………………………………………………………… 8
6.1.4 List of Precommissioning Forms…………………………………………… 9
6.2 Commissioning………………………………………………………………………. 9
6.2.1 Functional Performance Testing……………………………………………….. 9
6.2.2 List of Commissioning Forms…………………………………………………… 10
7 Equipment
7.1 Air Handling Unit……………………………………………………………………… 10
7.2 Fan Coil Unit…………………………………………………………………………… 10
7.3 Split Unit……………………………………………………………………………….. 11
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9 Attachments…………………………………………………………………………………. 12
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1. Scope
The scope of this document is to define the method to be applied to pre-inspection, start up, testing &
balancing and performance testing for HVAC Air systems, subsystems and related equipment and
components.
2. Responsibilities
a. Installation contractor to confirm the complete operational readiness of the HAVC system to allow
the commissioning to be performed.
b. Installation Contractor to verify the installation conformity to the design drawings and
specifications.
c. Installation Contractor to providing operation and maintenance manuals. Manual contents are
defined as the manufacturers' data on the HVAC equipment installed and must include the
following:
i. The manufacturers' method for Precommissioning, TAB and Performance Testing of
the HVAC equipment systems, subsystems and its components for correct operation
under actual load conditions.
d. Commissioning contractor to inspects the system after site readiness notification to determine if
the system is actually complete and ready to be started for testing. This shall be accomplished
using Pre Inspection Checklist and start up forms enclosed in Appendix I of this document.
e. Commissioning contractor to prepare a final commissioning report and documentation of final
system conditions.
f. Commissioning contractor to provide measuring instruments and logging devices to record test
data, and provide data acquisition equipment to record data for the complete range of testing for
the required test period.
g. Documents any deficiencies, prior to performance testing, which prevent the system from being
properly verified and any conditions caused by a deficiency and give them to the responsible
representative for correction.
h. Other responsibilities shall be as per the project scope of work and project specification.
3. References:
a. Project Specifications
b. ASHRAE Commissioning Guidelines
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4. Abbreviations
The following are common abbreviations used in this document:
CA Commissioning Authority
CX Commissioning
MC Mechanical Contractor
EC Electrical Contractor
CC Controls Contractor
FC Fire Fighting Contractor
CMC Communication Contractor
PC Plumbing Contractor
ZCC Zamil CoolCare
GC General contractor
CPI Commissioning Pre inspection Checklist
FPT Functional performance test
PF Pre-functional checklist
RFA Request for assessment
OMS Operations & Maintenance staff
5.0 Safety
· Every HVAC commissioning team member has a responsibility to work in a safe manner, not to
interfere with anything provided for their safety, and to report any hazardous situation, without delay, to
their immediate supervisor in the project site.
· Safety is every body's responsibility. Each has a duty to the other to maintain a working environment
that is, so far as is practicable, free from hazards and risk of injury to personnel. The elimination of
injury to employees and a reduction in the amount of damage or loss to equipment or materials must
be of utmost concern to all agencies involves in the commissioning process of HVAC system.
· Where it is impossible to provide a hazard-free environment, HVAC commissioning contractor accepts
the responsibility to provide protection, advice and information that will help combat particular hazards.
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6.0 Procedures
The procedures shall be described for each of the following phases of commissioning:
· Pre-commissioning
· Commissioning
6.1 Pre-Commissioning
6.1.1 Pre-Inspection Checklist
· After receiving the system readiness certificate from the installation contractor, pre-inspection
shall be conducted to validate the installation of all equipment to be commissioned. This shall
be done in accordance with the approved pre-inspection forms listed below in table 1.0 and
enclosed in Appendix I of this document.
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• Procedures
• Equipment Pre-Start up
• Make sure that the motor bearings are properly lubricated by the installation contractor
or by the motor supplied. Ensure that proper grade of the Grease has been utilized.
• Make sure that the transportation brackets are removed and vibration isolators are
positioned properly.
• Apply the jet air blowers to clean the frame and fan area of the motor.
• Carry out the mechanical de-coupling of the motor with the load. Disengage the driver
from the driven. Decoupling shall be as per manufacturer’s procedures only to prevent
damage to the property.
• Apply the pre-start up check list enclosed with this method statement.
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6.1.4 Follow is the list of basic forms that shall be applied for pre-inspection, start up and TAB.
6.2 Commissioning
6.2.1 Functional Performance Tests (FPT)
After systems are complete and equipment pre-inspection, start up, and testing and balancing have
been completed, functional performance testing shall be conducted in order to validate equipment,
component and systems performance. This shall be done in accordance with the functional
performance testing forms (FPT forms) included in Table 1.1 and enclosed in Appendix II of this
document.
