OSRAM KULIM

Commissioning and Test Plan for

AHU & DOAS

Ref. no:
Name: Silver Chuah Revision: 00
Date:
Contact no.:017-9269891

Company: York (Malaysia) Sales & Service Sdn

Bhd
Page 1 of 6

Commissioning and Test Plan for AHU & DOAS

Reviewed by Tialoc
Submitted by Package QA/QC SHE Manager Construction Approved by
Contractor Manager Manager Manager Tialoc Project
Manager
Signature:

Name:

Date:

Time:

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 OSRAM KULIM
Commissioning and Test Plan for
AHU & DOAS

Ref. no:
Name: Silver Chuah Revision: 00
Date:
Contact no.:017-9269891

Company: York (Malaysia) Sales & Service Sdn

Bhd
Page 2 of 6

1.0 Introduction
This document shall address the typical works for all AHU & DOAS start-up and T&C

2.0 Reference Documents

For all specifications referred to attached installation plan

3.0 Glossary, Acronyms and Abbreviations

AHU Air Handling Unit

DOAS Dedicated Outdoor Air System
T&C Testing and Commissioning
RH Relative Humidity

3.1 Planned Resources

3.2 Machinery and Equipment

No Description Quantity
1 Digital Power Meter (KYORITSU KEW SNAP 2002PA) 1
2 Pitot Tube micromanometer (TESTO 440 dP) 1
3 Temperature & RH Meter (Pro’s Kit MT-4616) 1
4 Digital Clamp Meter (KYORITSU 1009) 1
5 Barometer 1
6 Thermohydrometer 1

3.3 Persons Responsible

Designation / Name Contact Number

General Manager Teh Tian Siang
Project Manager Clarence Chan
Safety
Site Supervisor
Site Engineer Lim Ji Xiong

Trades Anticipated Numbers

Skilled worker
Supervisor
Safety supervisor

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 OSRAM KULIM
Commissioning and Test Plan for
AHU & DOAS

Ref. no:
Name: Silver Chuah Revision: 00
Date:
Contact no.:017-9269891

Company: York (Malaysia) Sales & Service Sdn

Bhd
Page 3 of 6

4.0 Logistic Plan

4.1 Coordination at site.

I. To identify the actual location for equipment start-up and T&C as per approved shop drawing.

II. Coordinate with M&E contractors for the schedule of works.

III. Ensure all material, equipment and tools are ready prior to commencing AHU/DOAS start-up and T&C

4.2 Storage of Material

I. All equipment needs to be stored with proper cover to prevent any affect to the quality of material.

II. Storage area shall not obstruct any access and property barricades with proper signage with PIC and

barrier ownership.

III. Storage to follow as per manufacturer recommendation.

4.3 Safety Arrangements and Equipment

I. Workers to attend safety induction conducted by site safety officer.

II. Workers shall practice minimal safety procedure with the use of safety helmet, safety vest, safety

gloves, safety boots and safety glasses.

III. Ensure all permit to work and related documents was approved before start installation work.

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 OSRAM KULIM
Commissioning and Test Plan for
AHU & DOAS

Ref. no:
Name: Silver Chuah Revision: 00
Date:
Contact no.:017-9269891

Company: York (Malaysia) Sales & Service Sdn

Bhd
Page 3 of 6

5.0 Work Methodology

5.1 Prior to unit start-up
 Daily tools box meeting will be conducted by Tialoc Personel.

 Commissioning plan to be applied

 Safety briefing of the day’s job will be done by supervisor 15 minutes prior to operation

 All units at site shall be inspected and ensured it is as per submittal and are thoroughly cleaned. With the

inspection together with Tialoc QC in charge person.

 Check the unit Tag name/model for AHU/DOAS

 Check the serial number for AHU/DOAS

 Inspect electrical connections. It should be clean and secure.

 Check that all air filters are in place and positioned properly.

 Close and secure all unit access doors.

