1.

INTRODUCTION

Testing adjusting and balancing (TAB) is an important process to complete the installation
of building services systems and make the systems perform as intended. It is also a critical
commissioning step uncovering problems in operation, installation and design of air
conditioning systems.

The following procedure has been prepared to cover the mechanical aspects of Pre-
commissioning, testing adjusting balancing the air and water systems.

2. GENERAL PROCEDURE

Preliminary office Work

Gather all applicable plans and specifications to include contract drawings, shop drawings,
“as-built” drawings, schematics and Manufacturers’ catalogs showing equipment data such
as the description, capacities, and recommendations on testing of their equipment and
equipment performance curves. All items will not be available, the more information that
can be gathered. Better understanding of a system and its components is needed to do a
proper balancing. Study the plans and specifications to become familiar with the system
and the Design Intent. Color and label the system and all of its components. This will make
plans easier to read.

Make out the report forms for each system being tested. Report forms will include
equipment test sheets and balancing sheets for the distribution system. It is also
recommend that a schematic drawing of each system be made. Schematics may be very
detailed showing the central system with pressure and temperature drops across
components, duct and pipe sizes, terminal devices, balancing valves and dampers, required
and actual flow quantities, etc. Do as much paperwork in the office as possible.

Preliminary field inspection:-

Inspect the job Condition at site

Inspect the distribution system as per drawing

Inspect the equipment as per drawing

Preliminary Procedures:-

1. Ductwork intact and properly sealed.

2. Set all volume control damper and variable air volume boxes to the full open
position, unless system diversity requires balancing in zones.
3. Set outside air dampers to the Design CFM.
4. Review Ductwork leak testing Report
5. Access doors installed and properly secured (Sealed).
6. Ductwork free from debris.
 7. Dampers (including fire and smoke dampers,) installed and accessible.
8. All other air distribution devices such as diffusers, etc., installed and functional.
9. Return air has an unobstructed path from each conditioned space back to the unit.
10. Filters should be clean and correctly installed.
13. Filter frame properly installed and sealed.
14. Coils cleaned and properly installed.
15. Drive components installed properly.
16. Pulley properly aligned and tight on their shafts.
17. Verify correct fan rotations and speeds.
18. Belt guard properly installed.
19. Automatic control dampers installed and functional.
20. Flexible connections installed properly.
21. Fan wheel aligned properly and adequate clearance in the housing.
22. Check motor amperages and voltages & make necessary adjustments.
3.2 Balancing Procedures:-

1. All related HVAC and exhaust air system should be operating properly.
2. Make Pitot tube traverses on all main supply and major branch ducts where possible
to determine the air distribution. Take extreme care that there is no damage to
HEPA filters by debris being pulled or pushed into them.
3. Measure and record the airflow of each terminal device in the system without
adjusting any terminal outlet. Flow measuring hoods are the preferred airflow-
measuring device.
4. The total airflow for the terminal outlets should be close to the Pitot tube traverse
air measurement of that branch, and the main duct traverse air measurement
should be within 5% of the total of all terminal outlet air measurements.
5. Adjust the terminals that are highest on airflow to about 5% under design airflow.
6. Adjust each terminal outlet throughout the zone or system to design airflow and
record measurements and make any necessary branch damper adjustments.
7. An additional adjusting pass throughout the system may be necessary. Make final
adjustments to the fan drive where required. Record all data.
8. Adjust terminal device vanes to minimize drafts and for proper air distribution.
9. Measure and record system static pressures.
13. Measure and record all coil entering air and leaving air dry bulb and wet bulb
temperatures.
14. Measure and record final fan motor full load amperages and voltages.
15. If the airflow is low, proceed with a proportional balancing. Proportional balancing is
purporting the air equally by dividing the total airflow by the design airflow to get
the percentage of airflow. Then multiplying the percentage of airflow to the design
airflow for the percentage of air to set to.
3.4 Specialist Test Instruments:-

Performance Testing & System Static Pressures- Pitot static tube and digital
micro manometer.

Terminal Readings – Electronic Anemometer, Analogue Anemometer, bolometer.

Temperature – Digital thermometer & laser gun.

Plant speed – Tachometer.

Electrical - Clip-on meter amp meter.

3.5 Documentation & Instrumentation:-

1. All instrumentation will be calibrated and will have valid certificate copies of which
will be when required.
2. Test sheets will be written and copies submitted to the project manager and
consultants for scrutiny and approval.
3. After completion of the testing, adjusting, balancing and submission of test sheets
data can be verified by consultant or clients representative.
3.6 List Of Test Sheets:-

S.no Description
1 FAHU Performance Test Sheet
2 FAHU Pressure Drop Test Sheet
3 Heat Recovery Wheel Performance Sheet
4 Heat Recovery Wheel Test Sheet
5 AHU Performance Test Sheet
6 AHU Performance Test Sheet With Return Air
7 Pressure Drop Test Sheet
08 Fan Performance Test Sheet
09 Traverse Test Sheet
10 Air Balance Test Sheet
11 VAV Terminals Test Sheet
12 Fan Coil Performance Test Sheet
13 Sound Test Sheet
14 Staircase Pressurization Test Sheet
15 Package Unit Performance Test Sheet
16 DX Split Unit Performance Test Sheet
4. WATER SYSTEM
4.1 Preliminary Procedures:-