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6.2.2 Follow is the list of basic forms that shall be applied for functional performance
testing of applicable equipment.
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7.4 Fans
7.4A Fresh Air Fan/ Fresh Air Handling Unit
a) Apply Forms ZCC 01 21 for verification of equipment readiness for pre commissioning, starting
up & commissioning of the equipment.
b) Apply Form ZCC 01 34 for Testing and balancing of the equipment.
c) Apply Form ZCC 01 53 for Functional Performance Testing of the equipment.
7.4B Exhaust Fan
a) Apply Forms ZCC 01 22 for verification of equipment readiness for pre commissioning, starting
up & commissioning of the equipment.
d) Apply Form ZCC 01 34 for Testing and balancing of the equipment.
b) Apply Form ZCC 01 54 for Functional Performance Testing of the equipment.
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· In case of any conflict among the above mentioned specs, precedence shall be given o the
project specifications.
9. List of attachments
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Appendix I
Appendix
Appendix III
PERFORMANCE ACCEPANCE for
Applicable instruments testing &
CERTIFICATE
SYSTEM DEFICENCY REPORT
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6.
NEBB TAB PROCEDURES
NEBB PROCEDURAL STANDARDS
SECTION 8 AIR SYSTEM
TAB PROCEDURES
8.1 INTRODUCTION
Testing, adjusting, and balancing of HVAC systems can best be accomplished by systematic
procedures. The NEBB TAB procedures presented in this section address the majority of system
commonly installed. It is the responsibility of the NEBB Certified TAB Firm to determine
appropriate procedures for systems not covered in this section.
8.2.2 Not all system types are addressed in this section. Confer with the engineer record to establish
the proper set-up conditions for specific system.
8.2.3 The following TAB procedures are basic to all types of air systems:
a) Verify that the construction team responsibilities for system installation and startup as
discussed in Section 3 are complete.
c) Confirm that every item affecting the airflow of a duct system is ready for the TAB work,
such as doors and windows being closed, ceiling tiles (return air plenums) in place, etc.
d) Confirm that automatic control devices will not adversely affect TAB operations. The control
systems shall be installed and commissioned by others prior to starting the TAB work.
f) Verify that all dampers are open or set, all related systems (supply, return, exhaust, etc.), are
operating, motors are operating at or below full load amperage ratings, and rotation is correct.
8.3.1 The most accurate and accepted field test of airflow is a Pitot tube traverse of the duct.
Procedures for conducting a Pitot tube traverse are found in Section 6. In situations where a Pitot
tube traverse(s) is not available, the system airflow may be determined by alternate methods, such
as anemometer or velocity grid traverses across coils and / or filters, or the summation of air
outlet measurements. These alternative methods are subject to a greater degree of error than Pitot
tube traverses and should be used with caution.
8.3.2 Additionally, if a Pitot tube traverse is available, a comparison of the total outlet airflow
measurement with the Pitot tube traverse readings, of the fan total airflow may assist in quantifying
possible duct leakage. It is important to note that differences between total air outlet volume and
Pitot tube traverse totals may be indicative of duct leakage, measurements errors, or incorrect area
factors. Accurate assessment of duct leakage requires a specific duct leakage test, which is outside the
scope of TAB work.
8.3.3 Fan curves can be used when other required data can be obtained, such as SP, rpm and bhp
(W). Experience has shown, however, that often not at all of the field readings will fall into place on
the fan and design system curves due to System Effect and measurements errors.
8.3.4 If the fan volume is not within plus or minus 10 percent of the design airflow requirement,
adjust the drive of the fan to obtain the approximate required airflow. At the conclusion of all system
balancing procedures, measure and record the fan suction static pressure, fan discharge static
pressures, amperage and air volume requirements. Confirm that the fan motor is not operating in
excess of its full load amperage rating. Care must be exercised when increasing fan speeds to avoid
exceeding the maximum rpm limit of the fan and the motor horsepower (W). (The motor power
increases as the cube of the fan speed change.) When new systems do not perform as designed, new
drives and motors often are required. Unless clearly specified in the contract documents, the
responsibility for these items is outside the scope of the NEBB Certified TAB Firm.
8.3.5 When performing static pressure readings on fan systems, it is necessary to take the readings
based on a common static reference point.
8.3.6 Using the methods outlined above, determine the volume of air being handled by the supply air
fan, and return air fan if used, If a central exhaust fan system is used, also determine the airflow being
handled by the exhaust fan. If several exhaust fans, such as power roof ventilators are related to a
particular supply air system, it generally is not necessary to measure the airflow of each such exhaust
fan until after the supply air system is balanced.
