EIAST

Clean Room
Facility
METHOD STATEMENT
for
DUCT LEAK TESTING

AJB Hightech LTD

9/10/2015
 Rev. 0

CLEAN ROOM FACILITY, EIAST Date 10 Sept. 2015

METHOD STATEMENT FOR DUCT LEAK TESTING

TABLE OF CONTENTS

SECTION - 1 : GENERAL OUTLINE

1.1 PURPOSE
1.2 SCOPE
1.3 REFERENCES
1.4 DEFINITIONS

SECTION - 2 : CRITERIA
2.1 TEST STANDARD
2.2 TEST RIG MAXIMUM CAPACITY
2.3 TEST PRESSURE MINIMUM REQUIREMENT

SECTION - 3 : TESTING PROCEDURE

3.1 PREPARATION OF TEST RIG FOR AIR DUCT LEAK TESTING
3.2 PERFORMING DUCT LEAKAGE TEST

SECTION 4 : ATTACHMENTS
4.1 TEST FORM
4.2 CALIBRATION CERTIFICATES
4.3 EQUIPMENT / INSTRUMENTATION
4.4 PREPARATION OF TEST RIG FOR AIR DUCT LEAK TESTING
4.5 PERFORMING DUCT LEAKAGE TEST
 Rev. 0

CLEAN ROOM FACILITY, EIAST Date 10 Sept. 2015

METHOD STATEMENT FOR DUCT LEAK TESTING

SECTION - 1 : GENERAL OUTLINE

M/s. AJB is employed as the agent for carrying out Duct Leak Testing at EIAST
Clean Room Facility.

1.1 PURPOSE

To define the methods of Duct Leak Testing.

1.2 SCOPE

The method statement covers the field testing of the relevant duct system to verify
conformance with the acceptable duct leakage to ensure that seams and joints in the
ductwork do not allow excessive quantities of processed air to escape.

1.3 REFERENCES

A. HVAC drawings.
B. DW143 (Practical Guide to Duct work Leakage Testing).

1.4 DEFINITIONS

A. AJB AJB Hightech Ltd, the Test and Balance Agency

B. DALT Duct Air Leakage Test
C. HVAC Heating Ventilation and Air-conditioning
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CLEAN ROOM FACILITY, EIAST Date 10 Sept. 2015

METHOD STATEMENT FOR DUCT LEAK TESTING

SECTION- 2 : CRITERIA

Test work shall be carried out in sections as the installation proceeds, prior to the
installation of wall panels, false ceiling, coverings and prior to connection of the
equipment.

2.1 TEST STANDARD

DW143 Standard : A Practical Guide to Ductwork Leakage Testing, is to be used

as reference throughout the testing. Whereas, the maximum permitted leakage should
be obtained from the formulae of the table below.

Static Pressure
Duct Limit Maximum Air leakage
Pressure Positive Negative Air Velocity limits
2
Class Pa Pa m/s l/s/m
0.65
Low-pressure 500 500 10 0.027*pt
Class A
0.65
Medium- 1000 750 20 0.009*pt
pressure
Class B
0.65
High pressure 2000 750 40 0.003*pt
Class C

2.2 TEST RIG MAXIMUM CAPACITY

Maximum area of ductwork which can be tested at a time is determined by the

allowable leakage rate for that section. This must not exceed 200 litres per
second (424cfm) for the Panda Series PAN300 Duct Leakage Tester. (Older models of
other duct leakage testers maximum capacity is up to 33 litres per second
(70cfm)).

