Cawangan Kejuruteraan Mekanikal – Edition 2016

Table of Contents

1.0 TESTING, ADJUSTING, BALANCING & COMMISIONING

REQUIREMENTS ............................................................................................... 3
1.1 GENERAL .................................................................................................................. 3
1.2 INSPECTION AND TESTING PLAN (ITP).................................................................. 4
1.2.1 Pre - Delivery Stage ........................................................................................... 6
1.2.1.1 Switchboard Factory Test ............................................................................. 6
1.2.2 Delivery Stage.................................................................................................... 7
1.2.3 Installation Stage............................................................................................... 7
1.2.3.1 Visual Inspection .......................................................................................... 8
1.2.3.2 Refrigerant Leak Test ................................................................................... 8
1.2.3.3 Refrigerant Charge Test ............................................................................... 8
1.2.3.4 Purging/ Flushing ......................................................................................... 9
1.2.3.5 Cable Continuity Test ................................................................................... 9
1.2.3.6 Pipe Gradient Test ....................................................................................... 9
1.2.4 Functional Performance Test ........................................................................... 9
1.2.4.1 Pre-Functional Performance Test ................................................................. 9
1.2.4.2 Air Cooled Split Unit (ACSU) ...................................................................... 10
1.2.4.3 Switchboard and Power Supply .................................................................. 11
1.2.4.4 Room Condition Test.................................................................................. 12
1.2.4.5 Mechanical Ventilation Test ........................................................................ 12
1.3 COMMISSIONING .................................................................................................... 14
1.3.1 Handing Over Documents............................................................................... 14
1.3.2 System Familiarisation Program .................................................................... 15

2.0 POST OCCUPANCY EVALUATION......................................................... 16

3.0 TESTING INSTRUMENTS & ACCESSORIES ...................................... 17

Section 4.6 TABC Specification – Air Cooled Split Unit System 1

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List of Tables
Table 1: Sample of Inspection and Testing Plan ................................................................... 5
Table 2: Switchboard Testing ................................................................................................ 7
Table 3: Test List In Installation Stage .................................................................................. 8
Table 4: Air Cooled Split Unit Inspection and Test .............................................................. 10
Table 5: Air Cooled Split Unit Control Test Requirements ................................................... 10
Table 6: Switchboard and Power Supply Inspection and Test Requirements ...................... 11
Table 7: Air Distribution System Inspection and Test Name ................................................ 12
Table 8: Fan Control Test List ............................................................................................. 13
Table 9: Post Occupancy Evaluation Form ......................................................................... 16
Table 10: Testing Instruments ............................................................................................. 17

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1.0 TESTING, ADJUSTING, BALANCING & COMMISIONING

REQUIREMENTS

1.1 GENERAL

This section specifies the requirements for all testing, adjusting, balancing and
commissioning (TABC) of mechanical works to be carried out under the contract. The
objectives of TABC are;

i. To verify the delivered materials are as per approved specification and good
physical condition.

ii. To verify the installation works are carried out in accordance to specification
and good engineering practises.

iii. To verify the performance in terms of functionality, safety, maintainability and

operational ability of the installed equipment/systems meet the specified
design intention through series of tests and adjustments.

iv. To ensure all test results are systematically recorded and verified prior to
system commissioning.

TABC works are divided into four stages as the following;

i. Pre Delivery stage.

ii. Delivery stage.

iii. Installation stage.

iv. Functional Performance Test stage.

Contractor shall submit Inspection and Testing Plan (ITP) of TABC works to be carried out in
accordance to this specification for Superintending Officer (S.O) review and approval.

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1.2 INSPECTION AND TESTING PLAN (ITP)

ITP shall consist of;

i. List of all TABC Requirement

All TABC works with specific scope and boundaries shall be clearly stated at every stage of
TABC works.

ii. TABC Work Schedules

TABC work schedules shall be integrated into main project schedules.

iii. Method Statements

TABC method statements shall consists of TABC procedures, responsibilities, necessary

tools, measuring equipment and accuracy, consumables and acceptance criteria. Type of
test required is listed in Schedule of Inspection and Testing.

Method statements and acceptance criteria for all equipment installation stage inspection
and functional performance testing shall be endorsed by manufacturer or manufacturer’s
valid representative.