8.3.7 Verify the system test data with the supply air and return air fans in the 100% outside air (OA)
and exhaust air (EA) mode. Use caution when ambient conditions may adversely affect system
operation.
8.4 BASIC AIR SYSTEM BALANCING PROCEDURES
Balancing air systems may be accomplished in various ways. Two acceptable methods for balancing
systems are presented. These methods are appropriate for supply, return and exhaust systems.
Regardless of the method, the objectives remain the same and the system will be considered
balanced in accordance with NEBB procedural standards when the following conditions are
satisfied:
a) All measured airflow quantities are within ± 10 percent of the design airflow quantities
unless there are reasons beyond the control of the NEBB Certified TAB firm.
Deficiencies shall be noted in the TAB report summary.
b) There is at least one path with fully open dampers from the fan to an air inlet or outlet.
Additionally, if a system contains branch dampers, there will be at least one wide-
open path downstream of every adjusted branch dampers.
a. Verify that all Grille, register and diffuser (GRD) dampers are wide open.
g. Compute the ratio of measured airflow to design airflow for each GRD.
h. The damper serving the GRD at the lowest percentage of design flow is not adjusted in this
procedure.
i. Adjust the damper serving the GRD with the next (second) lowest percentage of design until
all three GRD’s are the same percentage of design. These GRD’s are now in balance.
j. Adjust the damper serving the GRD with the next (third) lowest percentage of design until all
three GRD’s are the same percentage of design and in balance.
k. Continue this procedure until all GRD’s have been adjusted to be in balance at approximately
the same percentage of design airflow.
l. If necessary, adjust the fan speed to set all GRD’s at design airflow, ± 10%.
n. Mark all GRD’s with felt markers, spray paint, or in some other manner that is permanent, so
that adjustment may be restored if necessary.
Where a basic constant volume supply system has branch ducts, the procedure is:
q. The damper serving the branch at the lowest percentage of design flow is not adjusted in this
procedure.
r. Adjust the damper serving the branch with the next (second) lowest percentage of design
until both branches are the same percentage of design. These branches are now in balance.
s. Adjust the damper serving the branch with the next (third) lowest percentage of design until
all three branches are at the same percentage of design, and in balance.
t. Continue this procedures until all remaining branches have been adjusted to be in balance at
approximately the same percentage of design airflow.
u. If necessary, adjust the fan speed to set all branches at design airflow, ± 10%.
v. Perform the proportioning techniques specified in above steps a) through m) for the diffusers
on each branch.
x. Mark all dampers, with felt markers, spray paint, or other permanent technique, so that
adjustment may be restored if necessary.
This technique is initially described for a basic constant volume supply system without branch
ducts. It is also appropriate for exhaust or return duct systems.
a) Verify that all GRD dampers are wide open.
g) Starting at the fan, as the GRD’s closest to the fan will typically be the highest, adjust the
GRD volume dampers to a value approximately 10% below design airflow requirements.
h) As the adjustment proceeds to the end of the system, the remaining GRD airflow values will
increase
i) Repeat the adjustment passes through the system until all GRD’s at ± 10% design airflow
requirements and at least one GRD volume damper is wide open.
j) If necessary, adjust the fan speed to set all GRD’s at design airflow, ± 10%.
l) Mark all dampers, with pelt markers, spray paint, or other permanent technique, so that
adjustment may be restored if necessary.
Where a basic constant volume supply system has branch ducts, the procedure is:
o) Starting at the fan, as the branches closest to the fan will typically be the highest, adjust the
branch volume dampers to a value approximately 10% below design airflow requirements.
p) As the adjustment proceeds to the end of the system, the remaining branch airflow values will
increase.
q) If necessary, adjust the fan speed to set all branches at design airflow, ± 10%.
t) Mark all dampers, with felt markers, spray paint, or other permanent technique, so that
adjustment may be restored if necessary
8.5 CONSTANT VOLUME SUPPLY SYSYTEM
8.5.1 BASIC CONSTANT VOLUME SYSTEM
For the purpose of this Procedural Standard, a basic constant volume supply system is defined as
having a single fan and connecting ductwork to the outlets and inlets. The following balancing
procedures are appropriate for a basic constant volume systems:
a. Verify the construction team responsibilities for system installation and startup as discussed in
Section 3 are complete.
c. Confirm that the correct air filters have been installed. Review the specifications to determine
if a temporary filter blockage is required to simulate partially loaded filters.
