Inspection Procedure

27-SAIP-01 29 September, 2004

HVAC Inspection Requirements
Document Responsibility: Inspection Department

Saudi Aramco DeskTop Standards

Table of Contents

1 Scope............................................................. 2
2 Purpose.......................................................... 2
3 General.......................................................... 2
4 References..................................................... 2

Previous Issue: 31 December, 2000 Next Planned Update: 1 October, 2009

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Primary contact: Supervisor, IEU on 874-6604
Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

1 Scope

1.1 This SAIP covers instructions for the assigned Inspector on procedures and
items to check or verify for the installation of HVAC systems.

1.2 This SAIP covers the inspection of all aspects of HVAC systems including air-
side hydronic and electrical aspects of the systems.

1.3 This procedure shall be used in conjunction with the applicable manufacturer's
installation and maintenance instruction manual.

1.4 This SAIP is intended to establish a standardized methodology by Saudi Aramco

inspection personnel in the implementation of inspection programs within Saudi
Aramco facilities. The SAIP shall not be included in purchase order or contract
documents issued to outside agencies.

2 Purpose

2.1 The purpose of this SAIP is to highlight the main HVAC items requiring
inspection.

2.2 This procedure is to insure that the main inspection requirements are met and
that the findings and corrective actions are in standard format.

3 General

31. All inspection report forms shall be submitted to the responsible

maintenance/operations personnel or project representative. Copies shall be
retained in the Inspection Unit's field files.

3.2 The inspection report for any system shall consist of the following parts:

3.2.1 Equipment identification.

3.2.2 General requirements checklist.

3.2.3 Specific system/equipment.

3.2.4 Corrective action list.

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

4 References

The following Standards were used in the preparation of this procedure and should be
carefully reviewed by the Inspector prior to inspecting HVAC systems.

4.1 Saudi Aramco References

Saudi Aramco Engineering Standards

SAES-K-001 Heating Ventilating and Air Conditioning (HVAC)
SAES-K-002 Air Conditioning Systems for Essential Operating
Facilities
SAES-K-003 Air Conditioning Systems for Communication
Buildings.
SAES-K-100 Saudi Aramco Mechanical (HVAC)

Saudi Aramco Materials System Specifications

27-SAMSS-001 Packaged Water Cooled Centrifugal Chillers for
Utility Services
27-SAMSS-002 Direct Expansion Air Conditioning Systems for
Critical Services

4.2 Industry Codes and Standards

ASHRAE STD 1 Guideline for Commissioning HVAC Systems
ASHRAE Handbook 1991, Applications, Chapter 34, Testing Adjusting and
Balancing
NEBB Procedural Standards for Testing, Adjusting,
Balancing of Environmental Systems
NEBB Testing, Adjusting, Balancing Manual for
Technicians
SMACNA HVAC Duct Construction Standards - Metal and
Flexible
SMACNA HVAC Air Duct Leakage Test Manual
SMACNA HVAC Systems - Testing, Adjusting and Balancing
SMACNA Installation Standards for Residential Heating and
Air Conditioning Systems
SMACNA Rectangular Industrial Duct Construction
Standards

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

SMACNA Round Industrial Duct Construction Standards

Attached:

Inspection Reports/Checklists - for all HVAC systems ( 17 pages )

Equipment Identification
General Requirements
Handling Units
Fans
Filters
Ducts
Hydronic Coils
Electric Coils
Humidifiers
Pumps
Cooling Towers
Chillers
Hydronic Piping
Refrigerant Piping
Corrective Action List

Revision Summary
29 September, 2004 Revised the "Next Planned Update". Reaffirmed the contents of the document, and
reissued with editorial changes.

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

EQUIPMENT IDENTIFICATION:
1 EQUIPMENT TYPE :

2. LOCATION :

3. PLANT NO. :

4. TAG NO. :

5. MNFR. DRWG NO. :

6. MANUFACTURER :

7. MODEL :

8. SERIAL NO.:

GENERAL REQUIREMENTS:

CHECKLIST ITEM FINDINGS

1. All equipment installed in accordance with

Manufacturer's instructions and design documents.
2. All equipment are clean and all debris and foreign matter
are removed.
3. None of the equipment and components are damaged.

4. Adequate clearances are provided for service and

maintenance as required by Manufacturer and design
drawings.
5. All equipment are installed level.
6. Nameplate data of all equipment are in accordance with
the design documentation and certified Vendor
documents.
7. Special tools are provided where required.

8 Spare parts are provided in accordance with the design

and vendor documents, and spare parts are original and
the same as the parts they are to replace.
9. All safety systems and devices are in place and
functional.
10. Louvers are properly installed.
11. All air shafts and air plenums are finished without
noticeable air leakage.
12. Provisions are made for Testing, Adjusting and
Balancing (TAB) measurements.
13. All gauges and instruments are in place and functional.
14. Control systems are complete as per control systems
vendor documents.

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

15. Ensure pressure vessels associated with A/C Plants are

given individual engineering item numbers.

Air Handling Units

CHECKLIST ITEM FINDINGS

1. Unit interior and exterior is free of damage.

2. Field-assembled air handling unit housing does not

include any noticeable air leakage.
3. Vibration isolators (for motor-fan or entire air handling
unit, as applicable) are in place and functional.
4. Access doors and access-ways are properly sealed.

