by Delhi Chapter of ISHRAEdcishrae.org/pdf/MJ-14829-ISHRAE-Newsletter.pdfDEAR ISHRAE Members,...
20
INSTALLATION, MAINTENANCE & COMMISSIONING OF HVAC by Delhi Chapter of ISHRAE DCI (Delhi Chapter of ISHRAE) Indian Society of Heating Refrigerating & Air Conditioning Engineers Vol. X, Issue 2, Edition : September 2019, Editor : K.D. Singh, Co-editor : Tapas Kushwaha EQUIPMENT
Transcript of by Delhi Chapter of ISHRAEdcishrae.org/pdf/MJ-14829-ISHRAE-Newsletter.pdfDEAR ISHRAE Members,...
INSTALLATION, MAINTENANCE& COMMISSIONING OF
HVAC
by Delhi Chapter of ISHRAE
DCI (Delhi Chapter of ISHRAE)Indian Society of Heating Refrigerating & Air Conditioning Engineers
Vol. X, Issue 2, Edition : September 2019, Editor : K.D. Singh, Co-editor : Tapas Kushwaha
EQUIPMENT
PRESIDENTIAL ADDRESS
DEAR ISHRAE Members,
Greetings from Delhi Chapter of ISHRAE !!!
First of all I would like to thank all of you for your immense support to the Delhi
Chapter of ISHRAE (DCI) in last six month. Because of you positive efforts, DCI
achieved the New high and able to set his goal for the new sky of the world. I
would like to thank all the past presidents for their support to the DCI. Our team
got the new fuel from the past president team. Such type of great think tanks are very much required to
achieve new benchmark.
In the last few months abundant of programme/event has conducted very well, and few from them, I
would like to mention here like Annual General Meeting, Refrigeration Day & Past Presidents meet.
Recently Biz-quiz has been organised very well and a team from Delhi selected for the final round
during Refcold at Hyderabad. On the workshop front we have conducted more than 35 workshops till
now.
For the coming span of time, some of the program/event will be on the top priority. One of them is
VENTCONF 2019, which is being conducted on 2nd November 2019 at Indian Aviation Academy,
Vasant Kunj, New Delhi, with the burning theme of “Indoor Air Quality”. We request all of you to come
forward to support this event & make this event as a remarkable one for this year. Further we have plan
for the IBC conference on the 14th& 15th November 2019. DCI team is now gear up for the Acrex 2020
as well to make this event as a great one. Kids rally for “SAY NO TO SINGLE USE PLASTIC” has been
conducted very well with the support of kalpavriksh and Agua Core Pumpen Ltd. This was for the
support of the theme of our Honorable Prime Minister Mr. Narender Modi against the single use
plastic. These kind of activity will definitely generate some positive momentum to reduce the use of
plastic & more use of biodegradable things.
To boost up our CWC team, we are looking some fresh blood, who can devote time and new ideas to
the society in adding means in terms of ideas & time. I would like to request all the members who have
some positive vibration to do something for the HVAC & R society. Please come forward and take a
step, we are here to welcome you with your great thoughts.
Once again I would like to put my honorable thanks to all the members of Delhi chapter of ISHRAE,
CWC team, Past Presidents & Seniors for their inputs & valuable time for the DCI to make empowered
& charismatic chapter of ISHRAE.
Warm Regards
Pradeep Kumar Dua
PS: If you need to contact me for your feedback or any support please feel free to reach me at
9910034135 or [email protected]
www.dcishrae.org
PRESIDENTIAL ADDRESS
DEAR ISHRAE Members,
Greetings from Delhi Chapter of ISHRAE !!!
First of all I would like to thank all of you for your immense support to the Delhi
Chapter of ISHRAE (DCI) in last six month. Because of you positive efforts, DCI
achieved the New high and able to set his goal for the new sky of the world. I
would like to thank all the past presidents for their support to the DCI. Our team
got the new fuel from the past president team. Such type of great think tanks are very much required to
achieve new benchmark.
In the last few months abundant of programme/event has conducted very well, and few from them, I
would like to mention here like Annual General Meeting, Refrigeration Day & Past Presidents meet.
Recently Biz-quiz has been organised very well and a team from Delhi selected for the final round
during Refcold at Hyderabad. On the workshop front we have conducted more than 35 workshops till
now.
For the coming span of time, some of the program/event will be on the top priority. One of them is
VENTCONF 2019, which is being conducted on 2nd November 2019 at Indian Aviation Academy,
Vasant Kunj, New Delhi, with the burning theme of “Indoor Air Quality”. We request all of you to come
forward to support this event & make this event as a remarkable one for this year. Further we have plan
for the IBC conference on the 14th& 15th November 2019. DCI team is now gear up for the Acrex 2020
as well to make this event as a great one. Kids rally for “SAY NO TO SINGLE USE PLASTIC” has been
conducted very well with the support of kalpavriksh and Agua Core Pumpen Ltd. This was for the
support of the theme of our Honorable Prime Minister Mr. Narender Modi against the single use
plastic. These kind of activity will definitely generate some positive momentum to reduce the use of
plastic & more use of biodegradable things.
To boost up our CWC team, we are looking some fresh blood, who can devote time and new ideas to
the society in adding means in terms of ideas & time. I would like to request all the members who have
some positive vibration to do something for the HVAC & R society. Please come forward and take a
step, we are here to welcome you with your great thoughts.
Once again I would like to put my honorable thanks to all the members of Delhi chapter of ISHRAE,
CWC team, Past Presidents & Seniors for their inputs & valuable time for the DCI to make empowered
& charismatic chapter of ISHRAE.
Warm Regards
Pradeep Kumar Dua
PS: If you need to contact me for your feedback or any support please feel free to reach me at
9910034135 or [email protected]
www.dcishrae.org
Dear All, in my opinion, Indian HVAC industry except specialized jobs is
still evolving as far as proper installation, testing and commissioning is
concerned. Plan to share current scenario in HVAC industry in general
and bring out how known challenges still persist .Most of us are aware of
these challenges, and they are clearly specified in tenders, but their
implementation is not handled with the same seriousness. It is important
to realize that HVAC system needs to be installed, commissioned and
tested properly to achieve intended results for which investments have
been made. Undoubtedly, awareness about it is improving but still a lot
more is required to see all users get what has been promised /
anticipated.
Challenges in Installation Attitude: Biggest challenge, you would
agree is “chaltahei “ attitude. This is what leads to number of issues
related to installation. While we know, what all is needed for proper
installation, effort required for doing it is avoided. We feel , installation can
be managed by labour since it is a labour oriented job and hence is left to
labour or their supervisors. This manya times lead to improper installation
and then compromises (Jugad) are made to improve the same to the
extent possible. Labour/supervisors are doing it based on their
experience and whatever tools and tackles are available at that point of
time. We shouldn’t expect labour/supervisors to understand the latest
recommendations for installation of HVAC systems. We are capable of
doing anything but we don’t apply ourselves . So one of the challenge is
to change mind set and get involved for proper installation techniques,
not leaving entirely on labour supervisors/foremen. One should
understand how it is to be done and then monitor/supervise the same
being done through labour at site.
Proactive Planning: We are aware but rarely document it. Proactive
planning involving work method statements for each activity modified to
suit site conditions is very important and should be implemented to avoid
last minute surprises. To avoid any miss outs these work methods should
be prepared by team involving project engineers, supervisors and
concerned foremen and not just by project manager/project head so that
the entire team is clear and execute the same. These work methods
should specify sequence of operations with other agencies, if more than
one discipline is involved to perform particular activity. Documentation
should be deliberated/submitted and evaluated well in time. All tools/
tackles required for particular activity are arranged beforehand. Kindly
note, proper installation only will achieve intended results in testing and
commissioning. One should prepare list of activities to be performed
before actual installation so that nothing is missed out and cross check
everything is there to ensure smooth hassle free installation.
Construction team should not leave anything to the last minute.
Switch over to pre-fabricated items: Till date, we had been struggling
to get everything done at site through labour ( skilled/unskilled ). If one
gets skilled labour, he is lucky otherwise whole project schedule depends
on available type and number of labour. Overall project schedules go
haywire since they are largely dependent on availability of dedicated
labour. Construction team understands nightmare they have to go
through in almost all projects whenever desired number of labour is not
available. Here suggestion is to start switching over to prefabricated
items as far as possible and hence reduce labour work at site as is being
done internationally. Out of box thinking is needed to get most of the site
work reduced to assembling prefabricated items at site. Yes initially, it
shall involve lot of time in thinking / planning but it shall improve quality
and project schedules would be under better control. Wherever it has
been tried out, results are magnificent.
Engineers involved in construction/installation have to apply their mind
for proper installation and learn what all is already available but not being
implemented. We get bogged down by the problems one would face and
don’t try out anything new which shall help to improve upon project
installation. Of course, this all may seem to be more expensive at the
beginning, but believe me, end result shall be wonderful and satisfying.
Material Handling: Material handling at projects is another area where a
lot of rethinking is needed. Unloading/lifting or shifting material to its
designated place should be carried out in such a manner that there is not
even a scratch over the material. I can only vouch that if material is
handled like a paper, one can be sure of getting much better results in
terms of installation, testing and commissioning. As far as possible,
mechanisation should be applied ensuring safety as well as hassle free
operations. Similarly, storage of material is equally important otherwise
lot of material gets damaged and then the same material is tried out,
since wastage of this size had not been accounted for. This leads to
imperfect installation which in turn gets noticed during testing and
commissioning.
Designers to provide actual working space: One more important
point is designers doing design/shop drawings, showing layout
schemes should keep in mind actual working space required to perform
a particular activity e.g. pipes very close to slab and other pipes beside
need to be welded all-round. Proper alignment of pipes for welding etc.
when these are very close to slab or other services, similarly duct joints on
top side, while duct is very close to slab or other services. For a proper
installation, designers play a major role. If during initial planning these
aspects are not addressed, one can’t expect good installation, otherwise
drawings need to be modified/revised as per construction team’s
requirements.
Guidance and clarity: While there is no doubt that we can perform
better than anyone and personally, we could demonstrate this when a
challenge was given that no Indian construction team is capable of
understanding and doing it. Results were amazing, when cross checked
by foreign consultants. We showed them our leakage results after proper
installation were 30% of permissible values, creating lot of confidence
and ultimately changing their mind set. What it needs is guidance and
clarity on what needs to be done. So a proper training to all young
engineers is must. They should feel proud of their installation. Today they
are focussing on their earnings mainly and there is no passion for doing a
good installation. A proper grooming is essential and this is possible only
if seniors/companies get involved and start doing it religiously for
consistent performances.
Training: Training teams should be formed in every company, who keep
updating themselves with the latest installation re-commendation,
addressing site installation issues and suggesting design modifications
from proper installation point of view and grooming/training their
candidates regularly for best and consistent performances on all their
jobs. Trainee engineer should not be put straight on to the job without
intensive training otherwise they try to do their best as per contractor or
their foremen’s experiences. At times they try to economise which is not
always in projects interest.