 Remove all foreign material from the drain pan and check drain opening and condensate line for

obstructions.

 Ensure ducting connection is completed

 Ensure official casing leak test is done and approved

 Ensure all dampers are open (both supply and return duct)

 Ensure Installation of additional washable pre-filter on filter station. Install by ESM

 M5, F8 and carbon filter (if applicable) to be remained installed during T&C and flushing.

 Acknowledge the AHU/DOAS start-up check list by Tialoc before start-up the AHU/DOAS (referring

to the AHU/DOAS check list as attached)

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 5.2 Start-up procedure
After completing all start-up checks and procedures, the unit may be started. The following checks and
adjustments should be made during initial start-up:

 Inspect the entire motor for rust and corrosion.

 Bump-start unit and observe the fan wheel for proper rotation, as indicated by rotation arrow located on
fan housing.
 Measure the motor voltage and amperage on all phases to ensure proper operation. The readings
:
should fall within the range given on the motor nameplate.
 Pay particular attention to any vibration, noise or overheating of the motor and fan bearings.
(Bearings may run warm during break in).
 Supply and return dampers must be in good condition. ]

5.3 Testing and Commissioning

Let the unit run for 30 mins (for the air to circulate and stabilize to get the on-coil temperature and RH as
per report) and record below data in the T&C report as attached.

1. On / Off coil Temperature and RH

(a) Measuring using temperature and RH meter. The temperature & RH are measure directly
before and after the cooling coil
(b) Record the data and comparing to AHU report as approved in acconex

2. On/Off Temperature for Heat Wheel

a) Fresh air temperature before and after heat wheel
b) Exhaust air temperature before and after heat wheel

3. Air velocity / Air Volume (adjust the potential meter to get the air volume as design)
(a) The air velocity shall be measure at the measuring port at the discharge duct using pitot
tube micromanometer. The location of the measurement will be subject to system design
and site location availability.
(b) Calculate the air volume by using the formula
below Air volume = air velocity * Area
(c) Adjusting the potential meter to increase air volume to meet
specification Air volume = air velocity * Area

4. Motor Amps
(a) Measure the motor running amps for each EC fan by using the power meter

5. Motor Voltage
(a) Measure the main incoming voltage by using the power meter

6. Voltage value for potential meter

(a) Record the potential meter value (0~10V) in which performed the step 3. (C) above

7. Filter pressure drop measurement and recording

(a) Record the filter pressure drop for M5; F8 and carbon filter (if applicable) by referring to
the pressure gauge on the AHU body

8. Fan section limit switch testing (Cut-Off power when door is open)
(a) Open the fan section door when the unit is running.
(b) Observe if the EC fan can be cut-off and record the result

9. Emergency / Main disconnection Breaker Testing

(a) Testing the main disconnection breaker by turning it off when the unit is running

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 10. Light checking
a) to switch on the marine light to check on the light functionality

11. Individual fan cut off checking

a) Check individual fan cut off by switch off each individual fan’s MCB

12. Emergency push stop button and Main disconnection switch checking
a) Check the functionality of emergency stop button and main disconnection switch

6.0 Housekeeping

I. Housekeeping to be maintained during and after work done.

7.0 Identified Risk

I. The PPE required for this task is safety helmet, safety boot, hand gloves, electrical protection glove, eyes
protection and safety vest.
II. Please refer to Risk Assessment (HIRARC) attachment

8.0 Inspection, Testing and Commissioning Proposal

Inspection and Test Plans (ITP) shall include inspection at the following stage.

 Receiving of materials / machinery

 In-process inspection during installation
 Final stage prior to handover

ITP shall also address the “Hold Point”, where approval on the work activity is required.