d. Barometric dampers should be checked for free operation. If the dampers are equipped with
adjustable weights, they should be set to maintain the specified building static pressure. All
exhaust systems should be balanced before adjusting barometric relief dampers.
e. Verify that all manual branch and outlet volume dampers are locked 100% open.
h. Confirm that the voltage and amperage matches the motor rating.
l. Air handling units (AHU) equipped with a fixed outside air damper should be set to an
appropriate position as a starting point (caution should be used if freezing conditions are
expected).
m. The OA damper for air handling units using mechanical cooling should be adjusted to a
position estimated to equal design minimum airflow.
n. The OA damper for units using only ventilation air for cooling should be positioned 100%
open, with RA damper closed.
o. Determine if the AHU is rated for total static pressure (TSP) or external static pressure (ESP).
If the rating is for TSP, measure the suction and discharge static pressure at the return duct
and discharge duct. The suction static pressure measurement point can be immediately
adjacent to the unit. The discharge static pressure should be taken at a point 3 to 5 duct
diameters downstream of the fan discharge, and upstream of any elbows or turning vanes.
p. If testing with partially loaded filters is specified, measure the pressure drop across the air
filters and adjust a temporary blockage to meet specified requirements.
q. Measure the AHU total air volume by the most accurate method available. The method used
is at the discretion and judgment of the NEBB Qualified TAB Supervisor based on the
configuration of the unit and its ductwork.
s. Determine the method for adjusting outlets – proportional or stepwise, and balance the inlets
and outlets in accordance with the prescribed procedures.
t. After the supply, return, and exhaust systems are properly balanced, the supply air fan
capacity should be checked with 100 percent outside air if this alternative is included in the
system design. Appropriate damper adjustment should be made if necessary.
u. At the conclusion of all inlet and outlet balancing, re-adjust the AHU minimum outside air
ventilation rate, if required.
v. Record final data, prepare the report forms, and submit as required (see Section 5, Standards
for Reports and Forms).
NEBB PROCEDURAL STANDARDS
SECTION 9 HYDRONIC SYSTEM
TAB PROCEDURES
9.1 INTRODUCTION
Testing, adjusting, and balancing (TAB) of HVAC systems can best be accomplished by following
systematic procedures. The NEBB TAB procedures presented in this section are recommended
current best practices for balancing HVAC systems. The procedures in this section address the
majority of the systems commonly installed. It is the responsibility of the NEBB Certified TAB Firm
to determine appropriate procedures for systems not covered in this section.
Each type of HVAC system is designed to meet a set of performance parameters. This usually
includes maximum heating capacity and maximum cooling capacity. The NEBB Certified TAB Firm
should normally set-up a system in its maximum capacity, or “full load” condition prior to the TAB
process. It is this condition that presents the greatest challenge to a system’s ability to meet its design
hydronic flow.
Not all system types are addressed in this section. Consult with the system designer to establish the
proper set-up conditions for specific systems.
The following TAB procedures are basic to all types of hydronic systems:
a) Verify the construction team responsibilities for system installation and startup as discussed in
Section 3 are complete.
b) Confirm that every item affecting the hydronic flow in a piping system is ready for the TAB
work, i.e. pumps started and operating, piping systems flushed, filled, vented, chemical
treatment complete, air vents installed and operating, startup strainers screens removed and
replaced with final strainers screen, etc.
c) Confirm that the automatic control devices will not adversely affect TAB operations.
e) Verify that all valves are open or set, all related systems are operating, motors are operating at
or below full load amperage ratings, and pump rotation is correct.
It is preferable to balance hydronic systems by the use of calibrated flow measuring devices. Flow
measurement is accomplished by the use of differential pressure meters and calibrated balancing
valves, venturis and / or ultrasonic flow meters, This balance approach is very accurate because it
eliminates compounding errors introduced by the temperature difference or equipment pressure drop
procedures. Balance by flow measurement and good preplanning is needed.
NOTE: Verify that the pressure units of the differential pressure gauge and the pressure units found
on the flow charts provided by the manufacturer are identical. If pressure units are not the same ( i.e.
psi, in w.g., ft.w.g., Pa, kPa, mm, m³/h), pressure conversion will be required.
Self-Adjusting Valves
A self adjusting valve / flow sensing device utilizes internal mechanisms that constantly change
internal orifice openings to compensate for varying system differential pressures while maintaining a
preset flow rate. No external adjustment is available with this device. Pressure taps, providing
measurement of valve differential pressure, allow measurements of the system flow.
The NEBB Certified TAB Firm shall verify the valve flow rating from the data tag, and verify by
differential of the valve.