Safety: Another important aspect is Safety, we all understand its
importance but don’t implement with a mind set that it slows down the
progress. This should not be acceptable and no activity should be
allowed without safety practices being implemented. It has to be Safety
First motto and planning should be done considering safety practices in
mind. This shall ensure continuous availability of work force and timely
completion of projects also avoiding un-necessary issues related to
accidents and other legal hassles.
Quality: Another challenge is regular quality checks. We prepare and
submit list of quality checks to be carried out during execution. However
these are not implemented on regular basis. Many of the projects start
with lot of enthusiasm on quality, which slowly fades away with passage
of time and ultimately many of the defects remain till these get noticed
during testing and commissioning if they are affecting results.
Budget: The cost involved for above activities, if not budgeted can lead
to compromises only. We have to consider their importance and
implement corrective steps irrespective of their cost. For small savings
i.e. without proper installation, testing and commissioning, we keep
losing throughout life span of the systems. Sufficient budget/cost must
be allocated to perform all the above activities and run the system most
efficiently.
Challenges in Installation,Testing and Commissioningof HVAC systems
www.dcishrae.org
Dear All, in my opinion, Indian HVAC industry except specialized jobs is
still evolving as far as proper installation, testing and commissioning is
concerned. Plan to share current scenario in HVAC industry in general
and bring out how known challenges still persist .Most of us are aware of
these challenges, and they are clearly specified in tenders, but their
implementation is not handled with the same seriousness. It is important
to realize that HVAC system needs to be installed, commissioned and
tested properly to achieve intended results for which investments have
been made. Undoubtedly, awareness about it is improving but still a lot
more is required to see all users get what has been promised /
anticipated.
Challenges in Installation Attitude: Biggest challenge, you would
agree is “chaltahei “ attitude. This is what leads to number of issues
related to installation. While we know, what all is needed for proper
installation, effort required for doing it is avoided. We feel , installation can
be managed by labour since it is a labour oriented job and hence is left to
labour or their supervisors. This manya times lead to improper installation
and then compromises (Jugad) are made to improve the same to the
extent possible. Labour/supervisors are doing it based on their
experience and whatever tools and tackles are available at that point of
time. We shouldn’t expect labour/supervisors to understand the latest
recommendations for installation of HVAC systems. We are capable of
doing anything but we don’t apply ourselves . So one of the challenge is
to change mind set and get involved for proper installation techniques,
not leaving entirely on labour supervisors/foremen. One should
understand how it is to be done and then monitor/supervise the same
being done through labour at site.
Proactive Planning: We are aware but rarely document it. Proactive
planning involving work method statements for each activity modified to
suit site conditions is very important and should be implemented to avoid
last minute surprises. To avoid any miss outs these work methods should
be prepared by team involving project engineers, supervisors and
concerned foremen and not just by project manager/project head so that
the entire team is clear and execute the same. These work methods
should specify sequence of operations with other agencies, if more than
one discipline is involved to perform particular activity. Documentation
should be deliberated/submitted and evaluated well in time. All tools/
tackles required for particular activity are arranged beforehand. Kindly
note, proper installation only will achieve intended results in testing and
commissioning. One should prepare list of activities to be performed
before actual installation so that nothing is missed out and cross check
everything is there to ensure smooth hassle free installation.
Construction team should not leave anything to the last minute.
Switch over to pre-fabricated items: Till date, we had been struggling
to get everything done at site through labour ( skilled/unskilled ). If one
gets skilled labour, he is lucky otherwise whole project schedule depends
on available type and number of labour. Overall project schedules go
haywire since they are largely dependent on availability of dedicated
labour. Construction team understands nightmare they have to go
through in almost all projects whenever desired number of labour is not
available. Here suggestion is to start switching over to prefabricated
items as far as possible and hence reduce labour work at site as is being
done internationally. Out of box thinking is needed to get most of the site
work reduced to assembling prefabricated items at site. Yes initially, it
shall involve lot of time in thinking / planning but it shall improve quality
and project schedules would be under better control. Wherever it has
been tried out, results are magnificent.
Engineers involved in construction/installation have to apply their mind
for proper installation and learn what all is already available but not being
implemented. We get bogged down by the problems one would face and
don’t try out anything new which shall help to improve upon project
installation. Of course, this all may seem to be more expensive at the
beginning, but believe me, end result shall be wonderful and satisfying.
Material Handling: Material handling at projects is another area where a
lot of rethinking is needed. Unloading/lifting or shifting material to its
designated place should be carried out in such a manner that there is not
even a scratch over the material. I can only vouch that if material is
handled like a paper, one can be sure of getting much better results in
terms of installation, testing and commissioning. As far as possible,
mechanisation should be applied ensuring safety as well as hassle free
operations. Similarly, storage of material is equally important otherwise
lot of material gets damaged and then the same material is tried out,
since wastage of this size had not been accounted for. This leads to
imperfect installation which in turn gets noticed during testing and
commissioning.
Designers to provide actual working space: One more important
point is designers doing design/shop drawings, showing layout
schemes should keep in mind actual working space required to perform
a particular activity e.g. pipes very close to slab and other pipes beside
need to be welded all-round. Proper alignment of pipes for welding etc.
when these are very close to slab or other services, similarly duct joints on
top side, while duct is very close to slab or other services. For a proper
installation, designers play a major role. If during initial planning these
aspects are not addressed, one can’t expect good installation, otherwise
drawings need to be modified/revised as per construction team’s
requirements.
Guidance and clarity: While there is no doubt that we can perform
better than anyone and personally, we could demonstrate this when a
challenge was given that no Indian construction team is capable of
understanding and doing it. Results were amazing, when cross checked
by foreign consultants. We showed them our leakage results after proper
installation were 30% of permissible values, creating lot of confidence
and ultimately changing their mind set. What it needs is guidance and
clarity on what needs to be done. So a proper training to all young
engineers is must. They should feel proud of their installation. Today they
are focussing on their earnings mainly and there is no passion for doing a
good installation. A proper grooming is essential and this is possible only
if seniors/companies get involved and start doing it religiously for
consistent performances.
Training: Training teams should be formed in every company, who keep
updating themselves with the latest installation re-commendation,
addressing site installation issues and suggesting design modifications
from proper installation point of view and grooming/training their
candidates regularly for best and consistent performances on all their
jobs. Trainee engineer should not be put straight on to the job without
intensive training otherwise they try to do their best as per contractor or
their foremen’s experiences. At times they try to economise which is not
always in projects interest.
Safety: Another important aspect is Safety, we all understand its
importance but don’t implement with a mind set that it slows down the
progress. This should not be acceptable and no activity should be
allowed without safety practices being implemented. It has to be Safety
First motto and planning should be done considering safety practices in
mind. This shall ensure continuous availability of work force and timely
completion of projects also avoiding un-necessary issues related to
accidents and other legal hassles.
Quality: Another challenge is regular quality checks. We prepare and
submit list of quality checks to be carried out during execution. However
these are not implemented on regular basis. Many of the projects start
with lot of enthusiasm on quality, which slowly fades away with passage
of time and ultimately many of the defects remain till these get noticed
during testing and commissioning if they are affecting results.
Budget: The cost involved for above activities, if not budgeted can lead
to compromises only. We have to consider their importance and
implement corrective steps irrespective of their cost. For small savings
i.e. without proper installation, testing and commissioning, we keep
losing throughout life span of the systems. Sufficient budget/cost must
be allocated to perform all the above activities and run the system most
efficiently.
Challenges in Installation,Testing and Commissioningof HVAC systems
www.dcishrae.org
www.dcishrae.org
Challenges in testing and commissioning of HVAC
systems
Importance: Testing and commissioning, in most of the projects , is not
given its due importance. It is in fact a validation of proper design,
equipment/system selection and installation. Incorrect/improper
installation only delays testing and commissioning. It can be on account
of leakages beyond estimates or incomplete systems which need to be
plugged/ arrested before testing and commissioning can take place.
Many companies getting involved in doing testing/commissioning have
left it since time involved gets too long and they don’t get compensated
accordingly. It should not be considered just a formality. Due seriousness
should be attached to collect actual data and compare with design data
to ascertain deficiencies, modifications needed to run the system at
optimum efficiency. Testing and commissioning is a most important tool
to analyse what needs to be done further for optimising system efficiency.
This can become a learning lesson for design and installation but these
experiences are not utilised or beneficial use. Actual results can indicate
important points to be kept in mind for improvements in design and
installation for further jobs. Since, due weightage is not given, lot of
manipulation is done to justify on papers that everything is in order.
Effective testing and commissioning is possible when all snags / defects
are attended / removed.
Incomplete installation: One of the major issues experienced here is to
start testing /commissioning while installation is either not complete or
still have snags and defects. This delays the whole process and
ultimately teams involved start compromising on system completeness
without snags. Only necessary points which are required for parameters
measurement are rectified and rest of the systems are left at mercy.
Dedicated / knowledgeable team: Dedicated / knowledgeable team
should be deputed to cross check system actual parameters and list of
points should be prepared to improve upon these parameters without a
blame game. This nullifies the team effort and everyone tries to justify that
it is not his fault and the whole purpose of improving the system or
learning lessons from results becomes futile. Testing/commissioning
team should be considered a problem creator rather they should be
regarded as trouble shooters.
Now a days, when there is utmost awareness about energy efficiency, it is
of paramount importance to run systems at optimum efficiency, possible
through proper testing and commissioning only. All those parameters to
be tested and demonstrated need to be kept in mind and provisions kept
in systems for their measurements and proper calibrated measuring
tools should be used for the same.
Understanding of commissioning process:
This commissioning process
should first be understood
thoroughly. Following steps
should be observed for carrying
out commissioning :
• Review owner’s project
requirements
• Coordinate basis of design
document
• Commissioning
specifications
• Commissioning plan
• Design review
• Review submittals
• Construction observation
• Pre-functional checks
• Functional testing
• Training
• Review O&M manuals
• System manual
• Re-commissioning
• Commissioning report
Without carrying out above steps, commissioning is not complete.
Commissioning Team: this also is very important to execute
commissioning properly and most of the times it is left to 2-3 fellows. This
should include members from various quarters associated with the
project.
Owner’s Team: Construction engineer, project manager, facility
manager and maintenance team.
Contractor’s Team: Project manger, Quality control manager, Sub-
contractors ducting & piping.
Design Team: Architect, Mechanical designer, Electrical designer Over
and above, commissioning authority should be there.
Commissioning Problems:
these should be identified as
follows and then addressed
accordingly.
• Related to design: sufficient
maintenance clearance not
provided, demand control
ventilation at minimum VFD
position does not perform.
• Related to Installation: Duct
leakage, weather proofing,
corrosive couplings, bolts
and nuts, un-insulated /
Incomplete duct work, modulating dampers not installed correctly &
therefore not responding to control commands, condensation
• Related to Owner: He needs to take part in commissioning activities,
to actively monitor the building performance after turnover.
• Related to Contractor: Contractor needs to understand that they
benefit most from commissioning i.e. reduced warranty issues,
reduced contractor call backs.
• Related to commissioner: Less involvement during design phase,
functional tests are developed for individual equipment but not whole
systems, sensor calibration not verified, rigorous of commissioning
testing is brief, not detailed enough.