2.3 TEST PRESSURE MINIMUM REQUIREMENT

The system shall be tested at least 1.25 times its operating pressure.
 Rev. 0

CLEAN ROOM FACILITY, EIAST Date 10 Sept. 2015

METHOD STATEMENT FOR DUCT LEAK TESTING

SECTION- 3 : TESTING PROCEDURE

3.1 PREPARATION OF TEST RIG FOR AIR DUCT LEAK TESTING

Please refer to Attachment 4.4

3.2 PERFORMING A DUCT LEAKAGE TEST

Please refer to Attachment 4.5

SECTION 4 : ATTACHMENTS

4.1 TEST FORM

4.2 CALIBRATION CERTIFICATES
4.3 TEST EQUIPMENT / INSTRUMENTATION
4.4 PREPARATION OF TEST RIG FOR AIR DUCT LEAK TESTING
4.5 PERFORMING A DUCT LEAKAGE TEST
 Rev. 0

CLEAN ROOM FACILITY, EIAST Date 10 Sept. 2015

METHOD STATEMENT FOR DUCT LEAK TESTING

4.1 TEST FORM

 DUCT LEAKAGE TEST SHEET
TEST SPECS: DW143
PROJECT :
AREA :
LEVEL :
TEST REF. :

PHYSICAL DETAILS
A. Section of ductwork to be tested SRAC-TYP-02-03A (SUPPLY DUCT Section 2)
B. Drawing Number APRT-MEP-CSD-05
C. Pressure Classification ( CLASS: A, B, or C) A
D. Test Static Pressure ( Pt ) ( Pa ) 250
E. Air Leakage Limit (F = CL * Pt 0.65 ) ( LPS / m2 ) 0.977
2)
F. Surface Area of Duct Under Test (m 8.7
G. Maximum Permitted Leakage ( E * F) ( LPS ) 8.50

SURFACE AREA COMPUTATION

WIDTH AND DEPTH OR DIAMETER (mm) PERIPHERY (m) LENGTH (m) AREA (m)
400 x 250 1.3 4 5.2
300 x 200 1 3.5 3.5
x 0 0
x 0 0
x 0 0
x 0 0
x 0 0
TOTAL: 8.7

TEST RESULTS
H Duct Static Pressure Reading ( Pa ) 251
I Type of Flow Measuring Device FLOW GRID
J Range of Measurement of Flow Measuring Device 21.18 to 423.72
K Interpreted Leakage factor (F = CL * Pt 0.65 ) ( LPS / m2 ) 0.81
L Interpreted Air Flow Leakages Rate ( LPS ) 7.09
M Duration of Test ( normally 15 mins) 10
O Test Result PASSED
P Date and Time inspected 29-Aug-15

REMARKS:

Carried out by : OLIVER O. / VAL M. Signed: Date: 30-Aug

AJB HIGHTECH
Witnessed by : Signed: Date:
QA / QC ENGINEER
Witnessed by : Signed: Date:
CONSULTANT
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CLEAN ROOM FACILITY, EIAST Date 10 Sept. 2015

METHOD STATEMENT FOR DUCT LEAK TESTING

4.2 CALIBRATION
CERTIFICATES
 Rev. 0

CLEAN ROOM FACILITY, EIAST Date 10 Sept. 2015

METHOD STATEMENT FOR DUCT LEAK TESTING

4.3 EQUIPMENT /
INSTRUMENTATION
ENERGY AND

Duct Leakage Testers

Positive and Negative Duct

Accreditation (PANDA) System
AIRFLOW Instruments Model PAN300 Series
The PANDA system consists of the following:

Qty Description Part Number Reference Picture

1 Low flow nozzle 6002598

1 Primary duct adapter 6002638

spigot plus rubber bung
(to fit to test duct)

1 Cam lock primary spigot 6002607

(to connect flexi-duct to
PANDA)

2 4-in. (100-mm) 6002683

adjustable over lock
straps

1 13-ft (4-m) long 6002667

4-in. (100-mm) plastic
flexible duct

2 20-in. (500-mm) silicone AFL9020004

tubes (red)

1
Qty Description Part Number Reference Picture
2 20-in. (500-mm) silicone AFL9020005
tubes (blue)

1 16-ft (5-m) silicone tube AFL9020005

(blue)

1 Smoke cap holder AFL71549801

assembly

1 Smoke pellets AFL9004167

1 K-type thermocouple AFL82859201

probe
3 Instrument adapter AFL82859401

1 Operation and Users 6005447

manual
The following two instruments should be used in conjunction with the
PANDA unit:

TA465-P Multi- Refer to TA465 Operation and

function Instrument Service Manual supplied with the
instrument for additional parts
supplied as standard.