Acceptance criteria shall be stated as per Schedule of Design Requirements, technical

specification or any applicable standards.

ITP shall be updated for any changes and resubmitted to the S.O/S.O’s representative for
approval.

Prior to the commencement of the TABC works as per approved ITP, contractor shall issue
Request for Inspection and Testing (RFIT) to the S.O. During the TABC, contractor shall
have his supervising foremen and mechanics available to aid the testing and to perform any
adjustments as directed. The TABC works shall be carried out under the direction of
experienced personnel and witnessed by S.O or S.O’s representatives. No subsequent
installation works shall proceed without S.O’s approval of the test result.

Depending on the specific demands of individual installation, S.O’s Representative may

require additional or substitute testing works in regard to any elements in the installation
other than those indicated in this specification.

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Table 1: Sample of Inspection and Testing Plan

Test
Inspection / Test Scope and Method Expected
Stage Responsibility Form
Name Boundaries Statement Date
No
Switchboard/Control Switch Board
Pre Delivery MS-ITP-
Panel Test / Control Manufacturer TF-02 Feb-17
Stage PDI-02
(if applicable) Panel
Air Cooled
Equipment
Delivery Split Unit MS-ITP-
verification and Contractor TF-03 Mar-17
Stage outdoor and PDI-03
physical Inspection
indoor Unit
Pipe & MS-ITP-
Leak test Contractor TF-04 Mar-17
equipment PDI-04
Refrigerant MS-ITP-
Vacuum Contractor TF-05 Jun-17
pipe PDI-05
Support and hanger Equipment, MS-ITP-
Contractor TF-06 Jun-17
load test piping PDI-05
MS-ITP-
Charging gas pipe Contractor TF-07 Jun-17
Installation PDI-05
Stage Cable continuity Cable & MS-ITP-
Contractor TF-08 Jun-17
and insulation test wiring PDI-05
MS-ITP-
Gradient Pipe Test Drain pipe Contractor TF-09 Jun-17
PDI-05
Air Cooled
Split Unit , MS-ITP-
Visual Inspection Contractor TF-09 Jun-17
equipment PDI-05
and piping
Performance,
Pressure,
Control
system,
Functional Running MS-ITP-
Air Cooled Split Unit Contractor TF-10 Jun-17
Performance Amp, PDI-05
Stage Temperature,
Power input,
Vibration,
noise.

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1.2.1 Pre - Delivery Stage

Pre-delivery inspection and performance test shall be conducted if stated in the Schedule of
Inspection and Testing requirements. These tests shall be witnessed by the government’s
representative if deemed necessary by the S.O. All travelling, food and accommodation cost
of the government’s representatives related to witnessed performance test shall be borne by
the government.

A factory test shall be define as any test of equipment required as stated in the contract,
conducted at manufacturer’s plant or at an independent and accredited test facility approved
by the S.O.

Performance test method statement, test standard and acceptance criteria shall be
submitted to S.O for approval prior to such testing. The manufacturer shall produce a signed
test report to be submitted for S.O’s approval. Manufacturer shall be responsible for any
reworks and adjustment of the equipment if the test results fail to comply to the approved
acceptance criteria.

1.2.1.1 Switchboard Factory Test

Switchboard pre-delivery acceptance test shall be carried out before delivery to site. The
main circuits and the auxiliary circuits shall be tested to verify dielectric properties with
power-frequency test voltage of 2500Vac for 1 minute and insulation resistance under test
voltage of 1000V. Switchboard testing shall include inspection and checking of wiring,
electrical continuity, functionality of the protective circuits, connections and effectiveness of
mechanical actuating elements and logic circuit interlock. Test Results or Certificate duly
certified by Competent Person as in Electricity Regulations 1994 shall be issued for every
switchboard supplied and installed.

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Type testing for switchboard as per categorization shall be as per Table 2 below:

Table 2: Switchboard Testing

Category Current Rating Registration and type of test report

I I ≤ 600 A Suruhanjaya Tenaga (S.T)

Suruhanjaya Tenaga (S.T) & Partial Type

Test in accordance with MS IEC 60439-1
II 600 A ≤ I ≤ 1200 A
(i) Short Circuit Test
(ii) Temperature Rise Test

Suruhanjaya Tenaga & Full Type Test in

III I ≥ 1200 A
accordance with MS IEC 60439-1

1.2.2 Delivery Stage

All incoming material and equipment to site shall be inspected to verify that delivered items
are complying with contract specification, as per approved materials and good physical
conditions. Materials delivered to site shall be free from defects and adequately protected
against site conditions.