The pump impeller size is verified by measurement of the pump shut-off differential head. The shut-
off head value is compared to pump curve date to determine the size of the pump impeller. Pump
total head is determined by calculating the difference between the pump discharge pressure and
pump suction pressure. Using the total head, in appropriate units, determine the pump curve data
with data from flow meters and/or calibrated balancing valves.
When the design criteria of the equipment and the pressure loss are known, the flow rate may be
calculated by using the following equation:
Where:
Flow2 = calculated flow
Flow1 = rated flow
P2 = measured differential pressure
P1 = rated differential pressure
Where:
Q = Heat flow in Btuh (Watts)
cfm = Cubic feet per minute
L/s = Liter per second
¨t = Temperature difference – oF (oC)
For water:
(US) (SI)
Equation 9.3 Q = 500 x gpm x ¨t Q(W) = 4190 x L/s x ¨t
Q(kW) = 4190 x m3/s x ¨t
Where:
Q = Heat flow in Btuh (Watts or kilowatts)
gpm = Gallon per minute
L/s = Liters per second
m3/s = Cubic meter per second
¨t = Temperature difference – oF (oC)
Note that in Equation 9.3, the value of 500 (4190) is a constant that is used specifically for water.
This constant will change when the system is other than water, such as a glycol mixture, steam, or
refrigerant.
WARNING: This method can be used to verify that some flow is actually occurring at the
measurement location. It is important to note that the temperature difference method will most likely
result in significant uncertainty in the actual flow rates. This is an unavoidable consequence of the
compounding of measurement errors in the field.
Regardless of the method, the objectives remain the same and the system will be considered balanced in accordance with
NEBB procedural standard when:
a) All measured hydronic flow quantities are within ± 10 percent of the design hydronic flow
quantities unless there are reasons beyond the control of the NEBB Certified TAB Firm.
Deficiencies shall be noted in the TAB report summary.
b) There is at least one path with fully open balancing valves from the pump to a terminal
device. Additionally, if a system contains branch balancing valves there will be at least one
wide open path downstream of every adjusted branch balancing valve.
f) Compute the ratio of measured flow to design flow for each terminal unit.
g) The balancing valve serving the terminal unit at the lowest percentage of design flow is not
adjusted in this procedure.
h) Adjust the balancing valve serving the terminal unit with the next (second) lowest percentage
of design until both terminal units are the same percentage of design, These terminal units are
now in balance.
i) Adjust the balancing valve serving the terminal unit with the next (third) lowest percentage of
design until all three terminal units are at the same percentage of design, and in balance.
j) Continue this procedure until all remaining terminals have been adjusted to be in balance at
approximately the same percentage of design flow.
k) If necessary, adjust the pump volume to set all terminals at design ± 10%.
m) Mark or set all memory stops on all of the balancing valves so that the adjustment may be
restored if necessary.
Where a hydronic system has branch circuits with branch balancing valves, the proportional
balancing procedure is:
p) The balancing valve serving the branch at the same lowest percentage of design is not
adjusted in this procedure.
q) Adjust the balancing valve serving the branch with the next (second) lowest percentage of
design and in balance.
r) Adjust the balancing valve serving the branch with the next (third) lowest percentage of
design until all three branches are at the same percentage of design, and in balance.
s) Continue this procedure until all remaining branches have been adjusted to be in balance at
approximately the same percentage of design airflow.
t) If necessary, adjust the pump volume to set all branches at design flow, ± 10%.
u) Perform the proportioning techniques specified in above steps a) through m) for the terminal
units on each branch.
w) Mark or set all memory stops on all of the balancing valves so that the adjustment may be
restored if necessary.
f) Starting at the pump, as the terminal units closest to the pump will typically by the highest,
adjust the balancing valves to a value approximately 10% below design flow requirements.
g) As the adjustment proceeds to the end of the system the remaining terminal unit flow values
will increase.
h) Repeat the adjustment passes through the system until all terminal units are within ±10% of
design flow requirements and at least one balancing valve is wide open.
i) If necessary, adjust the pump volume to set all terminal units at design flow ±10%.
k) Mark or set all memory stops (see Section 1, Definitions) on all of the balancing valves so that
the adjustment may be restored if necessary.