PVM620 Refer to PVM620 Operation and

Micromanometer Service Manual supplied with the
instrument for additional parts
supplied as standard.
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CLEAN ROOM FACILITY, EIAST Date 10 Sept. 2015

METHOD STATEMENT FOR DUCT LEAK TESTING

4.4 PREPARATION OF TEST

RIG FOR AIR DUCT LEAK
TESTING
Preparing PAN300 System for Air Duct Leak
Testing
The following procedure should be followed carefully so that safe and
accurate leakage testing can be achieved:

Successfully completing a duct leakage test requires certain

information be compiled prior to starting the test. The list
below indicates the information required:

Type of leakage test to be performed (Positive or

negative).
Leakage standard to be followed.
Air tightness/leakage class to be achieved
Amount of ductwork to be tested, such as the complete
system or a statistical sample.

1. Select the section of the ductwork to be tested.

2. Calculate the surface area of the ductwork of the section to
be tested.
3. Temporarily seal the all openings of the ductwork except one,
which will be connected to the PAN300 duct leakage tester.
4. Position the PAN300 unit as close to the remaining opening in the
ductwork as possible to minimize the flexible tubing needed.
Minimize bends in the flexible tubing to reduce the pressure loss,
giving the best performance.
5. Make sure the Fan Control Switch on the Fan Speed Controller is
in the OFF position and the multi-turn Fan Speed Control
potentiometer is fully turned counter-clockwise using the pictures
of the VFD in Figure 1 as a reference. Plug the cord into the
PANDA unit as shown in Figure 2 and Figure 3. Then connect
the other end of the cord to a suitable electrical supply.
CAUTION: Remove the power cord from the PANDA duct
leakage tester before tilting it to the vertical
position to avoid damaging the cord.

Fan Speed
Control

Fan Control
Switch

On/Off
Switch

110 V 230 V
Figure 1. 110V and 230V Fan Speed Controllers

Note: The control pad on the Fan Speed Controller has been
disabled.

Figure 2. Receptacle for Figure 3. Connected Power Cord

Power Cord
6. Fit the primary duct adapter
spigot (black sheet metal with
rubber bung) to one end of the
4-in. (100-mm) diameter flexi-
tube. Make an air-tight seal
using one of the over lock
straps and lever-locking cam
provided as shown in Figure 4.
Adjust the fit of the over lock
strap with a screwdriver.
7. Securely attach the black
primary duct adapter
spigot/flexi-tube assembly to Figure 4. Flex Ductwork
the opening on the ductwork to Connected to Primary Adapter
be pressure tested. Spigot. Bung not shown.

8. If the static pressure tap on the

black Primary Duct Adapter is
open to the duct, connect the
16-ft (5-m) long blue silicone
tube to it as shown in Figure 5.

If the static pressure tap on the

black Primary Duct Adapter is
not open to the duct, drill a
4-mm hole in the duct and
insert about 6 inches (10 mm)
of the silicone tube into the
Figure 5. Connecting Pressure
duct. Seal around the hole with Tubing to Tap on Primary Duct
putty. Adapter. Bung not shown.
9. Connect the other end of the
4-in. (100-mm) flexi-tube to
the cam lock connector (grey cast aluminum without nozzle).
Make an airtight seal using the other over lock strap and lever-
locking cam provided. Adjust the fit of the over lock strap with a
screwdriver.
10. Determine if you are going to perform a high- or low-flow testing
and positive or negative testing. Set-up the duct leakage tester by:
a. For positive pressure,
high-flow testing,
remove the low flow
nozzle if it is installed.
Then, connect the grey
cast-aluminum cam
lock connector to the
outlet side of the
blower per Figure 6.
Close both cam lock Fan Cam Lock
arms at the same time Outlet Connector
to ensure proper fit.
Figure 6. Positive Pressure,
Connect the free end of High-Flow Set-Up
the 16-ft (5-m) silicone
tube to the pressure tap marked DUCT PRESSURE P3 (+) on
the black square box.

