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METHOD STATEMENT
FOR
TESTING AND COMMISSIONING

MECHANICAL VENTILATION & AIR

CONDITIONING SYSTEM

T&C Procedure Air Conditioning & Ventilation System Page 1

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 Revision History

Issue Prepared
Rev Date
Purpose by:
Signature Reviewed by Signature Approved by Signature

I. METHOD OF STATEMENT

A. AIR DISTRIBUTION SYSTEM

1.0 Criteria

The balancing tolerance will be based on SMACNA recommendations on the

tolerances acceptable in practice for terminal to terminal and branch to branch
balancing.

Supply and Extract branch or sub-branch with terminal

Damper Location serving
Single Space More than one space
Terminal % of proportional
+10% +10%
flow at index terminal
Branches & sub branches %
of proportional flow at index +10% +10%
sub-branch
Fan % of design flow +10%

Before starting air balancing, it is essential that the following conditions be fulfilled:
a. The building is complete. Ceilings, doors and windows installed, windows
glazed, doors or windows in their normal open or closed state. If spaces are
not architecturally sealed, abnormal pressure distributions will unbalance the
system and lead to inconsistent and insignificant results.
b. The duct system is completed and clean. Any duct leakage testing required
is completed remedial treatments fully carried out. All grilles, dampers,
diffusers, filters and coils installed.
c. The system is ready for setting to work. (See required TCx-certificate forms in
item no. IV).

2.0 Basic Principles

The technique to be used in balancing the air distribution system will be Proportional
Balancing Method which is accepted as the most appropriate method of effectively
regulating distribution systems. Successful application of the technique is dependent
upon the inclusion of sufficient regulating devices (volume dampers, splitter, etc.)
suitably positioned in the ductwork installation. The balancing procedure and
underlying principles describe in this section assume that such devices have been
installed in the ductwork branches to every terminal.

The principles of proportionally balancing require that all the dampers in the
distribution system be fully open and that at least one outlet volume damper (the
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 outlet with the lowest percent of design flow) will remain open. If the system has
branch ducts, at least one branch volume damper (the branch with the lowest percent
of design flow) will remain full open. Because the air outlets on the low pressure side
of any system the following proportionally balancing procedure can be used.

3.0 Preparation

a. Open all duct system and terminal dampers but keep the main fan damper partly
closed. Set the diffuser to give full downward discharge and set adjustable grille
louvers at right angle to the grille face. Open the plant dampers to establish the
conditions for the maximum demand system airflow.

b. Run the fan and check the motor current to ensure that its design full load value
is not exceeded. Adjust the main fan damper until the fan motor current is close
to the design value. If the amperage exceeds the nameplate full load amperage,
stop the fan to determine the cause or to make the necessary adjustment.

c. Walk around the system checking that air is flowing from each supply terminal or
being extracted. Confirm that all related system fans serving each area within the
space being balanced are operating. If not, pressure differences, and infiltration
and exfiltration may adversely influence the balancing. Preliminary studies will
have revealed whether or not the supply air quantity exceeds the exhaust air
quantity from each area. Positive and negative pressures zones should be
identified at the time.

Traverse Location:

Accurate pressure readings cant be taken in a turbulent air stream;

therefore, the traverse should be at least 8x duct diameters downstream and
2 duct diameters upstream from elbows, transitions, takeoffs, dampers or
other obstructions which cause turbulence. A minimum of 16 points but not
more than 64 must be measured in order to get a good average. To
determine the equivalent duct diameter of a rectangular duct use equation
1.0.

Equation 1.0
d = 4ab /
Where:
d = equivalent duct diameter in inches
a = length of one side of rectangular duct in inches
b = length of adjacent side of rectangular duct in inches
= 3.1416

Example 1.1: Find the equivalent duct diameter of a duct thats 24

wide by 20 high.

Solution:
d = 4 x 24 x 20 / 3.1416= 24.7

Therefore, a Pitot traverse will be approximately 198 (8x24.7) downstream

and 49 (2 x 24.7) upstream for obstructions.

d. Measure the total flow rate at the fan by a duct pitot-tube traverse and also
the fan pressure rise after checking the fan speed. The fan should be
delivering at least +10% of the design value. If the measured air volume of
the supply fan varies more or less than 10% from design, adjust the drive of
each fan to obtain approximate required air volume record fan suction static
pressure, fan discharge static pressure, amperage and air volume
measurements. Confirm that the fan motor is not overloaded. Also,
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 determine the volume of air being handled by the exhaust fan. If there is
several exhaust fans it is generally not necessary to measure air volume of
exhaust fans until after the supply system is balanced. Open the main
damper to ensure that the design full load current is not exceeded.