Where a hydronic system has branch circuits with branch balancing valves, the Stepwise
procedure is:
l) Follow above steps a) through e) above for the terminal units on each branch.
n) Starting at the pump, as the branches closest to the pump will typically be the highest, adjust
the branch balancing valves to a value approximately 10% below design requirements.
o) As the adjustment proceeds to the end of the system the remaining branch flow values will
increase.
p) If necessary, adjust the pump volume to set all branches at design flow, ±10%.
q) Balance the terminal units on each branch as described in above steps e) through i) above.
s) Mark or set all memory stops on all of the balancing valves so that the adjustment may be
restored if necessary.
c) Calculate the percentage of actual hydronic flow by the most appropriate method.
a) Verify that the construction team responsibilities for system installation and startup as
discussed in Section 3, Responsibilities, are complete.
b) Verify that all manual valves are open or preset as required, and all temperature control
(automatic) valves are in normal or desired position.
c) Verify that all automatically controlled devices in the piping or duct systems will not adversely
affect the balancing procedures.
d) With the pump(s) off, observe and record system static pressure at the pump(s).
e) Place the systems into operation, check that all air has been vented from the piping systems
and allow flow conditions to stabilize.
f) Verify that the system compression tank(s) and automatic water fill valve are operating and
set properly.
g) Record the operating voltage and amperage of the pump(s) and compare these with
nameplate ratings and thermal overload heater ratings. Verify the speed (rpm) of each pump.
h) If flow meters or calibrated balancing valves are installed, which would allow the flow rate of
the pump circuit(s) to be measured, perform the necessary work and record the data.
i) Measure the shut-off head of the operating pump by slowly closing a valve or balancing cock
in the pump discharge piping. Record the discharge and suction pressure at the pump gauge
connections and determine shut-off head. Preferably, one gauge should be used to read
differential pressure. It is important that gauge readings be corrected to the center line
elevation of the pump. Do not fully close any valves in the discharge piping of a positive
displacement pump. Severe damage may occur.
j) Using shut-off head, determine and verify each pump’s impeller size and operating curve.
Compare this data with the submittal data curves. If the test point falls on the design curve,
Proceed to the next step; if not, plot a new curve parallel with other curves on the chart, from
zero flow to maximum flow. Open the discharge balancing valve slowly to the fully open
position; record the discharge pressure , suction pressure and determine total operating head.
k) Using the total operating head, read the pump water flow from the previously established
corrected pump curve. If available, verify the pump curve data with data from flow meters
and/or calibrated balancing valves.
l) If the measured total head is greater than the design total head, the water flow will be lower
than designed.
m) If the measured total head is less than design, water flow will be greater; in which case the
pump discharge pressure should be increased by partially closing the discharge balancing
valve until the system water flow is approximately 110 percent of design.
n) Record the suction and discharge pressure and the water flow.
o) An initial recording of the flow distribution throughout the system shall be made without
making any adjustments. This can be performed by using the existing flow measuring devices,
or pressure / temperature ports, in the system, including any balancing devices at equipment
(i.e. chillers, boilers, hot water exchangers, hot water coils, chilled water coils, etc.).
p) Take a complete set of pressure drop measurements through all equipment and compare this
with submittal data readings. Determine which circuits have high or low water flow. Low
circuits may be air bound. Check and vent air if present in low flow circuits and retake
readings.
r) Use the proportional balancing method or the stepwise method described previously to adjust
the flow rates through the equipment.
s) After all final adjustments have been completed, perform a final check of the pressures and
the flow of all pumps and equipment. Re-measure the voltage and amperage of pump motors
and record the data.
t) After all TAB work has been completed, set all memory stops and mark or score all balancing
devices at final set points.
u) Record final unit data, prepare the report forms, and submit as required (see Section 5,
Standards for Reports and Forms).
a) Verify that the construction team responsibilities for system installation and startup as
discussed in Section 3, Responsibilities, are complete.
b) Place the system in a simulated full load condition. If diversity is present in the system,
temporary isolation of portions of the system piping and terminals units may be required.
c) Conduct the basic pump testing and flow procedures as outlined previously. If the pump is
controlled by a VFD, verify the pump is operating at its rated speed.
d) The terminal units are balanced using one of the balancing methods described previously.
e) When diversity is present in the system, upon completion of balancing procedures with a
portion of the system isolated, the isolated units are then opened and an equal capacity of
units closed.
f) Units isolated for the initial balancing procedure are then balanced to design flow rates.
g) The value of the variable flow control setpoint shall be measured and recorded. The control
contactor shall be provided with this information.
h) After all TAB work has been completed, set all memory stops and mark or score all balancing
devices at final set points.
i) Record final system data, prepare the report forms, and submit as required (see Section 5,
Standards for Reports and Forms).
Diversity is a design concept in a variable flow system that allows a system of terminal units to be
served by a pump that is rated for a fraction of the total system terminal unit capacity. Variable flow
systems with diversity may be encountered in TAB work.