Commissioning can delay equipment failure, it can extend the life of the
building and equipment resulting less maintenance time.
Recommendations: Commissioning authority should be hired by
owner, independent of design team and contractor.
I have tried to discuss few of the issues related to installation, testing and
commissioning. With the above in mind, we can surely develop a system
which shall be running at optimum efficiency.
Annual General Meeting on 11th September’2019 at India Habitat Centre, New Delhi
ISHRAE Certified professional AC Design Level-1, Module-2
ISHRAE Certified professional AC Design Level-1 Module-1
WORKSHOPS
AGM 2019
Raman Chawla : Mechanical Engineer from Delhi
College Of Engineering – Delhi with 37 years of
experience in construction, design and sales /
marketing of HVAC systems.
Rajesh Kumar : Mechanical Engineer from YMCA
Institute of Engineering, Faridabad with total 31 years of
experience in estimation. design, engineering,
construction and management of Air Conditioning,
Smoke Management and Tunnel Ventilation System.
Workshop on Ventilation for Healthcare by Mr. Nitin Verma Workshop on Cooling Tower by Mr. Devashish Deb
Commissioning Process Flow Chart – Construction Phase
www.dcishrae.org
Challenges in testing and commissioning of HVAC
systems
Importance: Testing and commissioning, in most of the projects , is not
given its due importance. It is in fact a validation of proper design,
equipment/system selection and installation. Incorrect/improper
installation only delays testing and commissioning. It can be on account
of leakages beyond estimates or incomplete systems which need to be
plugged/ arrested before testing and commissioning can take place.
Many companies getting involved in doing testing/commissioning have
left it since time involved gets too long and they don’t get compensated
accordingly. It should not be considered just a formality. Due seriousness
should be attached to collect actual data and compare with design data
to ascertain deficiencies, modifications needed to run the system at
optimum efficiency. Testing and commissioning is a most important tool
to analyse what needs to be done further for optimising system efficiency.
This can become a learning lesson for design and installation but these
experiences are not utilised or beneficial use. Actual results can indicate
important points to be kept in mind for improvements in design and
installation for further jobs. Since, due weightage is not given, lot of
manipulation is done to justify on papers that everything is in order.
Effective testing and commissioning is possible when all snags / defects
are attended / removed.
Incomplete installation: One of the major issues experienced here is to
start testing /commissioning while installation is either not complete or
still have snags and defects. This delays the whole process and
ultimately teams involved start compromising on system completeness
without snags. Only necessary points which are required for parameters
measurement are rectified and rest of the systems are left at mercy.
Dedicated / knowledgeable team: Dedicated / knowledgeable team
should be deputed to cross check system actual parameters and list of
points should be prepared to improve upon these parameters without a
blame game. This nullifies the team effort and everyone tries to justify that
it is not his fault and the whole purpose of improving the system or
learning lessons from results becomes futile. Testing/commissioning
team should be considered a problem creator rather they should be
regarded as trouble shooters.
Now a days, when there is utmost awareness about energy efficiency, it is
of paramount importance to run systems at optimum efficiency, possible
through proper testing and commissioning only. All those parameters to
be tested and demonstrated need to be kept in mind and provisions kept
in systems for their measurements and proper calibrated measuring
tools should be used for the same.
Understanding of commissioning process:
This commissioning process
should first be understood
thoroughly. Following steps
should be observed for carrying
out commissioning :
• Review owner’s project
requirements
• Coordinate basis of design
document
• Commissioning
specifications
• Commissioning plan
• Design review
• Review submittals
• Construction observation
• Pre-functional checks
• Functional testing
• Training
• Review O&M manuals
• System manual
• Re-commissioning
• Commissioning report
Without carrying out above steps, commissioning is not complete.
Commissioning Team: this also is very important to execute
commissioning properly and most of the times it is left to 2-3 fellows. This
should include members from various quarters associated with the
project.
Owner’s Team: Construction engineer, project manager, facility
manager and maintenance team.
Contractor’s Team: Project manger, Quality control manager, Sub-
contractors ducting & piping.
Design Team: Architect, Mechanical designer, Electrical designer Over
and above, commissioning authority should be there.
Commissioning Problems:
these should be identified as
follows and then addressed
accordingly.
• Related to design: sufficient
maintenance clearance not
provided, demand control
ventilation at minimum VFD
position does not perform.
• Related to Installation: Duct
leakage, weather proofing,
corrosive couplings, bolts
and nuts, un-insulated /
Incomplete duct work, modulating dampers not installed correctly &
therefore not responding to control commands, condensation
• Related to Owner: He needs to take part in commissioning activities,
to actively monitor the building performance after turnover.
• Related to Contractor: Contractor needs to understand that they
benefit most from commissioning i.e. reduced warranty issues,
reduced contractor call backs.
• Related to commissioner: Less involvement during design phase,
functional tests are developed for individual equipment but not whole
systems, sensor calibration not verified, rigorous of commissioning
testing is brief, not detailed enough.
Commissioning can delay equipment failure, it can extend the life of the
building and equipment resulting less maintenance time.
Recommendations: Commissioning authority should be hired by
owner, independent of design team and contractor.
I have tried to discuss few of the issues related to installation, testing and
commissioning. With the above in mind, we can surely develop a system
which shall be running at optimum efficiency.
Annual General Meeting on 11th September’2019 at India Habitat Centre, New Delhi
ISHRAE Certified professional AC Design Level-1, Module-2
ISHRAE Certified professional AC Design Level-1 Module-1
WORKSHOPS
AGM 2019
Raman Chawla : Mechanical Engineer from Delhi
College Of Engineering – Delhi with 37 years of
experience in construction, design and sales /
marketing of HVAC systems.
Rajesh Kumar : Mechanical Engineer from YMCA
Institute of Engineering, Faridabad with total 31 years of
experience in estimation. design, engineering,
construction and management of Air Conditioning,
Smoke Management and Tunnel Ventilation System.
Workshop on Ventilation for Healthcare by Mr. Nitin Verma Workshop on Cooling Tower by Mr. Devashish Deb
Commissioning Process Flow Chart – Construction Phase
Energy Efficient Cooling Tower by Mr. Subir Das VRF by Mr. Ajay Raj
Workshop on Purified Fresh Air Indoor Applications by Mr. Aditya Vats
WORKSHOP
Technical Workshops (ISHRAE Marathon) 13th to 14th Sept’19
Myth & Reality about Air-Conditioning by Mr. K.D Singh Indoor Air Quality Issues and Challenges by Dr Radha Goyal
Smoke Management Systemin Bldgs. By Mrs. Samta Bajaj Green Building by Mr. K.K Mitra
Energy Efficient Cooling Tower by Mr. Subir Das VRF by Mr. Ajay Raj
Workshop on Purified Fresh Air Indoor Applications by Mr. Aditya Vats
WORKSHOP
Technical Workshops (ISHRAE Marathon) 13th to 14th Sept’19
Myth & Reality about Air-Conditioning by Mr. K.D Singh Indoor Air Quality Issues and Challenges by Dr Radha Goyal
Smoke Management Systemin Bldgs. By Mrs. Samta Bajaj Green Building by Mr. K.K Mitra
In 1995, I was studying HVAC&R during my engineering
days, we used to find refrigerant gas leaks with soap
solution and Halide Torches. Now a days there are more
than 10 technologies developed and have transformed
the way refrigerant leaks are identified. Those days quality
of commissioning use to depend on time taken for
commissioning. Every step of commissioning was time
bound and a typical chiller commissioning would take 3 –
7 days. I clearly recall during my training days, once a
commissioning engineer re-commissioned a chiller after
breakdown in 8 hours. His speedy work was really
appreciated by customer and customer gave him an
appreciation letter. When he came back to office and
showed this appreciation letter to director engineering, he
was almost fired. Director was concerned about the
shortcuts he might have taken to commission this chiller
as if you follow standard operating procedure (SOPs) you
can’t complete job in 8hours.
Do we now get time like 3 – 7 days for commissioning? If
your answer is no then what have changed these days.
Let’s take some example. Those days most of chillers
were built on site as compared to today where we mostly
get completely refrigerant charged chillers on site. Even if
we need to recommission them available tools have
changed and equipped us to do it better and faster.
Pressure Testing: those days pressure testing will
involve Nitrogen pressure to be held in system for 24
hours and then we can proceed further. I exactly don’t
know reason of holding for 24 hours but as per my
assumption it must be limitation of technology. Say for
example a good calibrated pressure gauge used for
testing those days must be class 2 that
means it can give an error of + - 2% of
full-scale reading. If pressure test is
performed at 350 PSIG, the gauge
used must be 0 to 500 PSIG. This
Gauge will give and error of -10PSIG to
+10PSIG that means 20PSIG. In this
case of 350 PSIG pressure hold, 20
PSIG can be gauge error for 6% of
pressure drop can be due to
measurement error. So, if you need to
be certain that loss of nitrogen
pressure is not due to leak you need to
first overcome pressure gauge errors,
and only way to that is wait for longer
time. So, wait for 24 hours to 48 hours
and then conclude if pressure test is ok
or not. Now a day’s digital manifold
gauges are equipped with programs
that can make calculation and conclude in less than five
minutes if the same system will be able to hold pressure in
24 hour or not. This is possible because of their least
count of 0.1 PSIG which was not available in analog
gauges. Imagine if those days pressure test fails it was
very difficult to find leaks as Nitrogen leaks that time can
only be detected through soap solution. Soap solution
was also made using shampoo or detergent. So same
case if there is nitrogen test fail and we need to find leak
we have following key options today:
• More accurate bubble base leak detectors like Leak
Locator Plus which can detect minor leaks as bubbles
don’t collapse easy and can last much longer. Since
bubble are stable leaks make cloud formation around
leak point.
• Ultrasonic leak detectors are also available which
detects specific noise of gas leaks irrespective of gas
type. This have been very useful for commissioning
engineers.
• Another option is to use 95% Nitrogen and 5%
Hydrogen mixture instead of just Nitrogen for leak
testing in this case only 5% Hydrogen does not make
the mixture flammable but makes sniffing Hydrogen
much easier with electronic leak detectors for
Hydrogen.
Post Nitrogen Pressure Test comes vacuum and
dehydrations. Two stage, high capacity, Vacuum pumps
equipped with non-return valve and Gas Ballast valve and
large diameter vacuum rated hoses and core removal
Commissioning Tools Now and Then
tools makes vacuum much easier and faster. Also, same
digital manifold are equipped with micron gauges and
also built in programs to check for vacuum leak or
moisture in system. Once vacuum level say 500microns
is reached, system is kept on vacuum hold test similar to
nitrogen pressure hold test. This vacuum hold test is not
only for leak but also indicates if there is moisture in
system. If during hold time vacuum level breaks and rises
to nearly 5000 microns and then stabilizes then there is
moisture in system. This is due to vaporization of water in
vacuum till it reaches ambient temperature as boiling
point. The vacuum rise graph plotted during hold test
clearly indicated if there is leak or moisture or both in
system. Only once system passed vacuum hold test, you
are confident of good commissioning. This test also
concludes in few minutes due to pre-programed
algorithms; you save time and money.