What if fan RPM cant be measured?

If fan rpm cannot be measured we can determine the performance by using

the Fan Performance Curve/Graph by plotting the CFM and SP. The point of
intersection should collide on the fan curve or at least not +10% of the
design.

What if there is no possible location to perform traverse air measurement?

If there is no possible location we can use the vane anemometer. Using the
vane anemometer we can measure the fan CFM by getting four points of
reading or intervals depending on the size of the duct and dividing it from the
number of readings and multiply by the correction factor (K). The point
interval of vane should not be less than 100mm or greater than 150 mm
center to center distance of the vane. We can also use a balometer if
applicable on the size of diffuser.

4.0 Balancing Procedure

a. Determine which outlet has the lowest percent of design airflow (%D).
Typically the outlet with the lowest %D will be on the branch farthest from the
fan. This outlet will be called Key outlet.

* Design flow is either the original design airflow per the contract specifications
or new calculated design airflow.

* Percent design airflow is equal to the measured flow divide by the design
airflow.

b. Starting with the key outlet, as needed, adjust outlet of that branch duct in
sequence, from the highest percent of design air flow to the lowest percent of
design airflow.

* The ratio of the percent of design airflow between each outlet must be plus or
minus 10%. Ratio of design airflow is equal to outlet X %D divided by outlet Y
%D.

* To reduce airflow, volume dampers in the system should be adjusted in the

branch ducts and at the takeoffs and not the outlet since dampering at the
outlets results in excessive noise and poor air distribution.

c. Go to branch that has the outlet with the next lowest percent design flow as
determined from the initial readout. Typically this Key outlet will be on the
second farthest branch. Balance all the outlets on this branch to the key
outlet to within plus or minus 10% of the design airflow.

d. Continue until all the outlets on all branches have been balanced to within
plus or minus 10% of the design airflow on each other.

e. Starting with the branch with the lowest percent of design flow as the key
branch proportionately balance all branch ducts from the lowest %D airflow to
the highest %D airflow within 10% of each other.

f. Continue until all branches have been balanced.

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 g. Adjust the fan speed if needed to bring the system to within plus or minus
10% of the design airflow.

h. Reread all outlets and make any final adjustments.

5.0 Final Correlation

a. When the entire duct network is balanced, measure the flow in the main duct
using the pitot-tube and micro manometer. If the flow is higher than the design
value, adjust the main damper. If the pressure drop across the main damper in
the final position is a significant part of the total system pressure, a reduction in
fan speed should be considered.
If the flow is less than the design rating, open the damper making sure that the
maximum permissible fan motor current is not exceeded.

b. It is essential, while using the proportional balancing technique, that absolute flow
rates are calculated from time to time during the procedure and at the end in
order to ensure that there is a satisfactory correlation between the flow rates from
terminals in the sub-branches and main branches and the total system flow rate.
Due to wide variety and mix of terminals, which can be available on any one
system, flow rate technique may vary. Simply balancing on anemometer velocity
readings alone, with continual reference to absolute values can lead to poor
result.

c. Finally, recheck all terminals in terms of percentage of design. If a section is

shown to be out of balance, dampers can be reset, provided the flow in adjacent
section is not changed beyond the tolerance limit.

d. Lock all dampers in position. Alternatively, inscribe the position of the damper
arm and seal the operating screw.

e. Equipment Motor Side :

Record all pertinent data found in the name plate (power rating, Current Reading,
Voltage Reading, Speed, etc.).
While the equipment is running, measure the actual reading of the following:
a. Current Reading
b. Voltage Reading
Compare and verify the actual reading results to the equipment design
performance curve.

f. Record the Final Datas using the Testing & Commissioning Checklist format on
item no. IV.

B. AIR-CONDITIONING EQUIPMENT

1.0 Split & Multi-Split-Type (Direct Expansion)

All the Required Pre-commissioning Testing on the Equipment are the

Following:

1.1 Refrigerant Pipe Leak Testing

a. Open liquid line charging valve and connect gauge manifold.

b. Connect a cylinder of dry nitrogen to the gauge manifold.