The NEBB Certified TAB Firm should determine if the variable flow system has a diversity factor.
The diversity factor is an arithmetic ratio of the pumps rated hydronic flow capacity divided by a
summation of all terminal unit’s design maximum hydronic flow.
Variable systems with diversity can be the most difficult to balance satisfactorily. Any procedures
used will be a compromise, and shortcomings will appear somewhere in the system under certain
operating conditions. The NEBB Qualified TAB Supervisor should expect that some fine-tuning will
be necessary after the initial TAB work is complete.
c) Conduct the basic pump testing and flow procedures on the primary system as outlined
previously.
d) Place the secondary system in a simulated full load condition. If diversity is present in the
system, temporary isolation of portions of the system piping and terminal units may be
required.
e) Conduct the basic pump testing and flow procedures on the secondary system as outlined
previously.
f) The terminal units are balanced using either the stepwise or the proportional balancing
methods described previously.
g) When diversity is present in the system, upon completion of balancing procedures with a
portion of the system isolated, the isolated units are then opened and an equal capacity of
units closed. Units isolated for the initial balancing procedures are then balanced to design
flow rates.
h) After all final adjustments are made, perform a final check of the pressures and flow of all
pumps and equipment. Re-measure the voltage and amperage of pump motors and record
the data.
i) After all TAB work has been completed, set all memory stops and mark or score all
balancing devices at final set points.
j) Record final system data, prepare the report forms, and submit as required (see Section 5,
Standards for Reports and Forms).
The basic steps previously outlined form the foundation for balancing any hydronic distribution
system. In this subsection, additional or special balancing procedures are outlined for use in balancing
specific types of hydronic distribution systems.
a) Verify that the construction team responsibilities for system installation and startup as
discussed in Section 3, Responsibilities, are complete.
b) Conduct the basic pump testing and flow procedures as outlined previously.
c) Record the flow and / or inlet and outlet pressures of the tower piping if applicable. Check
against the manufacturer’s design information.
d) When a tower bypass control is used in the condenser water piping at the tower, measure the
pressure difference with full water flow going both through the tower and / or through the
bypass line. Set the bypass line. Set the bypass line balancing valve to maintain a constant
pressure at the pump discharge with the control valve in either position.
e) After all final adjustments have been completed, perform a final check of the hydronic
pressures and the flow of all pumps and equipment. Re-measure the voltage and amperage of
pump motors and record the data.
f) After all TAB work has been completed, set all memory stops and mark or score all balancing
devices at final set points.
g) Record final system data, prepare the report forms, and submit as required (see Section 5,
Standards for Reports and Forms).
b) With pump(s) off, observe and record the system static pressure at the pump(s).
d) Conduct the basic pump testing and flow procedures as outlined previously.
e) Determine the water flow through the evaporator, and condenser of present, using the flow
meters, calibrated balancing valves, or pressure / temperature ports. If the measured
differential pressure must be used, the flow data can be obtained from the manufacturer’s
submittal data curves or tables. Adjust the flow to design conditions and record the data.
f) After all final adjustments have been completed, perform a final check of the hydronic
pressure and the flow of all pumps and equipment. Re-measure the voltage and amperage of
pump motors and record the data.
g) After all TAB work has been completed, set all memory stops and mark or score all balancing
devices at final set points.
h) Record final system data, prepare the report forms, and submit as required (see Section 5,
Standards for Reports and Forms).
a) Verify that the construction team responsibilities for system installation and startup as
discussed in Section 3, Responsibilities, are complete.
b) Conduct the basic pump testing and flow procedures as outlined previously.
c) Record the water flow and / or inlet and outlet pressures of the tower piping if applicable.
Check against the manufacturer’s design information.
d) When a temperature control valve is used in the water piping at the boiler to control heating
water loop temperature, measure the pressure difference with full water flow going both
through the boiler and/or through the bypass line. Set the bypass line balancing valve, if
present, to maintain a constant pressure at the pump discharge with the control valve in either
position.
e) After all final adjustments have been completed, perform a final check of the hydronic
pressure and the flow of all pumps and equipment. Re-measure the voltage and amperage of
pump motors and record the data.
f) After all TAB work has been completed, set all memory stops and mark or score all balancing
devices at final set points.
g) Record final system data, prepare the report forms, and submit as required (see Section 5,
Standards for Reports and Forms).
a) Verify that the construction team responsibilities for system installation and startup as
discussed in Section 3, Responsibilities, are complete.
b) Determine the water flow through all heat exchangers in all circuits using flow meters or
calibrated balancing valves. If measured differential pressure must be used, the flow data
can be obtained from the manufacturer’s submittal data curves or tables.
c) Adjust the flow to design conditions at all heat transfer components as discussed in
Subsection 9.5.
d) After all final adjustments have been completed, perform a final check of the hydronic
pressure and the flow of all pumps and equipment.
e) After all TAB work has been completed, set all memory stops and mark or score all
balancing devices at final set points.
f) Record final system data, prepare the report forms, and submit as required (see Section 5,
Standards for Reports and Forms).