Liquid charging by weight and charge optimization with
liquid charging adapters like Blend Vaporizers make
charging of blends and well as single refrigerants easy
and quicker. Once charging is complete system is run
and continuous monitoring of suction superheat and
liquid subcooling with digital manifold ensures proper
refrigerant charge. These digital manifolds come with
temperature sensors for measuring accurate suction line
and liquid line surface temperatures. These manifolds
are programed with almost all refrigerants to enable
calculation of superheat and subcooling on manifold
itself. All this data is exported and recorded as authentic
commissioning report. This helps future charge
optimization and predictive maintenance.
www.dcishrae.org
l Size: DN 50 (2”) – DN 900 (36”)
l Pressure rating PN10 / PN16 / PN20
l 600 kPa / 1000 kPa / 1300 kPa Close off pressure available
l Body in Cast Iron / Ductile Iron / Carbon Steel / Stainless Steel
l Nylon coated SGI (Standard) or SS 410 / SS 304 / SS 316 Disc
l IP-68 rated (suitable) for outdoor applications
l Water proof, Anti rust & Anti corrosive design
l ON/OFF & Modulating Actuator available
l Self-locking facility
l Suitable for installation in at angle / position
MOTORIZED BUTTERFLY VALVE(With Advance Valves Guarantee of Service and Quality)
www.advancevalves.com
Pre-Insulated
MotorizedValves
Available
About the Author
Kapil Singhal, Managing Director
B P Refcool, 293 Sector 6,
IMT Manesar, Gurgaon 122050, Haryana, India.
Kapil Singhal is mechanical engineer and holds postgraduate diploma
in business administration. He has an overall experience of 22 years in
HVAC&R industry. He is an active member of ISHRAE and ASHRAE. He
is also a member of Refrigerants Technical Committee of ISHRAE and
ASHRAE. He has published papers in various industry journals and
magazines. He is Managing Director of BP Refcool, which is into
manufacturing and distribution of specialty products for HVAC&R
service tool and chemicals. Recently, B P Refcool has been focusing on
innovations around Refrigerant emission reduction thru advanced
recovery, Leak detection and monitoring. He can be reached at
In 1995, I was studying HVAC&R during my engineering
days, we used to find refrigerant gas leaks with soap
solution and Halide Torches. Now a days there are more
than 10 technologies developed and have transformed
the way refrigerant leaks are identified. Those days quality
of commissioning use to depend on time taken for
commissioning. Every step of commissioning was time
bound and a typical chiller commissioning would take 3 –
7 days. I clearly recall during my training days, once a
commissioning engineer re-commissioned a chiller after
breakdown in 8 hours. His speedy work was really
appreciated by customer and customer gave him an
appreciation letter. When he came back to office and
showed this appreciation letter to director engineering, he
was almost fired. Director was concerned about the
shortcuts he might have taken to commission this chiller
as if you follow standard operating procedure (SOPs) you
can’t complete job in 8hours.
Do we now get time like 3 – 7 days for commissioning? If
your answer is no then what have changed these days.
Let’s take some example. Those days most of chillers
were built on site as compared to today where we mostly
get completely refrigerant charged chillers on site. Even if
we need to recommission them available tools have
changed and equipped us to do it better and faster.
Pressure Testing: those days pressure testing will
involve Nitrogen pressure to be held in system for 24
hours and then we can proceed further. I exactly don’t
know reason of holding for 24 hours but as per my
assumption it must be limitation of technology. Say for
example a good calibrated pressure gauge used for
testing those days must be class 2 that
means it can give an error of + - 2% of
full-scale reading. If pressure test is
performed at 350 PSIG, the gauge
used must be 0 to 500 PSIG. This
Gauge will give and error of -10PSIG to
+10PSIG that means 20PSIG. In this
case of 350 PSIG pressure hold, 20
PSIG can be gauge error for 6% of
pressure drop can be due to
measurement error. So, if you need to
be certain that loss of nitrogen
pressure is not due to leak you need to
first overcome pressure gauge errors,
and only way to that is wait for longer
time. So, wait for 24 hours to 48 hours
and then conclude if pressure test is ok
or not. Now a day’s digital manifold
gauges are equipped with programs
that can make calculation and conclude in less than five
minutes if the same system will be able to hold pressure in
24 hour or not. This is possible because of their least
count of 0.1 PSIG which was not available in analog
gauges. Imagine if those days pressure test fails it was
very difficult to find leaks as Nitrogen leaks that time can
only be detected through soap solution. Soap solution
was also made using shampoo or detergent. So same
case if there is nitrogen test fail and we need to find leak
we have following key options today:
• More accurate bubble base leak detectors like Leak
Locator Plus which can detect minor leaks as bubbles
don’t collapse easy and can last much longer. Since
bubble are stable leaks make cloud formation around
leak point.
• Ultrasonic leak detectors are also available which
detects specific noise of gas leaks irrespective of gas
type. This have been very useful for commissioning
engineers.
• Another option is to use 95% Nitrogen and 5%
Hydrogen mixture instead of just Nitrogen for leak
testing in this case only 5% Hydrogen does not make
the mixture flammable but makes sniffing Hydrogen
much easier with electronic leak detectors for
Hydrogen.
Post Nitrogen Pressure Test comes vacuum and
dehydrations. Two stage, high capacity, Vacuum pumps
equipped with non-return valve and Gas Ballast valve and
large diameter vacuum rated hoses and core removal
Commissioning Tools Now and Then
tools makes vacuum much easier and faster. Also, same
digital manifold are equipped with micron gauges and
also built in programs to check for vacuum leak or
moisture in system. Once vacuum level say 500microns
is reached, system is kept on vacuum hold test similar to
nitrogen pressure hold test. This vacuum hold test is not
only for leak but also indicates if there is moisture in
system. If during hold time vacuum level breaks and rises
to nearly 5000 microns and then stabilizes then there is
moisture in system. This is due to vaporization of water in
vacuum till it reaches ambient temperature as boiling
point. The vacuum rise graph plotted during hold test
clearly indicated if there is leak or moisture or both in
system. Only once system passed vacuum hold test, you
are confident of good commissioning. This test also
concludes in few minutes due to pre-programed
algorithms; you save time and money.
Liquid charging by weight and charge optimization with
liquid charging adapters like Blend Vaporizers make
charging of blends and well as single refrigerants easy
and quicker. Once charging is complete system is run
and continuous monitoring of suction superheat and
liquid subcooling with digital manifold ensures proper
refrigerant charge. These digital manifolds come with
temperature sensors for measuring accurate suction line
and liquid line surface temperatures. These manifolds
are programed with almost all refrigerants to enable
calculation of superheat and subcooling on manifold
itself. All this data is exported and recorded as authentic
commissioning report. This helps future charge
optimization and predictive maintenance.
www.dcishrae.org
l Size: DN 50 (2”) – DN 900 (36”)
l Pressure rating PN10 / PN16 / PN20
l 600 kPa / 1000 kPa / 1300 kPa Close off pressure available
l Body in Cast Iron / Ductile Iron / Carbon Steel / Stainless Steel
l Nylon coated SGI (Standard) or SS 410 / SS 304 / SS 316 Disc
l IP-68 rated (suitable) for outdoor applications
l Water proof, Anti rust & Anti corrosive design
l ON/OFF & Modulating Actuator available
l Self-locking facility
l Suitable for installation in at angle / position
MOTORIZED BUTTERFLY VALVE(With Advance Valves Guarantee of Service and Quality)
www.advancevalves.com
Pre-Insulated
MotorizedValves
Available
About the Author
Kapil Singhal, Managing Director
B P Refcool, 293 Sector 6,
IMT Manesar, Gurgaon 122050, Haryana, India.