Caution: A full nitrogen cylinder is more than 2,000 psig at room

temperature. Use a pressure regulator. Extra care must be taken
during the charging of nitrogen gas.
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 c. Set the pressure regulator on the nitrogen cylinder at 350 psig.
Open the valve of the gauge manifold, then the shut-off valve of the
nitrogen cylinder. Charge enough nitrogen into the system to raise
the pressure to 350 psig.

Note: The valve of the gauge manifold and the liquid charging line
shall be opened before the opening of the shut-off valve of the
nitrogen cylinder.

d. First, check the gauge manifold, service hoses and service valve
connections for leaks. If pressure wont increase, check the system
for leaks. Leaks are located by applying soap solution to joints and
connections.

e. After the leaks are found, release the system pressure. Then,
repair leaks by cleaning and repairing the joints.

Note: No soldering shall be done on the system when under

pressure.

f. When the system is assumed to be leak free, add nitrogen gas to

raise the system pressure to 350 psig.

g. Re-check the system for leaks. If no leaks are found, allow the
pressure to remain for twenty four (24) hours. After this time check
the system pressure. If no pressure change was noted, the system
is considered leak free.

h. The system is now ready for evacuation.

1.2 Evacuation

1.2.1 Definition of Terms

a. Manifold Pressure The indicated pressure of the gases in the

system evacuation lines and piping of the vacuum pump while the
service valves are kept opened.
b. Equilibrium Pressure The actual pressure of the gases in the
system while the service valve connected to the vacuum pump is
closed.
c. Vacuuming is the process of removing moisture of the air or other
gasses on confined space (example: refrigerant pipe)

1.2.2 Evacuation Procedure

a. Perform pre-start check on the vacuum pump as called for in the

pumps operating instructions.
b. Purge refrigerant/ nitrogen from the system and exhaust it completely
to the atmosphere and not inside occupied quarters.
c. Start pump and warm-up for 10 minutes.
d. Connect evacuation line to the low-pressure service valve of the
system to be evacuated. Set-up is now ready for evacuation.
e. Start initial evacuation by opening the low-pressure service valve.
f. Allow the system to be evacuated to attain equilibrium pressure of
28Hg (500 microns). If the pressure fails to reach 28Hg (500
microns), then the system should be check for leaks.
g. Continue evacuation if equilibrium pressure indicates no leak.

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 h. Evacuate until equilibrium pressure of 28Hg (500 microns) or less is
attained.
i. Close both service valves and disconnect the evacuation line to the
system.
j. Immediately charge 2-5 psig of dry refrigerant vapor (R22) to break
the vacuum. System is now ready for next evacuation.
Note:
Breaking the initial vacuum with dry refrigerant will trigger reaction
with the refrigerant absorbing and mixing with any residual
contaminant. This will make it easy to remove the remaining
contaminants on the next vacuuming. Never break vacuuming with
Liquid Refrigerant.
k. Allow a few minutes time for chemical reactions to occur inside the
system.
l. Repeat item no. h, i, j, k, b, d & e in that order, three (3)
times to attain triple evacuation.
Note:
Do not turn-off vacuum pump when connected to an evacuated
system before closing the manifolds.
m. An evacuated system shall never be left at a high vacuum state for
more than three (3) minutes. It is imperative that it be charged just
after evacuation.
n. Under no condition is the motor compressor be started or operated
while the system is under a high vacuum. To do so, may cause
serious damage to the motor windings because of the reduced
dielectric strength of the space within the motor chamber.
o. Then system is ready for charging when manifold and equilibrium
pressure reads 28 Hg (500 microns).

1.3 System Commissioning Procedure

1.3.1 Pre-Commissioning Checklist

All outstanding works and punch list must be completed before
commissioning the system, by completing the Pre-commissioning
requirements. Equipment supplier is present during this setting to
work process.

1.3.2 Performance Test of the System

1. Start up the equipment for minimum of 1 hour (thermostat set

to 22oC and fan to high speed).
2. Check unit interlocking, pilot light, and control function.
3. Check the evaporator & condenser fan outlet temperature and
suction & liquid line pressure of the compressor.
4. Motor current shall not overload. Current readings shall be
within the range of motor nameplate rating for specified applied
voltage. (Condenser Fan Motor, FCU Fan Motor and
Compressor Motor)

5. Condenser air shall not re-circulate back to the condenser coil

(Short Cycle). We can determine or check if the air circulation
is good by getting the air inlet temperature and air outlet
temperature of the condenser. The air inlet temperature should
be almost equal on the ambient temperature not closer to the
air outlet temperature of the condenser.