Refer to Attachment 1: Inspection and Test Plans

9 List of Attachments/ Reference

1. Risk Assessment (HIRARC)

2. AHU/DOAS Start-up check list

3. AHU/DOAS T&C report

4. Calibration certificate

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 Project Name : Location :

Package Number : Date

Customer : AHU Tag Name

By : York (Malaysia) Sales & Serivce Sdn Bhd AHU Model

Serial Number :

Subject : AHU/DOAS Start-up Check List

Please check and tick on below before start-up.

1 Belt Tensioning

2 Incoming Power Supply

3 Wiring Socket Seal

4 Fan Rotation

5 Fan Wiring

6 Primary Filter – M5 (Check all the filter in secure place)

7 Secondary Filter – F8 (Check all the filter in secure place)

8 Carbon filter (if applicable)

9 Primary Filter Pressure Gauge

10 Scondary Filter Pressure Gauge

11 Temperature Gauge

12 Damper fully open

13 Cooling Coil Connection

14 Drainpipe Connection

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15 Test Instrument Calibration Certificate

16 Pressure Gauge Calibration Certificate

17 Temperature Gauge Calibration Certificate

18 Incoming power supply to light switches

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28 of 6
 HAZARD IDENTIFICATION RISK ASSESSMENT AND RISK CONTROL
Contractor Company Name: Project Title: Activity Assessed:
SPECIFIC DIMENSION SDN.BHD

Conducted by: Lim Ji Xiong Date: Job Reviewed by: Date:

EHS Approved for CBRE by: Date:

Hazard Identification Risk Assessment Risk Control

Sequence of Activity/ Task Potential Hazards Potential Impacts or Existing Control Measures Recommended Control

Probability
Effects Measures

Ranking
Severity

To inform & get approval from
project Coordinator and Area
Owner & EHS on the nature of
work to be carried out prior to work
commencement
 Miscommunication  Non compliance  Workers compulsory to
attend SHE training
required for the activities
before execute work.
 Foreign Workers and
management staffs with
valid work permit.
 SIC training and on job
training by task
management team.
 Workers to communicate
through TBM
Risk
1 1 low Other than project
coordinator, area owner
and EHS, please get an
approval from the system
owner as well. Ensure they
understand the scope and
the risk(s) of work to be
carried out.

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Conduct Toolbox Meeting to brief  Mis  *Non compliance  All workers and 1 1 low
the job sequence and possible communication management staffs
hazard encountered before start Steps of work involved must be briefed
work prior start to work.
 Tool box meeting shall be
conducted by supervisor
before start work.
 All workers shall perform
according to TBM
instruction. Get approved
Motorola site badge and
display full time at site.

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SEVERITY OF IMPACT
Severity Group Rank People Equipment/ Facility Property
Minor 1  Near miss  Near miss  Near miss
 Superficial injuries, minor burns, cuts &  No serious equipment or facility damage  Chemical spill requiring only routine
bruises; eye irritation from dust.  Losses up to RM10,000. cleanup.
 Losses up to RM10,000.

Major 2  Lacerations, severe burns, concussions,
serious sprains, minor fractures, electric
shock.
 Hearing loss, work related CTD, ill health
and minor disability.
 Equipment or Facility damage (repairable)  Chemical spill. Internally controlled.
 Losses more than RM10,000 and up to  Losses more than RM10,000 and up to
RM100,000. RM100,000.

Critical 3  Major fractures, multiple injuries, fatal  Major equipment or facility damage (need  Chemical spill require external help and
injuries, amputations & poisoning. replacement). expertise.
 Life shortening and/ or acute fatal disease.  Losses more than RM100,000.  Losses more than RM100,000.

PROBABILITY OF OCCURENCE
Probability Group Rank Expected Rate of Occurrence of Each Hazard
Unlikely 1 No more than once per year.
Possible 2 No more than two to three per year.
Frequent 3 Four or more per year

RISK RANKING
Probability Unlikely (1) Possible (2) Frequent (3)
Severity
Minor (1) Low Low Medium
Major (2) Low Medium High
Critical (3) Medium High High

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