Kapil Singhal is mechanical engineer and holds postgraduate diploma
in business administration. He has an overall experience of 22 years in
HVAC&R industry. He is an active member of ISHRAE and ASHRAE. He
is also a member of Refrigerants Technical Committee of ISHRAE and
ASHRAE. He has published papers in various industry journals and
magazines. He is Managing Director of BP Refcool, which is into
manufacturing and distribution of specialty products for HVAC&R
service tool and chemicals. Recently, B P Refcool has been focusing on
innovations around Refrigerant emission reduction thru advanced
recovery, Leak detection and monitoring. He can be reached at
List of New Members
1 GAURI SETH CE COMFORT ENGINEERS PVT. LTD.
2 HARJOT SINGH ANAND ANAND INSULATION
3 SHIVAM PURI AIR FLOW PVT. LTD.
4 ASHEESH GARG NIKOM INFRASOLUTIONS PRIVATE LIMITED
5 HARSH VARDHAN HOTEL SAROVAR
6 CHIRAG KATARIA CAMFIL AIR FILTRATION INDIA PVT. LTD.
7 SHIV PRAKASH DWIVEDI SYSTRA MVA CONSULTING INDIA PVT. LTD.
8 TOSH AGRAWAL ENERGY EFFICIENCY SERVICES LIMITED
9 MONIKA SINGH MONASH AIRCON PVT. LTD.
10 MS. ANANDA BRAHMI KAVURI ANT STUDIO
11 AJAY KUMAR ADVANCE INTERNATIONAL
12 VVA RAO KEY PATH INDIA PVT. LTD.
13 ANKUR MAMGAIN DDF CONSULTANTS PVT. LTD.
14 ARPIT KHURANA INTERIA DESIGN
15 ASHOK TYAGI DLF PACIFIC
16 VIVEK KUMAR V.V. ENTERPRISES
17 AKSHAY GOEL A.C. HUMIDIN AIR SYSTEMS
18 RAHUL LAL ADVANCE VENTILATION
19 LALIT KUMAR PARMAR RELIANCE RETAILS LTD.
20 SATISH KUMAR SHARMA CARRIER MIDEA INDIA PVT. LTD.
21 SANJEEV KUMAR TSI INCORPORATED
22 FAISAL AZMAT SHAH JKPCC LTD
23 NIKHIL SHARMA TECHNOVALUE SOLUTIONS PVT. LTD
24 VIKAS BHARDWAJ DELHI METRO RAIL CORPORATION
25 SARFARAZ ALAM UPDATER SERVICES PVT. LTD.
26 NARAYANAN .BEHARI LALL UPDATER SERVICES PVT. LTD.
27 SAI TEJA BANDARU INDIAN NAVY
28 NITIN AGGARWAL DYNA FILTERS PRIVATE LIMITED
29 ASHUTOSH VERMA FRESH FOOD TECHNOLOGY INDIA PVT. LTD.
30 GAUTAM KUMAR JHA FRESH FOOD TECHNOLOGY INDIA PVT. LTD.
31 NISHANT KUMAR EFFISENSE CONSULTING
32 VIDIT UPPAL AECOM INDIA PVT. LTD.
33 HARBANS LAL VERMA MUSKAN AIRCON
34 ADITYA VATS ADVIND HEALTHCARE INDIA
35 NIPUN MALHOTRA CASTLE VALVES LTD.
36 NEERAJ JURIANI AIR COOL REFRIGERATION
37 MANORMA CHAUHAN ETA ENGINEERING PVT. LTD.
38 AMARJEET KAUR ETA ENGINEERING PVT. LTD.
39 GURSHEEN KAUR ETA ENGINEERING PVT. LTD.
40 SUBHAM GHOSH KIRLOSKAR CHILLERS
41 SIRIL THODETI COMFONOMICS DESIGN VENTURES
42 SUBHADEEP SAMANTA L&T-MHPS BOILER PVT. LTD.
43 NIKHIL BHARTI FLAKTGROUP INDIA PVT. LTD.
44 AAKASH CHAND RAI BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE
45 SANJEEV KUMAR BARANWAL TATA CONSULTING ENGINEERS LIMITED
46 MOHD FARAZ ZAIDI BRAVIA TECHNO SOLUTIONS PVT. LTD.
47 SUMEET CHADDA BLUE SKY SYSTEM PVT. LTD.
48 ARJUN PAL DESICCANT ROTORS INTERNATIONAL PVT. LTD.
49 ANSHUL SAXENA SANDEN VIKAS INDIA PVT. LTD.
50 KUMAR SAURAV GLATT INGENIEURTECHNIK GMBH
51 AKSHAY BHATIA T. K. ELECTRONICS
52 KISHAN CHAND NISHAD ULTIMATE ENGINEERS
53 MANDEEP SINGH KAMAL ENGINEERS AND ASSOCIATES
54 DALVIR SINGH BRADY SERVICES PVT. LTD.
55 KARTIK PRABHAKAR PANASEA TECHNOLOGIES PVT. LTD.
56 ARJUN CHOUDHARY WEATHER COMFORT ENGINEERS PVT. LTD.
57 DHIRENDRA SHUKLA LUWA INDIA PVT. LTD.
58 MANOJ KUMAR MUTHUMANICKAM EESL
59 PRAN SAURABH ENERGY EFFICIENCY SERVICES LIMITED
60 HOMESH KUMAR HONDA CARS
61 AKSHAY MANGAL BROAD GROUP
62 GURDEEP SINGH GREENHECK INDIA PVT. LTD.
63 PUNEET CHAUHAN RAMBOLL INDIA PVT. LTD.
64 PRAYAS BALYAN GREENTEK ENGINEERS
65 BALRAJ POONIA CBRE SOUTH ASIA PVT. LTD.
66 ASHISH KUMAR STERLING & WILSON PVT. LTD.
67 ASHUTOSH KUMAR DUBEY SHAPOORJI PALLONJI AND COMPANY PRIVATE LIMITED
68 MANISH MOHAN ETA ENGINEERING PVT. LTD.
69 SANJEEV KUMAR PUNE METRO RAIL PROJECT
70 HARSHVARDHAN MANGE PUNE METRO RAIL PROJECT
71 KULDIP KUMAR MEHTA REGENT SYSTEM ENGG. PVT. LTD.
S.NO. MEMBER NAME COMPANY NAME S.NO. MEMBER NAME COMPANY NAME
List of New Members
1 GAURI SETH CE COMFORT ENGINEERS PVT. LTD.
2 HARJOT SINGH ANAND ANAND INSULATION
3 SHIVAM PURI AIR FLOW PVT. LTD.
4 ASHEESH GARG NIKOM INFRASOLUTIONS PRIVATE LIMITED
5 HARSH VARDHAN HOTEL SAROVAR
6 CHIRAG KATARIA CAMFIL AIR FILTRATION INDIA PVT. LTD.
7 SHIV PRAKASH DWIVEDI SYSTRA MVA CONSULTING INDIA PVT. LTD.
8 TOSH AGRAWAL ENERGY EFFICIENCY SERVICES LIMITED
9 MONIKA SINGH MONASH AIRCON PVT. LTD.
10 MS. ANANDA BRAHMI KAVURI ANT STUDIO
11 AJAY KUMAR ADVANCE INTERNATIONAL
12 VVA RAO KEY PATH INDIA PVT. LTD.
13 ANKUR MAMGAIN DDF CONSULTANTS PVT. LTD.
14 ARPIT KHURANA INTERIA DESIGN
15 ASHOK TYAGI DLF PACIFIC
16 VIVEK KUMAR V.V. ENTERPRISES
17 AKSHAY GOEL A.C. HUMIDIN AIR SYSTEMS
18 RAHUL LAL ADVANCE VENTILATION
19 LALIT KUMAR PARMAR RELIANCE RETAILS LTD.
20 SATISH KUMAR SHARMA CARRIER MIDEA INDIA PVT. LTD.
21 SANJEEV KUMAR TSI INCORPORATED
22 FAISAL AZMAT SHAH JKPCC LTD
23 NIKHIL SHARMA TECHNOVALUE SOLUTIONS PVT. LTD
24 VIKAS BHARDWAJ DELHI METRO RAIL CORPORATION
25 SARFARAZ ALAM UPDATER SERVICES PVT. LTD.
26 NARAYANAN .BEHARI LALL UPDATER SERVICES PVT. LTD.
27 SAI TEJA BANDARU INDIAN NAVY
28 NITIN AGGARWAL DYNA FILTERS PRIVATE LIMITED
29 ASHUTOSH VERMA FRESH FOOD TECHNOLOGY INDIA PVT. LTD.
30 GAUTAM KUMAR JHA FRESH FOOD TECHNOLOGY INDIA PVT. LTD.
31 NISHANT KUMAR EFFISENSE CONSULTING
32 VIDIT UPPAL AECOM INDIA PVT. LTD.
33 HARBANS LAL VERMA MUSKAN AIRCON
34 ADITYA VATS ADVIND HEALTHCARE INDIA
35 NIPUN MALHOTRA CASTLE VALVES LTD.
36 NEERAJ JURIANI AIR COOL REFRIGERATION
37 MANORMA CHAUHAN ETA ENGINEERING PVT. LTD.
38 AMARJEET KAUR ETA ENGINEERING PVT. LTD.
39 GURSHEEN KAUR ETA ENGINEERING PVT. LTD.
40 SUBHAM GHOSH KIRLOSKAR CHILLERS
41 SIRIL THODETI COMFONOMICS DESIGN VENTURES
42 SUBHADEEP SAMANTA L&T-MHPS BOILER PVT. LTD.
43 NIKHIL BHARTI FLAKTGROUP INDIA PVT. LTD.
44 AAKASH CHAND RAI BIRLA INSTITUTE OF TECHNOLOGY & SCIENCE
45 SANJEEV KUMAR BARANWAL TATA CONSULTING ENGINEERS LIMITED
46 MOHD FARAZ ZAIDI BRAVIA TECHNO SOLUTIONS PVT. LTD.
47 SUMEET CHADDA BLUE SKY SYSTEM PVT. LTD.
48 ARJUN PAL DESICCANT ROTORS INTERNATIONAL PVT. LTD.
49 ANSHUL SAXENA SANDEN VIKAS INDIA PVT. LTD.
50 KUMAR SAURAV GLATT INGENIEURTECHNIK GMBH
51 AKSHAY BHATIA T. K. ELECTRONICS
52 KISHAN CHAND NISHAD ULTIMATE ENGINEERS
53 MANDEEP SINGH KAMAL ENGINEERS AND ASSOCIATES
54 DALVIR SINGH BRADY SERVICES PVT. LTD.
55 KARTIK PRABHAKAR PANASEA TECHNOLOGIES PVT. LTD.
56 ARJUN CHOUDHARY WEATHER COMFORT ENGINEERS PVT. LTD.
57 DHIRENDRA SHUKLA LUWA INDIA PVT. LTD.
58 MANOJ KUMAR MUTHUMANICKAM EESL
59 PRAN SAURABH ENERGY EFFICIENCY SERVICES LIMITED
60 HOMESH KUMAR HONDA CARS
61 AKSHAY MANGAL BROAD GROUP
62 GURDEEP SINGH GREENHECK INDIA PVT. LTD.
63 PUNEET CHAUHAN RAMBOLL INDIA PVT. LTD.
64 PRAYAS BALYAN GREENTEK ENGINEERS
65 BALRAJ POONIA CBRE SOUTH ASIA PVT. LTD.
66 ASHISH KUMAR STERLING & WILSON PVT. LTD.
67 ASHUTOSH KUMAR DUBEY SHAPOORJI PALLONJI AND COMPANY PRIVATE LIMITED
68 MANISH MOHAN ETA ENGINEERING PVT. LTD.
69 SANJEEV KUMAR PUNE METRO RAIL PROJECT
70 HARSHVARDHAN MANGE PUNE METRO RAIL PROJECT
71 KULDIP KUMAR MEHTA REGENT SYSTEM ENGG. PVT. LTD.
S.NO. MEMBER NAME COMPANY NAME S.NO. MEMBER NAME COMPANY NAME
Start-Up, operation & Maintenance Of Cooling Tower
Before Start-up
Among other sources, outbreaks of
Leginnaires’ disease have reportedly
been traced to cooling towers,
Maintenance and water treatment
procedures that prevent amplification
and dissemination of Legionella and
other airborne bacteria should be
formulated and implemented BEFORE
systems are operated and continued
regularly thereafter to avoid the risk
sickness or death.
CLEANING - New installations should
be cleaned and treated with biocides by a
water treatment expert before startup.
Remove any dirt and trash, which has
accumulated in the cold-water basin.
Remove any sediment from the cold-
water collection basin, sump, screens.
Use a water hose to flush cold-water
collection basins.
OPERATE WATER SYSTEMS - Start
the circulating water pumps. Increase the
flow of circulating water gradually to
match design water flow rate. Circulate
water over the cooling tower continuously
for several days before stating the
mechanical equipment and placing the
cooling tower into continuous operation.
When starting cooling tower, follow
procedures outlined below.
INSPECTION - It is imperative that all
operating assemblies are inspected
before they are placed in operation. The
following is a list of components to be
checked before starting the tower:
1. Check tightness of bolts in fan
cylinder joints.
2. Check the following bolted joints in
the fan and drive assemblies
a. Fan hub clamp bolts
b. Fen hub cover bolts
3. Rotate fan by hand to be sure of free
rotation and ample tip clearance.
4. Check motor insulation with a
“Megger”.
5. Lubricate the motor according to
motor manufacturer’s instructions.
6. Test run each fan separately for a
short time, Check for excessive
vibration or unusual noise. If either is
present, see Troubleshooting Guide
on pages 10 and 11 of this manual.
Fan must rotate clockwise when
viewed from above .
7. Check functioning of makeup water
supply.
8. Make sure the blow-down carry the
proper amount of water.
Starting Procedure
WATER SYSTEM
Fill the cold water collection basin and
circulating water system until the
operating level is reached. Prime and
start the circulating water pumps.
Increase the flow of circulating water
gradually to design water flow rate to
avoid water hammer could damage the
distribution piping systems.
Clean the sump screens several times
during the first week of operation.
After this, clean sump screens weekly.
STARTING FAN
Start the fan. Check motor load with watt
meter, or take operating volt and ampere
read ings and ca lcu la te mo to r
horsepower. Pitch fans to pull correct
contract horsepower when circulating
design water rate at design hot water
temperature.
Operation
Entering water temperature in excess of
125 F may result in fill deformation.
TOWER PERFORMANCE
Keep the cooling tower clear and water
distribution uniform to obtain continued
maximum cooling capacity. The capacity
of a cooling tower to cool water to give
cold water temperature varies with the
wet-bulb temperature and heat load
applied to the cooling tower. As the wet-
blub temperature linearly with the wet-
blub temperature.