6. If no abnormality is found in the system, test the actual

performance of the unit by completing the Testing and
Commissioning form on item no. IV.

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 2.0 Variable Refrigerant Flow (VRF)

All the Required Pre-commissioning Testing on the Equipment is the

Following:

2.1 Refrigerant Pipe Leak Testing

a. Open liquid line charging valve and connect gauge manifold.

c. Connect a cylinder of dry nitrogen to the gauge manifold.

Caution: A full nitrogen cylinder is more than 2,000 psig at room

temperature. Use a pressure regulator. Extra care must be taken
during the charging of nitrogen gas.

d. Set the pressure regulator on the nitrogen cylinder at 44 psig.

Open the valve of the gauge manifold, then the shut-off valve of the
nitrogen cylinder. Charge enough nitrogen into the system to raise
the pressure to 218 psig.

Note: The valve of the gauge manifold and the liquid charging line
shall be opened before the opening of the shut-off valve of the
nitrogen cylinder.

e. First, check the gauge manifold, service hoses and service valve
connections for leaks. If pressure wont increase, check the system
for leaks. Leaks are located by applying soap solution to joints and
connections.

e. After the leaks are found, release the system pressure. Then,
repair leaks by cleaning and repairing the joints.

Note: No soldering shall be done on the system when under

pressure.

f. When the system is assumed to be leak free, add nitrogen gas to

raise the system pressure to 540 psig.

i. Re-check the system for leaks. If no leaks are found, allow the
pressure to remain for twenty four (24) hours. After this time check
the system pressure. If no pressure change was noted, the system
is considered leak free.

j. The system is now ready for evacuation.

2.2 Evacuation

2.2.1 Evacuation Procedure

n. Perform pre-start check on the vacuum pump as called for in the

pumps operating instructions.
o. Purge refrigerant/ nitrogen from the system and exhaust it completely
to the atmosphere and not inside occupied quarters.
p. Start pump and warm-up for 10 minutes.
q. Connect evacuation line to the low-pressure service valve of the
system to be evacuated. Set-up is now ready for evacuation.
r. Start initial evacuation by opening the low-pressure service valve.

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 s. Allow the system to be evacuated to attain equilibrium pressure of
28Hg (500 microns). If the pressure fails to reach 28Hg (500
microns), then the system should be check for leaks.
t. Continue evacuation if equilibrium pressure indicates no leak.
u. Evacuate until equilibrium pressure of 28Hg(500 microns) or less is
attained.
v. Close both service valves and disconnect the evacuation line to the
system.
w. Immediately charge 2-5 psig of dry refrigerant vapor (R22) to break
the vacuum. System is now ready for next evacuation.
Note:
Breaking the initial vacuum with dry refrigerant will trigger reaction
with the refrigerant absorbing and mixing with any residual
contaminant. This will make it easy to remove the remaining
contaminants on the next vacuuming. Never break vacuuming with
Liquid Refrigerant.
x. Allow a few minutes time for chemical reactions to occur inside the
system.
y. Repeat item no. h, i, j, k, b, d & e in that order, three (3)
times to attain triple evacuation.
Note:
Do not turn-off vacuum pump when connected to an evacuated
system before closing the manifolds.
z. An evacuated system shall never be left at a high vacuum state for
more than three (3) minutes. It is imperative that it be charged just
after evacuation.
n. Under no condition is the motor compressor be started or operated
while the system is under a high vacuum. To do so, may cause
serious damage to the motor windings because of the reduced
dielectric strength of the space within the motor chamber.
p. Then system is ready for charging when manifold and equilibrium
pressure reads 28 Hg (500 microns).

1.4 System Commissioning Procedure

1.4.1 Pre-Commissioning Checklist

All outstanding works and punch list must be completed before
commissioning the system, by completing the Pre-commissioning
requirements. Equipment supplier is present during this setting to
work process.