The following is a general list of items to be checked:-

1. Strainers and piping free from debris, cleaned, and flushed.

2. Set all balancing devices to full open position.
3. Construction strainer baskets replaced with permanent baskets.
4. Set mixing valves and control valves to full coil flow & close coil by-pass valves.
5. System filled to the proper level and the pressure-reducing valve set.
6. Automatic and manual air vents properly installed and functional
7. All air purged from the system.
8. Water in the expansion tanks at the proper level.
9. All valves, flow meters, and temperature/pressure tap installed correctly, accessible
and functional.
10. Terminal coils installed, piped correctly, and accessible.
11. Pumps properly aligned, grouted and anchored.
12. Verify correct pump rotations and proper drive alignments.
13. Vibration isolators properly installed and adjusted.
14. Flexible connections installed properly.
15. Measure and record pump motor amperages and voltages.
16. Check pump flow before balancing coils.
17. Water treated Chemicals & their Quantity as per recommended PPM.
Chiller

1. All operating and safety settings for temperature and pressure are correct.
2. Chiller, condenser started, and operating correctly.
Controls

1. Controls complete and functional.

2. Make initial tests on all pumps applicable to the system being balanced.
3. Balance and adjust the distribution system.
4. Take final reading.
5. Complete reports.
4.2 Balancing Procedures:-

1. Adjust pump to design flow and record data.

2. Adjust chillers to design flows and temperatures and record data. If the Pump is
pumping water to coils first start there, always follow the piping.
3. If flow-measuring devices are used, record the flow data throughout the system
before adjusting the system.
4. Measure and record pressure drops through all coils or units and Compare with
submittal data for high and low flows.
5. Adjust high flows to near design.
6. Measure and record final pump pressure, amperes, and voltages.
7. Measure and record all coil and or unit pressure drops entering and leaving water
temperatures.
8. Measure and record all data from all flow measuring devices.
 4.6 List of Test Sheets:-

S.no Description
1 Chiller Performance Test Sheet
2 Pump Performance Test Sheet
3 Water Balance Test Sheet
4 Heat Exchanger Performance Test Sheet

5. DOP Testing PROCEDURE:

 DOP TEST OF HEPA FILTERS TO BE PERFORMED BY AN OUTSIDE AGENCY AND THE HEAD
ENGINEERING SHOULD ENSURE THAT THIS SOP IS FOLLOWED BY OUTSIDE AGENCY.
 THE MEASUREMENT TO BE DONE BY USING A CALIBRATED PHOTOMETER HAVING
TRACEABILITY TO NATIONAL STANDARDS.
 FEED THE DOP AEOSOL AT FRESH AIR INLET OF AHU.
 CONNECT ONE OF DOP MEASURING PROBE TO UPTREAM PORT OF PHOTOMETER.
 TURN THE KNOB PROVIDED ON PHOTOMETER AT UPTREAM POSITION.
 HOLD THE DETECTOR OF DOP MEASURING PROBE BEFORE HEPA FILTER OR AT THE PORT
PROVIDED IN THE PLENUM.
 PRESS A KEY FOR 100% CONCENTRATION.
 PHOTOMETER WILL SCAN THE DOP FOR 100% CONCENTRATION
 CONNECT THE DOP MEASURING PROBE TO DOWNSTREAM PORT OF PHOTOMETER.
 TURN THE KNOB PROVIDED ON PHOTOMETER AT DOWNSTREAM POSITION.
 DO THE SCANNING AFTER HEPA FILTER AT A DISTANCE OF 25mm FROM THE HEPA FACE OR
AT THE PORT PROVIDED ON PLENUM. WHEREVER ACCESS OF FILTER IS NOT POSSIBLE TAKE
THREE SAMPLES TO CHECK THE REPEATABILITY
 THE FILTER AND ITS INSTALLATION SHOULD NOT SHOW LEAKAGES GREATER THAN 0.01%
CONCENTRATION.
 IF THE DOWNSTREAM LEAKAGE EXCEEDS 0.01 %, THE INSTALLATION TO BE RECTIFIED FOR
ANY LEAKAGES NEAR FLANGES USING SILICON SEALANT.
 AGAIN SCAN THE FILTER AND THE INSTALLATION WITH DOP.
 IF THE DOWNSTREAM LEAKAGE EXCEEDS 0.01 %, THE FILTER SHALL BE SENT FOR TESTING.
 AFTER RECTIFICATION OF THE LEAKAGES IF THE LEAKAGE DOES NOT FALL WITHIN 0.01%
REPLACES THE HEPA FILTER WITH NEW AND REPEAT THE DOP TESTS AS PAR THE STEPS 5.1
TO 5.10.
 THE DOP TEST FOR THE HEPA FILTERS OF HVAC SYSTEM AND PROCESS EQUIPMENT SHALL BE
PERFORMED ONCE IN A YEAR AND HEPA FILTERS OF THE LAF SHALL BE PERFORMED ONCE IN
A SIX MONTHS. 5.18 THE DOP TESTING SHALL BE CARRIED OUT AS PAR DOP TESTING
SCHEDULE. UPDATE: DOP IS NOW REPLACED BY PAO (POLY ALPHA OLEFIN)

6. ADDENDUMS
6.1 Sample Test Sheets

Performance test Sheet for Air Handling Unit

Supply Terminal test Sheet for Air Handling Unit
Return Terminal test Sheet for Air Handling Unit
Duct Traverse Point
Chiller Performance Sheet
Chilled Pump Performance Sheet
Condenser Water Pump Performance Sheet