System Testing

All testing and balancing shall be made in the presence of the Engineer or his representative or other inspecting authority. Give not less than 5 days prior notice, in writing, to these parties before making any tests.

Supply all necessary skilled labour, helpers, equipment and materials for tests, operating and adjusting the systems and for fully instructing the Employer or his representatives in the operation of the system.

Protect valves and equipment from damage during tests.Include connection to previously tested sections, if the systems are tested in sections.

Prior to the balancing procedure, operate all systems for at least 16 consecutive hours, or longer if required, to prove satisfactory automatic operation.If systems shutdown is experienced for any reason, repeat and test until 16 consecutive hours are achieved.Operate equipment as recommended by the equipment manufacturers and in such a manner as to avoid damage to the work of other trades.

Submit to the Consulting Engineers for review a log of all tests made which shall include time, temperature, pressure and other readings necessary to indicate that the systems have been operated and tested as required by the Specification.

Upon completion of testing and balancing submit six (6) copies of the recorded test data for the Consulting Engineers evaluation and approval.

Flow quantities for Air side, Chilled and Condenser Water Systems shall be verified by the Consulting Engineers and Clients representatives before the report is submitted.

Testing of Medium and Low Pressure Ducts

The Medium and Low Pressure ducts shall be tested for air leaks in accordance with Clauses.

Testing of Piping

All pressure systems specified to be tested using water as the test medium shall be first checked by pre-testing the test section, or system, with compressed air at 34.5 pig for a period of 3/minutes.Correct all leaks disclosed by the pre-set before proceeding with the specified testing using water as the test medium.

Test all piping as noted below with no leaks or no loss of pressure. Repair or replace defective piping until tests are accomplished successfully.

System	Test Pressure	Test Medium	Test Duration
Chilled Water Piping	1724 kPa	Water	24 hours
Condenser Water Piping	1724 kPa	Water	d
Condensate drains	3m hd	Water	24 hours
Refrigerant Piping	2070 kPa	Dry Nitrogen	4 hours

For refrigerant piping, proceed further as follows:

Test points of possible leakage to assure pressure tightness with halide testing device.
Evacuate system to 100 microns using high vacuum pumps.
With Vacuum pump stopped, system shall maintain vacuum for a period of 24 hours without losing vacuum of more than 50 microns.
Refrigerant shall be charged only after the pressure tightness has been proven.

Testing of Electrical Work

Supply necessary meters, instruments, temporary wiring and labour to perform all required tests and adjustment of equipment and wiring installed and connected under this Sub-Contract, including the electrical equipment supplied by others to determine proper polarity, phasing, freedom from earth faults and shorts and the proper operation of equipment, meters relays etc.

All materials and manner of installation shall be in strict accordance with the applicable requirements of the local Authorities.The installation must pass all inspections, and will be subject to the approval of such authorities and the Engineer.

Wherever any codes, laws, etc., require any work to be tested or approved the contractor shall provide proper facilities for access and for inspection, all at his own expense.

Tests shall be made for continuity and identification of each conductor.Both ends of a given conductor shall be identified alike.Before circuit terminal connections are made, continuity and identification shall be checked by means of a D.C. test device using a bell or buzzer or battery powered phone to ring out the wires.

All earth tests shall be made with 100 volt merger test-type instrument.

Test each circuit for grounds and shorts by means of a merger insulation testing instrument which shall impress a voltage of not less than 100 volts D.C. upon the circuit under test.Any circuit showing an insulation resistance less than the minimum values given in the Wiring Rules shall be investigated and week points corrected.All circuitsunder merger insulation test shall be connected to the respective final terminals and switches or breaker, in the `OFF' position.

Correct or replace any nominal current carrying circuit which is defective or earthed.Also correct all trouble encountered by test and set breakers and relays as directed so that equipment will be in proper operating condition, before being placed in service.

Following establishing procedure, equipment will be energised after certification that the installation is satisfactory.Final operational tests shall determine that the wiring connections are correct.

Pre Balance Checks and Start Up

The Air and Water Systems will be checked out at specified below, and started and started up prior to balancing.