1.4.2 Performance Test of the System

1. Start up the equipment for minimum of 1 hour (thermostat set

to 22oC and fan to high speed).
2. Check unit interlocking, pilot light, and control function.
3. Check the evaporator & condenser fan outlet temperature and
suction & liquid line pressure of the compressor.
4. Motor current shall not overload. Current readings shall be
within the range of motor nameplate rating for specified applied
voltage. (Condenser Fan Motor, FCU Fan Motor and
Compressor Motor)

5. Condenser air shall not re-circulate back to the condenser coil

(Short Cycle). We can determine or check if the air circulation
is good by getting the air inlet temperature and air outlet
temperature of the condenser. The air inlet temperature should
be almost equal on the ambient temperature not closer to the
air outlet temperature of the condenser.

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 6. If no abnormality is found in the system, test the actual
performance of the unit by completing the Testing and
Commissioning form on item no. IV.

2.1 Pre-commissioning Checklist

1. All outstanding works or punch list should be completed and pre-

commissioning requirements must be completed. (See Testing and
Commissioning form on Item No. IV)

2.2 Performance Test of the System

1. Start the equipment for a minimum of 1hour with a thermostat setting of
22oC and fan speed of high speed if digital controlled. If the analog
controlled set the thermostat to 8 and fan to high cool.
2. If no abnormality is found in the equipment, test the actual performance
of the unit by completing the Testing & Commissioning form on item no.
IV.

C. VENTILATION EQUIPMENT

1.0 System Commissioning Procedure

1.1 Pre-Commissioning Checklist

All outstanding works and punch list must be completed before

commissioning the system, by completing the Pre-commissioning
requirements. Equipment supplier is present during this setting to
work process.

1.2 Fan Performance Test

1. Start up the equipment for minimum of 10 - 15 minutes.

2. Check the Fan Motor Rotation if correct.
3. Check unit interlocking, pilot light, and control function.
4. Motor current shall not overload. Current readings shall be within
the range of motor nameplate rating for specified applied voltage.
5. If no abnormality is found in the system, test the actual
performance of the unit by completing the Testing and
Commissioning form on item no. IV.

III. DOCUMENTS REQUIRED

1. Equipment or System Design Data

2. Approved Equipment or System Shop Drawing, Materials & Brochures
Submittal
3. Pre-Construction Test Records or QC Documents
4. Reference Drawing or AFC
5. Equipment / System As-built
6. Calibration Certificate of Test Instruments to be used on Testing
7. Testing and Commissioning Forms
8. Psychrometric Chart

IV. TEST INSTRUMENTS

A. Air Measurement
1. Pro Hood Flow Grid
2. Vane Anemometer
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 3. Micro Manometer Flow / Pressure
4. Micro Manometer Pressure
5. Inclined Tube Manometer
6. Pitot Tube (Static)
7. Pitot Tube (Telescopic)
8. Balometer

B. Temperature Measurements
1. Sling Psychrometer
2. Whirling Hygrometer
3. Thermo Hygrometer
4. Infrared Thermometer

C. Electrical Measurements
1. Clamp Meter
2. Multi Tester
3. Earth Impedance Tester
4. Phase Rotation Tester

D. Motor Speed & Sound Level Measurements

1. Tachometer
2. Sound Level Meter

E. Pressure Measurements & Refrigerant Pipe Testing

1. Compound Pressure Gauge Manifold (High and Low)
2. Vacuum Pump
3. Refrigerant Leak Detector
4. Pressure Regulator

All instruments shall be calibrated prior to use on site, as required in the Construction
Technical Specification.

IV. TESTING AND COMMISSIONING FORMS

1. Air-Distribution System
1.1 Design Information Checklist
1.2 Pre-commissioning Checklist
1.3 Final Inspection Checklist
1.4 Setting to Work Checklist
1.5 Duct System (Main Duct Traverse)
1.6 Duct System (Branch Duct Traverse)
1.7 Duct System (Branch Duct Terminal Summary)
1.8 Fan Performance Test

2. Split Type A/C Units (ACCU & FCU)

2.1 Pre-commissioning Checklist of FCU & ACCU
2.2 Functional Test of FCU
2.3 Functional Test of ACCU

3. Ventilation Equipment
3.1 Visual & Functional Test of Toilet Exhaust Fan
3.2 Exhaust Fan - Pre-commissioning Checklist
3.3 Exhaust Fan Fan Performance Test
3.4 Supply Fan Pre-commissioning Checklist
3.5 Supply Fan Fan Performance Test
3.6 Transfer Fan Pre-commissioning Checklist
3.7 Transfer Fan Fan Performance Test

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