7.
TAB FORMS
Zamil CoolCare
Testing Balancing Div. HYDRONIC PUMP
NEBB Certification No. 3265
Tel: 03-8100250 ext.100 TEST REPORT
PROJECT:
PROJECT:
LOCATION
DCORR.
MANUF. MODEL SERIAL No.
CAPACITY REFRNT.
PROJECT SYSTEM/UNIT
LOCATION
DE
Valve Actual
Manufacturer Design Actual Actual
Service Full Valve
Size Model Flow Valave Flow Notes
Designation Open Setpoint
Figure no. L/s PD L/s
Flow (Degree)
REMARKS:
REMARKS:
PROJECT: System/Unit:
LOCATION/ZONE: DATE
D CORR. FACTOR:
Unit Designation kW
Manufacturer RPM
Discharge Phase
Out.Air.Damp position
Ret.Air.Damp.Position
REMARKS:
PROJECT: SYSTEM/UNIT
LOCATION/ZONE: SERVICE
ALTITUDE: DENSITY: CORR. FACTOR:
Distance
from Bottom
POSITION 1 2 3 4 5 6 7 8 9 10 11 12
1
2
3
4
5
6
7
8
9
10
11
12
DISTANCE FROM
DUCT EDGE
VELOCITY
SUB-TOTALS
REMARKS:
PROJECT: SYSTEM:
REMARKS:
PROJECT: SYSTEM:
500x300
AB-PACU 1 - SAR-1 0.8 291 2.43 658 5.48 310 2.58 106%
(0.12)
500x300
AB-PACU 2 - SAR-1 0.8 291 2.43 277 2.31 300 2.50 103%
(0.12)
400x300
AB-PACU 3 - SAR-2 0.8 208 2.17 508 5.29 227 2.36 109%
(0.096)
400x300
AB-PACU 4 - SAR-2 0.8 208 2.17 298 3.10 222 2.31 107%
(0.096)
REMARKS:
REMARKS:
REMARKS:
PROJECT: DESIGNATION
FACILITY FCU No
LOCATION CORR.
DESIGN DESIGN
MOTOR VOLTAGE CURRENT
ACTUAL ACTUAL
OUTLET DATA
REMARKS:
PROJECT:
DENSIT
FAN DATA FAN No. FAN No. FAN No.
Unit designation
Location / Service
Manufacturer
Model Number
Serial Number
Class
TEST DATA DESIGN ACTUAL DESIGN ACTUAL DESIGN ACTUAL
Total Airflow L/S
Total Outlet Airflow L/S
Fan Discharge/Suction S.P
Total S.P or ESP Pa
Motor kW
Motor RPM
Motor Rated Volts
Motor RatedAmps
Motor Rated Phase
Motor Operating Hz.
Motor Service Factor
Motor Make/Frame
Fan RPM
Operating Voltage
Operating Amps T1/T2/T3
REMARKS:
PROJECT:
DENSIT
FAN DATA FAN No. FAN No. FAN No.
Unit designation
Location / Service
Manufacturer
Model Number
Serial Number
Class
TEST DATA DESIGN ACTUAL DESIGN ACTUAL DESIGN ACTUAL
Total Airflow L/S
Total Outlet Airflow L/S
Motor kW
Motor RPM
Motor Rated Volts
Motor RatedAmps
Motor Rated Phase
Motor Operating Hz.
Motor Service Factor
Motor Make/Frame
Operating Voltage
Operating Amps T1/T2/T3
REMARKS:
SOUND LEVEL
Tel: 03-8100250 ext.100
Fax: 03-8587305
READINGS
PROJECT: RSCC BUILDING NO 0912 Building:
Sound
Design Temp Set Temp. Actual Temp Time
Room No Description. Level Remarks
DB 0F RH% DB 0F DB 0F RH% dBA hh:mm
Test Date: 13/6/2012 Readings by: Miedy. Instrument Used: Sound level meter BK----------, Temperature / Humidity meter: Fluke 971 Page____ of ____