A cooling tower will not control heat load.
The flow rate of water circulated through
the cooling tower will determine the
temperature range of cooling in
conjunction with a given heat load. The
hot water and cold water temperature will
increase with higher heat loads.
HOT WATER DISTRIBUTION
SYSTEM
Maintain uniform water distribution at the
nozzles (uniform spray cone). The
amount of tower circulated should
approximate the contract requirements
and the nozzie pressure should be kept
constant. Lower pressure may indicate
excessive losses in the piping system
and/or insufficient pump capacity;
greater pressure might indicate clogged
nozzles and/or over pumping. If a greatly
reduced water flow rate in desired, it may
be advisable to change nozzle sixes to
obtain the desired pressure and maintain
proper water distribution. Minimum and
maximum flow rates should be adjusted
+20% for even distribution.
COLD WATER COLLECTION BASIN
A suitable depth must be maintained to
keep the pumps from pulling air into the
line. The amount of “makeup” water
required to keep the water in the
collection basin at the required depth
depends upon the “evaporation loss”
and “blow-down”
FAN DRIVE
When using two-speed motors, allow a
time delay of 20 seconds minimum after
de-energizing the high-speed winding
before energizing the low-speed
winding. Tremendous stresses are
placed on driven machinery and motors
unless the motors are allowed to slow to
low-speed RPM or less before the low-
speed winding is energized.
Vacant Posi�ons
Dy. Manager – Marke�ngB. Tech, MBA. Experience7-8 years prefer in HVACIndustries for North India
Manager – Marke�ngB. Tech, MBA. Experience8-10 years prefer in HVACIndustries for West India(Prefer Mumbai Region)
Apply in full confidence at
[email protected] (Prefer Mumbai Region)
K-12 Awareness regarding Menstrual Education@ Dolly
Public School, Agra
SUB-CHAPTERACTIVITIES
Workshop on HVAC Controls Training by Mr. P. K. Goel
WORKSHOP
K-12 ACTIVITY
K-12 Activity at Surya Model School, New Delhi on 14th August'2019
Regional Chapter Chair Meeting @ Masoori
www.dcishrae.org
Start-Up, operation & Maintenance Of Cooling Tower
Before Start-up
Among other sources, outbreaks of
Leginnaires’ disease have reportedly
been traced to cooling towers,
Maintenance and water treatment
procedures that prevent amplification
and dissemination of Legionella and
other airborne bacteria should be
formulated and implemented BEFORE
systems are operated and continued
regularly thereafter to avoid the risk
sickness or death.
CLEANING - New installations should
be cleaned and treated with biocides by a
water treatment expert before startup.
Remove any dirt and trash, which has
accumulated in the cold-water basin.
Remove any sediment from the cold-
water collection basin, sump, screens.
Use a water hose to flush cold-water
collection basins.
OPERATE WATER SYSTEMS - Start
the circulating water pumps. Increase the
flow of circulating water gradually to
match design water flow rate. Circulate
water over the cooling tower continuously
for several days before stating the
mechanical equipment and placing the
cooling tower into continuous operation.
When starting cooling tower, follow
procedures outlined below.
INSPECTION - It is imperative that all
operating assemblies are inspected
before they are placed in operation. The
following is a list of components to be
checked before starting the tower:
1. Check tightness of bolts in fan
cylinder joints.
2. Check the following bolted joints in
the fan and drive assemblies
a. Fan hub clamp bolts
b. Fen hub cover bolts
3. Rotate fan by hand to be sure of free
rotation and ample tip clearance.
4. Check motor insulation with a
“Megger”.
5. Lubricate the motor according to
motor manufacturer’s instructions.
6. Test run each fan separately for a
short time, Check for excessive
vibration or unusual noise. If either is
present, see Troubleshooting Guide
on pages 10 and 11 of this manual.
Fan must rotate clockwise when
viewed from above .
7. Check functioning of makeup water
supply.
8. Make sure the blow-down carry the
proper amount of water.
Starting Procedure
WATER SYSTEM
Fill the cold water collection basin and
circulating water system until the
operating level is reached. Prime and
start the circulating water pumps.
Increase the flow of circulating water
gradually to design water flow rate to
avoid water hammer could damage the
distribution piping systems.
Clean the sump screens several times
during the first week of operation.
After this, clean sump screens weekly.
STARTING FAN
Start the fan. Check motor load with watt
meter, or take operating volt and ampere
read ings and ca lcu la te mo to r
horsepower. Pitch fans to pull correct
contract horsepower when circulating
design water rate at design hot water
temperature.
Operation
Entering water temperature in excess of
125 F may result in fill deformation.
TOWER PERFORMANCE
Keep the cooling tower clear and water
distribution uniform to obtain continued
maximum cooling capacity. The capacity
of a cooling tower to cool water to give
cold water temperature varies with the
wet-bulb temperature and heat load
applied to the cooling tower. As the wet-
blub temperature linearly with the wet-
blub temperature.
A cooling tower will not control heat load.
The flow rate of water circulated through
the cooling tower will determine the
temperature range of cooling in
conjunction with a given heat load. The
hot water and cold water temperature will
increase with higher heat loads.
HOT WATER DISTRIBUTION
SYSTEM
Maintain uniform water distribution at the
nozzles (uniform spray cone). The
amount of tower circulated should
approximate the contract requirements
and the nozzie pressure should be kept
constant. Lower pressure may indicate
excessive losses in the piping system
and/or insufficient pump capacity;
greater pressure might indicate clogged
nozzles and/or over pumping. If a greatly
reduced water flow rate in desired, it may
be advisable to change nozzle sixes to
obtain the desired pressure and maintain
proper water distribution. Minimum and
maximum flow rates should be adjusted
+20% for even distribution.
COLD WATER COLLECTION BASIN
A suitable depth must be maintained to
keep the pumps from pulling air into the
line. The amount of “makeup” water
required to keep the water in the
collection basin at the required depth
depends upon the “evaporation loss”
and “blow-down”
FAN DRIVE
When using two-speed motors, allow a
time delay of 20 seconds minimum after
de-energizing the high-speed winding
before energizing the low-speed
winding. Tremendous stresses are
placed on driven machinery and motors
unless the motors are allowed to slow to
low-speed RPM or less before the low-
speed winding is energized.
Vacant Posi�ons
Dy. Manager – Marke�ngB. Tech, MBA. Experience7-8 years prefer in HVACIndustries for North India
Manager – Marke�ngB. Tech, MBA. Experience8-10 years prefer in HVACIndustries for West India(Prefer Mumbai Region)
Apply in full confidence at
[email protected] (Prefer Mumbai Region)
K-12 Awareness regarding Menstrual Education@ Dolly
Public School, Agra
SUB-CHAPTERACTIVITIES
Workshop on HVAC Controls Training by Mr. P. K. Goel
WORKSHOP
K-12 ACTIVITY
K-12 Activity at Surya Model School, New Delhi on 14th August'2019
Regional Chapter Chair Meeting @ Masoori
www.dcishrae.org
Tower Maintenance
Well-maintained equipment given the best operating results
and the least maintenance cost. It is recommend for setting up
a regular inspection schedule to insure effective, safe operation
of the cooling tower. Use the schedule as referred to obtain
continuously good performance with the least tower
maintenance. See cooling Tower inspection check list in this
manual. Keep a continuous lubrication and maintenance
record for each cooling tower.
HOT WATER DISTRIBUTION SYSTEM
Keep the circulating water and distribution system (piping and
nozzles) clean and free of dirt, algae, and scale. Algae and
scale may clog nozzles, eliminators, fill piping, and may collect
on the equipment served thus reducing its performance. An
access hatch in the fan deck with ladder to an intermediate
platform provides surface protection before walking on the fill.
DRIFT ELEMINATORS
Eliminators should be kept clean
Do not walk or step on the eliminators without planking and
safety harness.
COLD WATER COLLECTION BASIN
Inspect collection basin occasionally for leaks and repair if
necessary. Keep cold water outlets clean and free of debris.
Makeup and circulating water controls must operate freely and
maintain the desired water quantity in the system.
ELECTRIC MOTOR
Lubricate and maintain each electric motor in accordance with
the manufacturer’s instructions. If repair work is necessary,
contact the nearest representative of the motor manufacturer.
FAN
Inspect fan blade surfaces every six months.
PAINTING
Periodically clean and, if necessary, recoat all metal parts
subject to corrosion.
Inspection and maintenance Schedule
General Recommendations
More frequent inspection and maintenance may be desirable.
Our Annual Partner-2019-20
ALP Aeroflex India Private Limited is a joint venture between ALP Overseas Private
Limited of India & Eastern Polymers Industries of Thailand for manufacturing of
EPDM and Nitrile Rubber Insulation Sheets, Tubes and Accessories for Thermal &
Acoustic insulation. The corporate office of the company is situated at the
corporate hub of Haryana, Gurgaon, India, and has its plant at Rudrapur in state
of Uttarakhand.
PRODUCT PROFILE
ALP Aeroflex India Private Limited offers a complete range of insulation products
and accessories. This includes closed cell elastomeric Nitrile & EPDM rubber
sheets, tubes in various lengths, thicknesses and dimensions, special products
like Accosound, Accofoam, Antimicrobial, High Strength, High temperature, Self-
sealing pre-slit tubes for customized applications.
About the Author
Mr. Subir Das
(IMP President)
Subir Das has an industry experience of over 30 years and is one of the most respected person in the cooling tower industry in India. He has a Science
Graduate in physics Honors from Calcutta University and Advance Mechanical Engineering from Imperial College London (U.K). He left for his training with
Film Cooling Towers, UK in 1980 and continued his studies in Thermal Engineering at the prestigious Imperial College, London. After his training he returned to
India in 1983 and decided to move out of West Bengal and settled in New Delhi. A self-made man, Subir Das with his dedication was able to set up a brand
providing the best quality product with maximum efficiency. He overlooks the day to day activities at the company and is the key advisor on all key issues. He
was awarded with the Rashtriya Udyog Ratna Award for the contribution of Flow-Tech Air to the economic growth of the cooling. Subir Das was past president
of Delhi Chapter of ISHRAE.
www.dcishrae.org
Fan
& f
an
Gro
un
d
Mo
tor
Elim
inato
r
Fill
Co
ld W
ate
r B
asin
Ho
t W
ate
r D
istr
ibu
tio
n
Flo
at
Valv
e
Su
cti
on
Scre
en
Co
ntr
ol V
alv
es
Str
uctu
ral M
em
be
r
Casin
g
Fan
Cylin
de
r
Lad
de
rs
1. Inspection for clogging M M W W
2. Check for unusual noise or vibration D
3. Inspect keys, keyways and setscrews S S S
4. Make sure vent are open S
5. Check fan blde tip clearance S
6. Check motor connection S
7. Check water level D D
8. Inspect General condition W S S S
9. Tighten loose bolts S S S Y S Y S S S S S Y S
10. Clean S
11. Repaint R R R R R S R R R R
12. Rebalance R R
13. Inspect/repair for safe use R
14. Inspect and repair before each use Y Y Y
D-Daily W-Weekly M-Monthly Q-Quarterly S-Semiannally Y-Yearly R-as required
Tower Maintenance
Well-maintained equipment given the best operating results
and the least maintenance cost. It is recommend for setting up
a regular inspection schedule to insure effective, safe operation
of the cooling tower. Use the schedule as referred to obtain
continuously good performance with the least tower
maintenance. See cooling Tower inspection check list in this
manual. Keep a continuous lubrication and maintenance
record for each cooling tower.