1.2.3 Installation Stage

List of inspection and testing works during installation as per Table 3;

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Table 3: Test List In Installation Stage

Inspection /Test name System/Component Objectives

Verify that all equipment

Air Cooled Split Unit,
Visual Inspection installation as per technical
equipment and piping
specifications
Refrigerant pipe & Verify refrigerant and integrity of
Refrigerant Leak Test
Equipment all pipe joints and fittings.
Verify refrigerant gas, pressure &
Refrigerant Charge Test Refrigerant gas
running amp
Refrigerant pipe and Verify that all pipes are internally
Purging/Flushing
Drain pipe clean
Verify cable continuity
Cable Continuity Test Electrical Cabling
effectiveness
Verify condensate drain pipe
Pipe Gradient Test Drain pipe
gradient as per specification.

1.2.3.1 Visual Inspection

All installation shall be subjected to technical specifications and drawings.

1.2.3.2 Refrigerant Leak Test

During test, all brazing joints, bends, fitting and valves shall be visual checked for any leaks
or deformations for the entire piping system. Expanded conditions of all piping shall be
carefully studied and any necessary change in hangers, anchors or guide locations shall be
made.

Use nitrogen gas or electronic leak detector for refrigerant gas leakage. All pipes, valves,
fitting, etc. shall be tested to the minimum of 1.5 times the working pressure, whichever is
greater for period of 2 hours.

Pressure and leak tests of refrigerant piping systems are normally carried out on completion
of the system, before pipework is insulated.

1.2.3.3 Refrigerant Charge Test

Refrigerant Charge Test shall be as per manufacturer recommendation.

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1.2.3.4 Purging/ Flushing

To eliminate the probability of such chocking and damage, the internal surfaces of the piping
system network need to be flushed clean.
Components that can be potentially damaged/choked by particles or debris from the flushing
process shall be isolated from the flushing circuit and cleaned individually.

1.2.3.5 Cable Continuity Test

Cable continuity test shall be performed on each power cable by ohmmeter method. Perform
an acceptance test on cables, including terminations and joints, after cable system
installation and before the cable system is placed into service. In accordance with
ANSI/IEEE 400, by means of direct voltage (dc) and recorded in the testing form.

1.2.3.6 Pipe Gradient Test

The entire drain pipe carrying condensate water from equipment air conditioning shall be
tested with water flow.

1.2.4 Functional Performance Test

List of functional performance test are as the following. All Functional Performance Test shall
commence after all inspection and testing during installation stage has been completed.

1.2.4.1 Pre-Functional Performance Test

a. Accuracy Test

Before the commencement of the functional performance test, the contractor shall carry
out field calibration check for the functional accuracy of measuring, regulating and similar
equipment, forming part of installation including gauges, transducers, sensors, switches
and meters.

All calibration certificates of all measuring facility shall be submitted to the S.O.

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1.2.4.2 Air Cooled Split Unit (ACSU)

Table 4: Air Cooled Split Unit Inspection and Test

Inspection /Test name Objectives

Air Cooled Split Unit General Verify that equipment physical conditions are acceptable.
Inspection
ACSU Refrigerant High/Low Verify ACSU protection against refrigerant high/low
Pressure Protection Test pressure condition
Air Cooled Split Unit Control Verify that control system function as per design control
Test strategies.

a. Air Cooled Split Unit General Inspection

Air Cooled Split Unit shall be visually inspected for any deviation from approved shop
drawings, approved material and identification of any physical defects that may arise during
installation works.

b. ACSU Refrigerant High/Low Pressure Protection Test

ACSU ability to cut off in the event of excessively high refrigerant pressure and low
refrigerant pressure. The test shall be carry out by manipulating high/low pressure switch
setting and observe tripping of compressors.

c. Air Cooled Split Unit Control Test

Each Air Cooled Split Unit control system shall be tested against their design as detail out in
Table 5.