Finally, verify that the FLOW GRID MODE pressure taps on

the inlet tubes are connected to the FLOW GRID pressure
taps, i.e., P1 (+) to P1 (+) and P2 (-) to P2 (-).
b. For positive pressure,
low-flow testing, add Low Flow
Fan Inlet
Nozzle
the low-flow nozzle to
the blower inlet if it is
not installed per
Figure 7. Then, connect
the grey cast-aluminum
cam lock connector to
the outlet side of the
blower per Figure 6.
Close both cam lock
arms at the same time Figure 7. Positive Pressure,
to ensure proper fit. Low-Flow Set-Up

Connect the free end of the 16-ft (5-m) silicone tube to the
pressure tap marked DUCT PRESSURE P3 (+) on the black
square box.
c. For negative pressure,
high-flow testing,
remove the low flow
nozzle if it is installed.
Then, connect the grey
cast aluminum cam
lock connector to the
inlet side of the blower
per Figure 8. Close Fan Cam Lock
both cam lock arms at Inlet Connector
the same time to ensure
proper fit. Figure 8. Negative Pressure,
High-Flow Set-Up
Connect the free end of
the 16-ft (5-m) silicone tube to pressure tap marked DUCT
PRESSURE P4 (-) on the black square box.

Finally, verify that the FLOW GRID MODE pressure taps on

the inlet tubes are connected to the FLOW GRID pressure
taps, i.e., P1 (+) to P1 (+) and P2 (-) to P2 (-).
d. For negative pressure, Low Flow
low-flow testing, add Nozzle
the low-flow nozzle to
the blower inlet if it is
not installed. Then,
connect the grey cast
aluminum cam lock
connector to the low-
flow nozzle per Figure
9. Close both cam lock Fan Cam Lock
arms at the same time Inlet Connector
to ensure proper fit.
Figure 9. Negative Pressure,
Low-Flow Set-Up
Connect the free end of
the 16-ft (5-m) silicone
tube to pressure tap marked DUCT PRESSURE P4 (-) on the
black square box.
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CLEAN ROOM FACILITY, EIAST Date 10 Sept. 2015

METHOD STATEMENT FOR DUCT LEAK TESTING

4.5 PERFORMING DUCT

LEAKAGE TEST
Performing a Duct Leakage Test

The PAN300 duct leakage test system includes a Model PVM620

Micromanometer and a Model TA465-P Ventilation Meter. During
duct leakage testing, the Model PVM620 Micromanometer measures
the duct static pressure while the Model TA465-P Ventilation Meter
measures the airflow rate.

Refer to the Operation and Service Manuals for the Model PVM620
Micromanometer and the Model TA465-P Ventilation Meter to use
these instruments in other applications. If you do not have the
manuals, download them from TSIs website www.tsi.com.

Measuring Duct Static Pressure

1. Turn ON the Model PVM620.
2. Zero the Model PVM620 pressure sensor with both ports open to
the atmosphere.
3. Connect the (+) port on the Model PVM620 to P3 (+) to measure
the duct static pressure (see Figure 6).
4. Leave the (-) port on the Model PVM620 open to the atmosphere.
Note: Refer to the Model PVM620 Operation and Service Manual
for instructions on using data logging to automatically record
the duct static pressure.
Measuring Duct Leakage Flow
1. Turn ON Model TA465-P.
2. Zero the Model TA465-P
pressure sensor with both
ports open to the atmosphere.
3. Connect the Model TA465-P
to the PAN300 by connecting
the (+) and (-) ports on the
Model TA465-P to the P1 (+)
and P2 (+) ports located
inside the black box of the
PAN300as shown in Figure 10. Connecting Instruments
Figure 10. to PANDA Tester in
High Flow Mode

4. Connect the thermocouple to

the Model TA465-P.
5. Insert the thermocouple
probe into the blower inlet
through the hole marked TC1
as shown in Figure 11.
Thermocouple
Hole Figure 11. Thermocouple
Insertion Hole

Turning on the PAN300 Duct Leakage Tester

1. Switch the PANDA unit on.
a. For 230V models position the Mains Power switch of the
inverter to the ON position to power the Inverter speed
controller. The Fan motor is not energized.
b. 110V models do not include a separate power switch. The
PANDA unit is turned on when the power cord is plugged in.
2. Position the Fan Control switch to the RUN position to energize
the fan.
3. Increase the fan to the desired speed by turning the Fan Speed
Controller clockwise. To decrease the fan speed, turn the Fan
Speed controller counter-clockwise.
Using Leakage Test Application in the Model TA465-P
CAUTION: The Model PVM620 and Model TA465-P meters
must be zeroed before entering the Leakage
Test Application.