HOT WATER DISTRIBUTION SYSTEM
Keep the circulating water and distribution system (piping and
nozzles) clean and free of dirt, algae, and scale. Algae and
scale may clog nozzles, eliminators, fill piping, and may collect
on the equipment served thus reducing its performance. An
access hatch in the fan deck with ladder to an intermediate
platform provides surface protection before walking on the fill.
DRIFT ELEMINATORS
Eliminators should be kept clean
Do not walk or step on the eliminators without planking and
safety harness.
COLD WATER COLLECTION BASIN
Inspect collection basin occasionally for leaks and repair if
necessary. Keep cold water outlets clean and free of debris.
Makeup and circulating water controls must operate freely and
maintain the desired water quantity in the system.
ELECTRIC MOTOR
Lubricate and maintain each electric motor in accordance with
the manufacturer’s instructions. If repair work is necessary,
contact the nearest representative of the motor manufacturer.
FAN
Inspect fan blade surfaces every six months.
PAINTING
Periodically clean and, if necessary, recoat all metal parts
subject to corrosion.
Inspection and maintenance Schedule
General Recommendations
More frequent inspection and maintenance may be desirable.
Our Annual Partner-2019-20
ALP Aeroflex India Private Limited is a joint venture between ALP Overseas Private
Limited of India & Eastern Polymers Industries of Thailand for manufacturing of
EPDM and Nitrile Rubber Insulation Sheets, Tubes and Accessories for Thermal &
Acoustic insulation. The corporate office of the company is situated at the
corporate hub of Haryana, Gurgaon, India, and has its plant at Rudrapur in state
of Uttarakhand.
PRODUCT PROFILE
ALP Aeroflex India Private Limited offers a complete range of insulation products
and accessories. This includes closed cell elastomeric Nitrile & EPDM rubber
sheets, tubes in various lengths, thicknesses and dimensions, special products
like Accosound, Accofoam, Antimicrobial, High Strength, High temperature, Self-
sealing pre-slit tubes for customized applications.
About the Author
Mr. Subir Das
(IMP President)
Subir Das has an industry experience of over 30 years and is one of the most respected person in the cooling tower industry in India. He has a Science
Graduate in physics Honors from Calcutta University and Advance Mechanical Engineering from Imperial College London (U.K). He left for his training with
Film Cooling Towers, UK in 1980 and continued his studies in Thermal Engineering at the prestigious Imperial College, London. After his training he returned to
India in 1983 and decided to move out of West Bengal and settled in New Delhi. A self-made man, Subir Das with his dedication was able to set up a brand
providing the best quality product with maximum efficiency. He overlooks the day to day activities at the company and is the key advisor on all key issues. He
was awarded with the Rashtriya Udyog Ratna Award for the contribution of Flow-Tech Air to the economic growth of the cooling. Subir Das was past president
of Delhi Chapter of ISHRAE.
www.dcishrae.org
Fan
& f
an
Gro
un
d
Mo
tor
Elim
inato
r
Fill
Co
ld W
ate
r B
asin
Ho
t W
ate
r D
istr
ibu
tio
n
Flo
at
Valv
e
Su
cti
on
Scre
en
Co
ntr
ol V
alv
es
Str
uctu
ral M
em
be
r
Casin
g
Fan
Cylin
de
r
Lad
de
rs
1. Inspection for clogging M M W W
2. Check for unusual noise or vibration D
3. Inspect keys, keyways and setscrews S S S
4. Make sure vent are open S
5. Check fan blde tip clearance S
6. Check motor connection S
7. Check water level D D
8. Inspect General condition W S S S
9. Tighten loose bolts S S S Y S Y S S S S S Y S
10. Clean S
11. Repaint R R R R R S R R R R
12. Rebalance R R
13. Inspect/repair for safe use R
14. Inspect and repair before each use Y Y Y
D-Daily W-Weekly M-Monthly Q-Quarterly S-Semiannally Y-Yearly R-as required
ASHRAE GUIDE LINE 0 – defines the commissioning process as a
quality oriented process for achieving, verifying and documenting
that the performance of facilities, systems and assemblies meets
the defined objective and criteria and also commissioning process
is a capable way of verifying that the facility and its systems meets
the owners project requirements. It actually suggests, measures,
evaluates, and verifies that the HVAC systems of building are
operating the way the owner intended and in effect help reduce
operating and capital cost to maximize gains.
The Goal of HVAC commissioning is to ensure that HVAC systems in
buildings are operating the way the owner intended through its life
cycle.
Today, Commissioning is recognized by all stake holders as the
most important part of a HVAC installation process.
Most of us believe that the commissioning process comes at the
end of the whole design, supply and installation process of a HVAC
system, but the commissioning actual begins at the design stage
itself. The normal process is to appoint a commissioning agent at
the start of the project reporting to the owners directly to keep him
away from the influence of architects and consultants.
Owners
Commissioning Agent
Project Manager
Architects
Consultant
Mechanical Contractor
The commissioning agent actually does the following:
a) Identifies the potential issues during design.
b) Identifies resolves issues during construction.
c) Ensures successful day one operations and confirms that
building equipment and system operated and perform properly.
d) Ensures O and M documentation is complete.
e) Operating staff is trained.
f) Ensures reduction in operation and maintenance costs.
g) Improves IAQ, occupant comfort and productivity.
h) Reduces project close out issues.
i) Ensures integration of various systems.
j) Ensures environment, health and safety to occupants and
property protection.
k) Improves efficiencies, lowers cost and increases sustainability.
l) Sets measurable goals for everyone.
m) Establishes accountability.
n) Changes the way people perform.
o) Allows contractors and designers to measure success as well
as deficiency.
p) Higher value of rentable space.
q) Reduction in common deficiencies.
r) Help in full review of existing operating protocol.
s) He is responsible for the owners objectives being met.
Type of Commissioning:-
a) Initial Commissioning : It is done with construction of a new
building or a new HVAC system in a existing building.
b) Retro Commissioning :- First time Commissioning that is being
implemented in a existing building or existing HVAC equipment.
c) Recommissiong :- It is commissioning of the existing HVAC
system that were commissioned initially but have gone through
some modifications and under alternations during the course of
time or the owner wants to recheck the performance of the AC
system over a period of time.
Introduction to comissioning Instruments :-
a) AIR CAPTURE HOOD :-
• Multipurpose Electronic Air Balancing Instrument.
• Measures Air Volume Directly At Diffusers And Grills.
• Auto Zeroing Pressure Sensor.
• Automatic Density Correction Increase Reading Accuracy.
• USB Interface.
• Pilot Tube.
• Static Pressure Probes.
b) TACHOMETER :-
• Accuracy - ± (0.05%)
• Sampling Time – 0.5 Sec (Over 1200 RPM)
• Detecting Distance – 50-500 MM
• Measures speed (RPM) of rotating machinery.
c) SLING PHYSCHROMETER:-
• Comprises of a dry bulb and wet bulb temperature.
• Based on which the RH can be worked out.
d) LUTRON – DIGITAL ANEMOMETER :-
• Air velocity – 0.4-30 m/s
• Accuracy - ±2% OR 0.1 m/s
• Operating environment – 0-500C
• Used for measuring velocity of air across a Cross section or
terminal.
e) DIGITAL VIBRATION METER :-
• Measures periodic motion to check imbalance and deflection of
moving machinery and thus vibrations.
f) DB METER (MODEL-SL4010)
Sound Level Meter
Function
Range : 35 ~ 130 dB
Resolution : 0.1 dB
Measurement frequency : 31.5 ~ 8.000 Hz
Feature
• Frequency & time weighting
• A frequency weighting
• Fast time weighting
• Built-in adjustment VR is available for easy calibration
g) CO METER :-
• Used for finding CO gas leaks with Accuracy ±5% or ±10 ppm
• CO concentration Values from 1-1000 ppm.
• Used to measure CO in car bar basements.
h) IAQ METER :-
• Simultaneously measures multiple parameters such as: CO,
CO , Temperature, RH, to monitor IAQ2
• Calculates Dew Point, Web Bulb Temperature, Absolute
Humidity, Humidity Ratio and % Outside Air.
• Examines building IAQ conditions to optimize worker
productivity.
• The monitor can also check CO levels and determine the rate of 2
exchange, or the % of outside air, being introduced to a building
per ASHRAE standard 62.1
Importance of Commissioning in today's Era
www.dcishrae.org
I) PM 2.5 METER & VOC METER :-
• Range of PM2.5: 0-999 μg/m³.
• Range of PM10: 0-1999 μg/m³.
• Minimum resolution of < 0.3 μm.
• Relative error Maximum of ±10% and ±10μg/m³.
• Response time: Less than 10 seconds when scene changes
j) CO METER + HUMIDITY TEMPERATURE :-2
• CO Range – 0-400ppm2
• CO Sensor –NDIR, long term reliability.2
• CO with alarm setting2
• Data hold record (Maximum and Minimum)
k) ULTRASONIC FLOW METER :-
Testing Pressure : 16 Bar
Nominal Pressure : 10 Bar
Minimum Pressure : 0.1 Bar
Pressure Loss : <0.63 Bar
Media Temperature : 0.1 to 60°C
Relative Humidity : 100%
Ambient Temperature : 70°C
Max. mean temperature : 55°C
over 24 Hrs
Remote reading : Wireless M-Bus (inscripted
– protect personal Data
against unauthorized
monitoring)
Reprogramming/Downloading : Through optical port
store data
Data storage facility : upto 10 years.
Battery Life : 10 Years
RF Frequency : 868.0 Mhz
Available line sizes : 15, 20, 25, 32, 40NB
MOC : SS/ABS
Process Connection : BSP Threading (male)
• Used for measuring water flow rates in pipes.
l) DUCT LEAKAGE TESTING MACHINE:-
• Duct leakage reduces Air quantities at the terminals.
• Difference in quantity measured between source and the
terminals.
• This is called a transmission loss.
• The static pressure, duct quantity and openings are factors that
effect duct leakage.
• Workmanship the most important factor to duct leakage.
• Each duct must be designed for a specific Duct pressure
Classification, if not defined 250 Pa or one inch is the basis of
compliance.
AN UNSEALED CLASS: CLASS 48
Duct Pressure Class does not mean the Fan Static Pressure until unless it is
specified.
Appendix E: SMACNA -- HVAC AIR DUCT LEAKAGE TEST MANUAL
Leakage Factor “Lf” - CFM / 100 Sq. ft of Duct
Commissioning and reporting :
This is the most important part of the commissioning process,
where the actual measured data is plotted against the design data,
to check the net deviation.