Table 5: Air Cooled Split Unit Control Test Requirements

Type of Air Cooled

Description
Split Unit Control

Temperature Control Adjust thermostat setting above and below controlled parameter
value (e.g. return air or space air temperature) and observe
response in compressor on/off.

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1.2.4.3 Switchboard and Power Supply

List of Switchboard and power supply inspection and test name are listed in Table 6. Detail
method statement for testing shall be submitted conforming to the test requirements in this
specification. Only competent as in Electricity Regulations 1994 shall conduct the
switchboard testing.

Table 6: Switchboard and Power Supply Inspection and Test Requirements

Inspection /Test name Description

Switchboard General • Verify physical switchboard components are as per

Inspection specification.
• Check for tripping setting and system trip
• Check for wiring, motor insulation and record data.
• Check for cable terminal tightness.
• Check for equipment and panel grounding connection.
• Check for any sign for cable heating. Cable
temperature shall be measured and verify against
IEEE standards for temperature rise during full load.
• Check for voltmeter, and ammeter function and
accuracy record running voltage and ampere.
• Check for control circuit function as intended.
• Check for contractors, relays, ACB , MCCB, MCB ,
type, size and ratings as per specification.
Power Supply Test • Verify that power supply parameters are within
permissible range, safety protections are in place and
physical condition of switch board and cabling works
are acceptable as per specification and approved
shop drawings.
• Verify rotation of equipment/phase sequencing
according to manufacturer recommendation
• Verify phase protection relay installation and function.
Overcurrent and Earth Fault • Circuit breaker and Earth Fault Protection calibration
Protection and discrimination shall be conducted and
coordinated between electrical contactors.
• Circuit breaker and Earth Fault Protection shall be
tested against simulated leakage current.
• IDMT tripping delay shall be selected/programmed
suitable for equipment starting overloading preventing
nuisance tripping during starting.

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1.2.4.4 Room Condition Test

Space temperature and relative humidity shall be recorded either by temperature and
humidity data logger or spot measurements using sling psychrometer as per S.O instruction.
Time of measurement shall coincide with Air Cooled Split Unit test period.

Temperature and humidity data logger shall be used to measure temperature and humidity
at these locations;

• Location where occupants are known to spend most of their time.

• Furthest zone and high heat load area.

• Critical areas such as Medical Record, High Dependency Ward (HDW), Isolation
Room, Central Sterile Supply Department (CSSD), Laboratory, Medical store, Server
room as decided by S.O.

For all other areas, spot measurements using sling psychrometer shall be used during
anticipated peak and minimum cooling load period as per S.O instructions.

Building operation and weather conditions during testing such as outdoor air temperature
and humidity, internal load factors i.e. population, lighting and equipment data shall be
recorded. Room condition test report shall be submitted to S.O during testing.

1.2.4.5 Mechanical Ventilation Test

List of mechanical ventilation system inspection and test name are listed in Table 7.

Table 7: Air Distribution System Inspection and Test Name

Inspection/ Test name Objectives

Fan General Inspection Verify that equipment physical conditions are acceptable.

Fan Volumetric Air Flow Verify that air flow is as per design flow.
Test
Fan Control Test Verify that control system function as per design control
strategies.
Noise Level Test Verify noise level within permissible limit.

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a. Fan General inspection

Fan shall be visually inspected for any deviation from approved shop drawings, approved
material and identification of any physical defects that may arise during installation works.

b. Fan Volumetric Air Flow test

Air flow measurement in ducts shall be measured by either pitot tube traverse average
method or vane anemometer (depending on site conditions). All points for pitot tube insertion
shall be prepared and reseal adequately after measurement. For ductless fan, vane
anemometer shall be used.

c. Fan Control test

Fan control test shall be carried out as per Table 8:

Table 8: Fan Control Test List

Type of Fan Control Method

Temperature Control Adjust thermostat setting above and below controlled

parameter value and observe response in fan operation.
Temperature reading of the served space shall be
recorded via temperature data logger for 24 hrs fan
operation.

Schedule operation Adjust timer schedule and observe response in fan

operation.

d. Noise Level Test

Noise level measurement shall be carried out via Sound Level Meter Type 2 / Class 2
General Purpose Grade for field use ± 1.0 dB. All measurement points are at a height of
1.5m from the floor at every enclosed space/zone. Measurement shall be made when fan is
on and another one when in off condition (background noise level).