Complete water pressure and duct pressure testing for leakage.
Complete all 'Punch List' check items.
Install all dampers and other balancing devices as called for in the construction documents and verify the same are properly installed, indexed and in good working order.
Check all motor starters and verify that the heater sizing is correct, taking length of electrical feeders into consideration. Record AMP readings on all motors.
Check out and align all equipment drives.
Set all fan sheaves to provide the indicated capacities at specified static pressures (RPM as specified).
Set all manual balancing dampers, valves and balancing valves at 100% open position.Verify that all fire dampers are open.
All adjustable pitch pulleys shall be removed from the motor shaft.The shaft and pulley threads shall be cleaned, lightly oiled, and pulley remounted, aligned and properly adjusted.
Clean interior of all plenums, casings and ducts and install all filters before starting systems.
Make sure all controls systems are calibrated and functioning properly.
Place all systems in automatic operation.
Operate systems for 16 consecutive hours without shutdown with all equipment in perfect working order.Manufacturer's representative must be present at initial start-up all equipment.
Check fan and pump bearings for grease.
Install clean prefilters and install high efficiency filters in all systems prior to starting air balance.
Provide availability of personnel from all the related mechanical and controls contractors during balancing.

Test Reporting Forms

General

Test forms used for testing and balancing shall be set up to include the following information.Each sheet shall have job name and address, name of air conditioning sub-contractor, architect and engineer instruments used to perform tests, and name of test technician or test engineer.All forms shall be submitted in typewritten form.A minimum of 6 copies shall be submitted.Test sheets shall be similar to those shown in Table 10-1 through 10-5.

Diffusers, Grilles and Registers - Test Sheets

The tests shall be submitted as per details in Table 10-3.

Complete water pressure and duct pressure testing for leakage.
Fan Systems and/or zone number.
Room number or area designation.
Outlet code number which shall correspond to code number of outlet on air balance code drawing.
Size of Outlet - manufacturer's listed size.
Type of Outlet - per manufacturer's model designation.
Manufacturer of Outlet
Manufacturer's effective area for each size
Required m/s and required l/s of each outlet
Test resultant m/s and 1/s of each outlet
Final resultant m/s and 1/s of each outlet

Air Handling Equipment Test Sheets

The tests shall be submitted as per details in Table 10-1.

The test sheets shall provide details of the following items:

System Fan Number	Fan RPM
Fan Manufacturer	Size of Sheave Driver
Total CFM	Size of Sheave Driven
Return Air CFM	Belt sizes and number
Outside Air CFM	Motor Manufacturer
Total Static Pressure	Motor Size, Voltage
Suction Static Pressure	Phase & RPM KW
Discharge Static Pressure	Amperage Nameplate Rating
Coil Pressure Drop	Final Operating Amperage
Filter Pressure Drop	Overload Setting

Exhaust Fans Fresh Air Fans and Pressurization Fans Test Sheets

The tests shall be submitted as per details in Table 10-2.

Each sheet shall list in column or form the following required items for each conditions obtained.

System Fan Number Amperage Nameplate Rating
Fan Manufacturer Final Operating Amperage
Size and Model Fan RPM
Motor HP, Voltage & Phase Total Static Pressure Total 1/s, Overload Setting

Test, Code Drawings

Each Report shall contain a single line drawing of air distribution system with fan system and zone number indicated.Each and every outlet, supply, and return shall be indicated on this drawing by a number corresponding to the number on the outlet test sheet, enabling the Engineer to locate each outlet for this drawing.

Drawing shall be clear and neat and shall list name of job and location of same.

Temperature Test Sheets

Temperature test sheets shall list both specified and test conditions in opposite columns.Items listed on this sheet shall be as follows:

Entering Air D.B. & W.B. Temperature
Leaving Air D.B. & W.B. Temperature
Entering Coil Water Temperature
Leaving Coil Water Temperature
Outside Air - D.B. & W.B. Temperature
Room temperature reading to be checked against thermostat setting

Air Side Testing and Balancing

The Air System shall be tested and balanced as under:

Test and adjust fan RPM to design requirements.
Test and record motor full load amperes.
Make Pitot Tube traverse of main supply ducts and obtain design 1/s at fans.
Test and record system static pressures, suction discharge and total.
Test and adjust system for design 1/s recirculated air.
Test and adjust system for design 1/s outside air.
Test and record entering air temperatures DB/WB.
Test and record leavingair temperature DB/WB.
Adjust all main supply and return air ducts to proper design 1/s.
Adjust all zones to proper design 1/s supply and return.
Test and adjust each diffuser, grille and register to within 10% of design requirements.
Each grille, diffuser, register shall be identified as to location and area.
Size, type and manufacturer of diffusers, grilles, registers, and all tested equipment shall be identified and listed.Manufacturer's ratings on all equipment shall be used to make required calculations.
Readings and tests of diffusers, grilles, and registers shall include required velocity and test resultant velocity.Required 1/s and test resultant CFM after adjustments.
In co-operation with control manufacturer's representative, set adjustments of automatically operated dampers to operate as specified, indicated and/or noted.
All diffusers, grilles, and registers shall be adjusted to minimise drafts in all areas.
As part of the work of this contract, the Contractor shall make any changes in the pulleys and belts for correct balance as required at no additional cost to Owner.
For variable volume systems the Sub-Contractor shall set all boxes for minimum and for maximum air flow, balance and take 1/s, static pressure readings for each setting.

Water Systems Testing and Balancing

Pre Balancing Checks

The Air Balancing should have been completed before the Water balancing begins.The Contractor is to ensure that the following works are completed prior to commencement of water balancing.

Open all valves to full open position, including coil stop valves, bypass valves, and return line balancing cocks.
Remove all strainers and clean same and replace in system.
Examine water in system and ensure water has been treated and is cleaned.This is to be verified by Owner's representative.
Check pump rotation.
Check expansion tanks to determine they are not air bound and the system is completely full of water.
Check all air vents at high points of water systems and determine all are installed and operated freely.Bleed any air out of systems.
Set all temperature controls so all coils are calling for full cooling.
Check operation of all automatic valves.
Check and set operating temperatures of chillers to design requirements.

Initial Balancing

Set Chilled Water Pumps to proper gallons per minute delivery.
Adjust water flow of chilled water through chiller.
Check leaving water temperatures and return water temperatures through chiller. Reset to correct design temperatures.
Check water temperature at inlet side of Cooling coils.Note rise or drop of temperatures from source.
Proceed to balance each chilled water coil.
Upon completion of flow readings and adjustments at coils, set all memory stops and record all data.

Final Balancing

Upon completion of the above, the final balancing shall be completed as follows:

After adjustments to coils are made, recheck settings at the pumps and chillers and readjust if required.
Install pressure gauges on coil, read pressure drop through coil at set flow rate on call for full cooling. Set Pressure drop across bypass valve to match coil full flow pressure drop. This prevents unbalanced flow conditions when coils are on full bypass.
Set Chilled Water bypass to pressure differential specified on drawings.
Record and check the following items at each cooling elements:

Flow Rate
Inlet Water Temperature
Leaving Water Temperature
Pressure drop of each coil
Pressure drop across bypass valve
Pump operating suction and discharge pressures and final total discharge head.
List of all mechanical specifications of pumps
Rated and actual running amperage and KW of Pump Motor

Upon completion of final balancing, all information shall be inserted of a sheet listing all items required by specifications and be included in complete test and balance report. All sheets shall be neatly typed. Submit sample forms to the M & E Engineer for approval prior to starting balancing.

Test of Refrigeration Machines

The Refrigeration machines shall be tested by the equipment supplier for performance, and compliance with specification.The Contractor shall liaise and co-ordinate with the equipment supplier to carry out the tests.

The test shall consist of operating the equipment at prevailing conditions and recording chilled water temperature and condenser water flow in 1/s and power input.

Calculated refrigeration tonnage shall be compared with predicted full and part load curves provided by the manufacturer.These curves shall indicate power input plotted against tons of refrigeration output at condenser water temperature ranging from 36.4°C and 0.5°C intervals.

Chilled Water and Condenser Water quantities shall have been determined from measurements of 1/s handled by water pumps.

Test shall consist of a minimum continuous run of 6 hours with 24 readings made for each item above, unless continuously recordings instruments are used.

Supply calibrated instruments for testing.Instruments shall be calibrated immediately prior to tests and after completion of tests.

The noise level of the equipment shall be measured and recorded.

Testing of Cooling Towers

The Cooling Towers shall be tested together with the refrigeration machines to verify that the design requirements are met.

Record all temperature readings for records.

The noise level of the equipment shall be measured and recorded.

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Testing and Balancing of HVAC System