A sample commissioning document for a axial flow fan is attached.
Such documentation must be done for all mechanical equipment
and supporting infrastructure which goes to build the entire HVAC
system.
Sample Commissioning document for Axial flow fan :-
Tag No. of fan as per drawing/ Date :-
As per site :- Location :-
Name Plate details :
Model No :
S.No. Description Design Actual
1. External static pressure 20 mm
2. CFM 12000
3. Noise level at 3m distance 68 dB(A)
4. Efficiency 76%
5. FLA 6.18
6. Starting Current 26.5
(Mechanical (Project (Commissioning (Owners
Contractor) Manager) Agent) representative)
Conclusion :-
HVAC consumes about 35% of the total energy consumed in a
commercial building and hence has the maximum scope for energy
conservation. India is projected to be a 5 trillion dollar economy by
2024, while this ambitious goal promises a prosperous and bright
future, it puts a stress in power infrastructure . With this anticipated
growth the power requirements would increase atleast by fifty
percent if not double. We need a process driven commissioning
system to help achieve a sustainable growth, thereby conserving
our natural and national resources.
(You could write back to [email protected]
for a complete presentation)
Pressure Leakage Class ---- CFM / 100 Sq FT
Inch of W.G. Class 3 Class 6 Class 12 Class 24 Class 48
½ 1.9 3.8 7.6 15.3 30.6
1 3 6 12 24 48
2 4.7 9.4 18.8 37.7 75.4
3 6.1 12.2 24.5 49 98
4 7.4 14.8 29.5 59 118.1
5 8.6 17.1 Not Defined
6 9.6 19.2
7 10.6 21.2
8 11.6 23.2
9 12.5 25.6
Duct Pressure Class 1”, 2” w.g. 3” w.g. 4”, 6” w.g.
Seal Class
Sealing Requirement
Leakage Class :
Rectangular
Round
C
All Transverse Joints
Class 24
Class 12
B
All Transverse & Longitudinal Seams
Class 12
Class 6
A
All Transverse Joints, Longitudinal Seams &
Wall Penetrations
Class 6
Class 3
About the Author
Mr. K.D Singh
Managing Director – Aircon Engineers Pvt. Ltd., a 25 year old
HVAC system integration company engaged in designing,
execution and commissioning HVAC projects.
ASHRAE GUIDE LINE 0 – defines the commissioning process as a
quality oriented process for achieving, verifying and documenting
that the performance of facilities, systems and assemblies meets
the defined objective and criteria and also commissioning process
is a capable way of verifying that the facility and its systems meets
the owners project requirements. It actually suggests, measures,
evaluates, and verifies that the HVAC systems of building are
operating the way the owner intended and in effect help reduce
operating and capital cost to maximize gains.
The Goal of HVAC commissioning is to ensure that HVAC systems in
buildings are operating the way the owner intended through its life
cycle.
Today, Commissioning is recognized by all stake holders as the
most important part of a HVAC installation process.
Most of us believe that the commissioning process comes at the
end of the whole design, supply and installation process of a HVAC
system, but the commissioning actual begins at the design stage
itself. The normal process is to appoint a commissioning agent at
the start of the project reporting to the owners directly to keep him
away from the influence of architects and consultants.
Owners
Commissioning Agent
Project Manager
Architects
Consultant
Mechanical Contractor
The commissioning agent actually does the following:
a) Identifies the potential issues during design.
b) Identifies resolves issues during construction.
c) Ensures successful day one operations and confirms that
building equipment and system operated and perform properly.
d) Ensures O and M documentation is complete.
e) Operating staff is trained.
f) Ensures reduction in operation and maintenance costs.
g) Improves IAQ, occupant comfort and productivity.
h) Reduces project close out issues.
i) Ensures integration of various systems.
j) Ensures environment, health and safety to occupants and
property protection.
k) Improves efficiencies, lowers cost and increases sustainability.
l) Sets measurable goals for everyone.
m) Establishes accountability.
n) Changes the way people perform.
o) Allows contractors and designers to measure success as well
as deficiency.
p) Higher value of rentable space.
q) Reduction in common deficiencies.
r) Help in full review of existing operating protocol.
s) He is responsible for the owners objectives being met.
Type of Commissioning:-
a) Initial Commissioning : It is done with construction of a new
building or a new HVAC system in a existing building.
b) Retro Commissioning :- First time Commissioning that is being
implemented in a existing building or existing HVAC equipment.
c) Recommissiong :- It is commissioning of the existing HVAC
system that were commissioned initially but have gone through
some modifications and under alternations during the course of
time or the owner wants to recheck the performance of the AC
system over a period of time.
Introduction to comissioning Instruments :-
a) AIR CAPTURE HOOD :-
• Multipurpose Electronic Air Balancing Instrument.
• Measures Air Volume Directly At Diffusers And Grills.
• Auto Zeroing Pressure Sensor.
• Automatic Density Correction Increase Reading Accuracy.
• USB Interface.
• Pilot Tube.
• Static Pressure Probes.
b) TACHOMETER :-
• Accuracy - ± (0.05%)
• Sampling Time – 0.5 Sec (Over 1200 RPM)
• Detecting Distance – 50-500 MM
• Measures speed (RPM) of rotating machinery.
c) SLING PHYSCHROMETER:-
• Comprises of a dry bulb and wet bulb temperature.
• Based on which the RH can be worked out.
d) LUTRON – DIGITAL ANEMOMETER :-
• Air velocity – 0.4-30 m/s
• Accuracy - ±2% OR 0.1 m/s
• Operating environment – 0-500C
• Used for measuring velocity of air across a Cross section or
terminal.
e) DIGITAL VIBRATION METER :-
• Measures periodic motion to check imbalance and deflection of
moving machinery and thus vibrations.
f) DB METER (MODEL-SL4010)
Sound Level Meter
Function
Range : 35 ~ 130 dB
Resolution : 0.1 dB
Measurement frequency : 31.5 ~ 8.000 Hz
Feature
• Frequency & time weighting
• A frequency weighting
• Fast time weighting
• Built-in adjustment VR is available for easy calibration
g) CO METER :-
• Used for finding CO gas leaks with Accuracy ±5% or ±10 ppm
• CO concentration Values from 1-1000 ppm.
• Used to measure CO in car bar basements.
h) IAQ METER :-
• Simultaneously measures multiple parameters such as: CO,
CO , Temperature, RH, to monitor IAQ2
• Calculates Dew Point, Web Bulb Temperature, Absolute
Humidity, Humidity Ratio and % Outside Air.
• Examines building IAQ conditions to optimize worker
productivity.
• The monitor can also check CO levels and determine the rate of 2
exchange, or the % of outside air, being introduced to a building
per ASHRAE standard 62.1
Importance of Commissioning in today's Era
www.dcishrae.org
I) PM 2.5 METER & VOC METER :-
• Range of PM2.5: 0-999 μg/m³.
• Range of PM10: 0-1999 μg/m³.
• Minimum resolution of < 0.3 μm.
• Relative error Maximum of ±10% and ±10μg/m³.
• Response time: Less than 10 seconds when scene changes
j) CO METER + HUMIDITY TEMPERATURE :-2
• CO Range – 0-400ppm2
• CO Sensor –NDIR, long term reliability.2
• CO with alarm setting2
• Data hold record (Maximum and Minimum)
k) ULTRASONIC FLOW METER :-
Testing Pressure : 16 Bar
Nominal Pressure : 10 Bar
Minimum Pressure : 0.1 Bar
Pressure Loss : <0.63 Bar
Media Temperature : 0.1 to 60°C
Relative Humidity : 100%
Ambient Temperature : 70°C
Max. mean temperature : 55°C
over 24 Hrs
Remote reading : Wireless M-Bus (inscripted
– protect personal Data
against unauthorized
monitoring)
Reprogramming/Downloading : Through optical port
store data
Data storage facility : upto 10 years.
Battery Life : 10 Years
RF Frequency : 868.0 Mhz
Available line sizes : 15, 20, 25, 32, 40NB
MOC : SS/ABS
Process Connection : BSP Threading (male)
• Used for measuring water flow rates in pipes.
l) DUCT LEAKAGE TESTING MACHINE:-
• Duct leakage reduces Air quantities at the terminals.
• Difference in quantity measured between source and the
terminals.
• This is called a transmission loss.
• The static pressure, duct quantity and openings are factors that
effect duct leakage.
• Workmanship the most important factor to duct leakage.
• Each duct must be designed for a specific Duct pressure
Classification, if not defined 250 Pa or one inch is the basis of
compliance.
AN UNSEALED CLASS: CLASS 48
Duct Pressure Class does not mean the Fan Static Pressure until unless it is
specified.
Appendix E: SMACNA -- HVAC AIR DUCT LEAKAGE TEST MANUAL
Leakage Factor “Lf” - CFM / 100 Sq. ft of Duct
Commissioning and reporting :
This is the most important part of the commissioning process,
where the actual measured data is plotted against the design data,
to check the net deviation.
A sample commissioning document for a axial flow fan is attached.
Such documentation must be done for all mechanical equipment
and supporting infrastructure which goes to build the entire HVAC
system.
Sample Commissioning document for Axial flow fan :-
Tag No. of fan as per drawing/ Date :-
As per site :- Location :-
Name Plate details :
Model No :
S.No. Description Design Actual
1. External static pressure 20 mm
2. CFM 12000
3. Noise level at 3m distance 68 dB(A)
4. Efficiency 76%
5. FLA 6.18
6. Starting Current 26.5
(Mechanical (Project (Commissioning (Owners
Contractor) Manager) Agent) representative)
Conclusion :-
HVAC consumes about 35% of the total energy consumed in a
commercial building and hence has the maximum scope for energy
conservation. India is projected to be a 5 trillion dollar economy by
2024, while this ambitious goal promises a prosperous and bright
future, it puts a stress in power infrastructure . With this anticipated
growth the power requirements would increase atleast by fifty
percent if not double. We need a process driven commissioning
system to help achieve a sustainable growth, thereby conserving
our natural and national resources.
(You could write back to [email protected]
for a complete presentation)
Pressure Leakage Class ---- CFM / 100 Sq FT
Inch of W.G. Class 3 Class 6 Class 12 Class 24 Class 48
½ 1.9 3.8 7.6 15.3 30.6
1 3 6 12 24 48
2 4.7 9.4 18.8 37.7 75.4
3 6.1 12.2 24.5 49 98
4 7.4 14.8 29.5 59 118.1
5 8.6 17.1 Not Defined
6 9.6 19.2
7 10.6 21.2
8 11.6 23.2
9 12.5 25.6
Duct Pressure Class 1”, 2” w.g. 3” w.g. 4”, 6” w.g.
Seal Class
Sealing Requirement
Leakage Class :
Rectangular
Round
C
All Transverse Joints
Class 24
Class 12
B
All Transverse & Longitudinal Seams
Class 12
Class 6
A
All Transverse Joints, Longitudinal Seams &
Wall Penetrations
Class 6
Class 3
About the Author
Mr. K.D Singh
Managing Director – Aircon Engineers Pvt. Ltd., a 25 year old
HVAC system integration company engaged in designing,
execution and commissioning HVAC projects.