1. Press the MENU key to access MENU

the menu system on the Zero Press
Model TA465-P. Display Setup
2. Use the keys to highlight Settings
the Applications item. Flow Setup
Actual/Std Setup
3. Press the (ENTER) key to
Data Logging
access the Applications menu.
Zero CO
Applications
Calibration
Discover Printer

4. Select Leakage Test and press APPLICATIONS

key. Draft Rate
Heatflow
Turbulence
% Outside Air
Leakage Test

5. Select either the EN Standard LEAKAGE TEST

or SMACNA leakage test. EN Standard
SMACNA
Instrument Operation if EN Standard Test Protocol is Selected
1. Enter key parameters: LEAKAGE TEST
a. Surface Area of ductwork Surface Area
section to be tested. Static Pressure
Flow Device
b. Static Pressure of test, as
Tightness Class
measured by Model
Test Length
PVM620 micromanometer.
Run Test
c. Flow Device as Nozzle or
Flow Grid.
d. Leakage class as A, B, C, or D. Note that tests with negative
pressures must be selected as negative tests, as indicated by -.
e. Test Length, or duration of leakage test, usually 5 minutes.
2. Increase the blower speed until LEAKAGE TEST
the desired static pressure is
Leakage Factor x.xx
achieved.
Leak Limit x.xx
3. When the static pressure has Leak Rate x.xx
stabilized, select Run Test and Status OK
press . Flow Device Flow Grid
4. The display will show the Baro Pressure 20.20
readings on the right. Leakage Temperature 20C
Factor and Leak Rate will Time 9:55
update in real time, while other Standard TestXXX
parameters will remain constant. Sample
0
If the Leakage Factor and Leak (Sample Saved 1)
Rate are sufficiently stable,
press the START soft key or the key to begin the leak test.
Pressing the ESC key will exit back to the previous screen.
5. After the leak test is complete, the Model TA465-P will prompt
you to press the SAVE or PRINT soft key. You can also press the
ESC key here to back out to the previous screen without saving
the data.

After completing leakage testing for a section of duct, you can move
on to the next section.
Instrument Operation if SMACNA Test Protocol is Selected
1. Enter key parameters: LEAKAGE TEST
a. Surface Area of ductwork Surface Area
section to be tested. Static Pressure
Flow Device
b. Static Pressure of test, as
Leakage Class
measured by Model
Test Length
PVM620 micromanometer.
Run Test
c. Flow Device as Nozzle or
Flow Grid.
d. Leakage class as a number LEAKAGE TEST
from 1 to 48. Typical values Leakage Factor x.xx
are 3, 6, 12, 24, or 48. Leak Limit x.xx
Leak Rate x.xx
e. Test Length, or duration of Status OK
leakage test. Flow Device Flow Grid
2. Increase the blower speed Baro Pressure 20.20
until the desired static pressure Temperature 20C
is achieved. Time 9:55
Standard TestXXX
3. When the static pressure has
Sample
stabilized, select Run Test and
press . 0
(Sample Saved 1)
4. The display will show the Stop(Save) Print
readings on the right. Leakage
Factor and Leak Rate will update in real time, while other
parameters will remain constant.

If the Leak Factor and Leak Rate are sufficiently stable, press the
START soft key or the key to begin the leak test. Pressing the
ESC key will exit back to the previous screen.
5. After the leak test is complete, the Model TA465-P will prompt
you to press the SAVE or PRINT soft key. You can also press the
ESC key here to back out to the previous screen without saving
the data.

After completing leakage testing for a section of duct, you can move
on to the next section.