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1.3 COMMISSIONING

Commissioning includes achieving, verifying, and documenting that the performance of

facilities, systems, and assemblies meets defined objectives and criteria.

All completed test forms and test summary shall be submitted to S.O’s representative for
final review and approval. Having satisfied that all appropriate tests have been conducted
and the performance of the installation meet the design objectives; S.O’s representative will
issue or recommends to the S.O for the issuance of Certificate of Practical Completion
(CPC).

1.3.1 Handing Over Documents

After issuance of Certificate of Practical Completion, contractor shall submit all related
project handing over documents as the following;

a) Test Report complete with fully verified Inspection checklist and Test Forms.
b) Defects List
c) Operation and Maintenance Manual which includes
a. Standard/ Manual Operating Procedures
b. Preventive Maintenance Schedule and Manual
c. Equipment/Product Engineering Data.
d. Operation set point (temperature, relative humidity, pressure etc)
e. Contractor and manufacturer contact details
f. Inventory List
d) As-Built drawings
e) Schedule of System Familiarization Program to end users.

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1.3.2 System Familiarisation Program

In-class and practical System Familiarisation Program shall be conducted to the personnel
nominated by S.O within one (1) month of issuance of Certificate of Practical Completion.

Program shall focus on:

• Overview of design concept and objectives
• Operation instruction & competency requirement
• Maintenance procedures
• Critical operating parameters monitoring and
• Emergency response & safety procedures.
• Environmental protection procedures.

Contractor shall submit program modules and materials to S.O for approval prior to
commencement of training. Particulars of trainee shall be recorded and send to S.O for
records.

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2.0 POST OCCUPANCY EVALUATION

Post Occupancy Evaluation shall be performed by the contractor one (1) month before the
end of defect liability period.

Space temperature and relative humidity shall be measured at all respective temperature
zone. Temperature, relative humidity and air speed shall be within specification. Any
adjustment to the system are required if the data deviate from the specification.

A survey shall be carried out to evaluate user experiences with the air conditioning and
ventilation system from comfort, operation ability or any other related problems. Survey form
as in Table 9 shall be used. All survey form shall be submitted to S.O for references.

Table 9: Post Occupancy Evaluation Form

Block

Floor

Space

ACSU No

Room Conditions

Parameters Measured value Comment

o
Dry Bulb Temperature C

Relative Humidity %

User Survey

1) Any difficulty in operating the system? If Yes, please state the details.

2) Any specific problem system? If Yes, please state the details.

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3.0 TESTING INSTRUMENTS & ACCESSORIES

All permanent sensors and gauges use for measurement of temperature, pressure and flow
shall be factory calibrated and all calibration certificates shall be submitted to S.O prior to
testing works.

The contractor shall provide all necessary testing, calibrating instruments and labour
required for the testing, adjusting, balancing and commissioning of the air-conditioning and
mechanical ventilation system installed under the contract.

The contractor shall also allow for any necessary replacement of parts in order to achieve
the conditions specified in the drawings and specification. Provisional sum for that purpose is
provided in Schedule of Price.

Testing instruments specification shall be but not limited to as per Table 10:

Table 10: Testing Instruments

Measurement Type of Instruments Accuracy

Dry bulb and humidity Temperature and Relative Temperature measurement
(logging) Humidity data logger accuracy: ±0.5 °C
(0°C<T<30oC) and 1.5% of
reading at 30°C<T<70oC).
Humidity measurement
accuracy: ±2%RH (from 15°C
to 25°C)

Dry bulb and humidity Sling Psychrometer ± 0.5oC

(One off)

Ampere Clampmeter 2.0% ± 5 digits (45-65Hz)

(instantaneous)

Voltage Clampmeter 1.5% ± 5 digits

(instantaneous)

Noise (Full spectrum) Sound Level Meter Class 1 Class 1 as per IEC 61672-
1:2002

Noise (Average) Sound Level Meter Class 2 Class 1 as per IEC 61672-
1:2002

Vibration Vibration Analyser ± 5% of reading (from 0.01 g to

50 g); where “g” in meter per
second square.

Pressure/Charging Manifold Gauge Class 1.0 accuracy gauges

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