5. Duct flexible connections to air handling units and/or

fans are airtight, properly aligned and ducts are
supported independent of equipment.
6. Starters, disconnect switches and all other electrical
connection are in place, operational, and meet the
requirements of the Electrical Inspector.
7. Condensate drain pan is sloped properly and drain
piping is provided with trap.
8. Filters are in place and clean.

9. Lights inside AHU, where required, are the type

specified and are functional.

Fans

CHECKLIST ITEM FINDINGS

1. Fan rotation is correct.

2. Wheel clearance and balance checked.

3. Motor and fan bearings are properly lubricated.

4. Vee belts and drive are properly aligned.

5. Belt tension is correct and drive set screws are tight.

Belts have been checked after run-in period.
6. Belt guards, drive guards and protective screens are in
place where indicated.
7. Flexible connection to duct is provided and duct is
properly aligned.
8. Starters, disconnect switches and all other electrical
connections are in place, operational, and meet the
requirements of the Electrical Inspector.

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

Filters

CHECKLIST ITEM FINDINGS

1. Filter size and type conform to design and certified
Vendor documents.
2. Filters used for testing are removed and new / clean
filters are in place.
3. Filter frame leakage is within acceptable limits of design
and certified vendor documents.
4. Access for filter replacement is provided and
acceptable.
5. Orientation conforms with airflow direction.

6. Substitute media of chemical filters, used during

testing, is replaced with proper service media, as per
specification.
7. Chemical filter units are properly supported

Ducts

CHECKLIST ITEM FINDINGS

1 Air distribution duct sizes, sheet metal gauges and duct

configurations conform with design drawings.
2. Grilles, diffusers and registers (type and sizes) conform
with design.
3. Registers and diffusers are open.

4. Each fan has been started, prior to installation of grilles

and diffusers, and all debris is blown from duct work.
5. Ductwork is free from damage, supported properly and
tightly connected to equipment and air devices.
6. Ductwork is properly aligned with building structures.

7. Duct hanger spacing is verified.

8. Flexible connections are provided at each fan

inlet/outlet and are not in tension.
9. All fans and connecting ducts are properly aligned.
10. Balancing dampers are installed in each duct branch,
as required.
11. Flexible duct installations (type and length) conform
with NFPA-90A.
12. All dampers (manual and automatic) are operational
through the full range (0-100%).
13. Manual dampers are locked in position, as specified in
design and/or Vendor documents.
14. Chains or rods are provided for in-accessible and
adjustable diffusers, as required.

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

Ducts (Cont.)

CHECKLIST ITEM FINDINGS

15. Access doors are closed and tight.

16. Fire dampers are open and accessible through access

doors.
17. Fire dampers are installed in accordance with SMACNA
"Fire, Smoke and Radiation Damper Installation Guide".
18. Required listing label (UL) is attached to fire dampers.

19. Terminal units are open, set properly and supported

independently from ducts.
20. Turning vanes are installed and properly secured in
square elbows.
21. Ductwork sealed and leak-tested as required.

22 Air shafts and air transfer openings in walls and ceilings

are finished.
23. Air intakes or outlets, protruding from building structure,
are properly reinforced and/or supported to withstand
wind pressure.
24 Duct insulation conforms with design requirements.

Hydronic Coils

CHECKLIST ITEM FINDINGS

1 Following coil data are in accordance with the design

and certified Vendor documents: size, type,
construction, number of rows, fin spacing, and
orientation
2. Fins are not damaged and free of debris and
obstructions.
3. Piping connections are correct as indicated on the
design and certified Vendor documents
4. Piping is properly connected and supported to avoid
stresses on coil headers.
5. Piping valves are in proper position.

6. Sufficient access is provided for coil maintenance and

coil-bundle removal.

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

Electric Coils

CHECKLIST ITEM FINDINGS

1. Airflow direction across coil is correct.

2. The required safety interlock, cut-outs and switches are

in place and operational.
3. There are no obstructions to coil and air flow.

4. Coil is clean and free of debris.

5. Heating elements are the required distance from any

combustible material.
6. Duct connections are complete and leak tight.

7. Additional support for coil is provided where required.

8. Heater de-energizes when air handling unit is off.

9. All electrical connection are provided as required by

design documents and meet the requirements of the
Electrical Inspector.

Humidifiers

CHECKLIST ITEM FINDINGS

1 Humidifier capacity complies with design requirement.

2. Water supply and drain are properly piped, and unit is

properly wired.
3. Humidistat is installed and wired.

4. Flush cycle is functional

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

Pumps

CHECKLIST ITEM FINDINGS

1 Pump rotation is verified.

2 Motor, drive and pump alignment is verified.

3. Belt guards, drive guards and protective screens are in

place.
4. Drive set screws are tight.

5. All electrical connections and devices are complete and

operational.
6. All required lubrication is provided.

7 All piping connections are complete.

8 Strainers are installed at pump suction and baskets are

cleaned/replaced since testing.
9 All isolation valves, flanges and/or unions are installed
to permit pump removal from system.
10 Vibration isolators are installed.

11 In-line pump and motor assemblies are independently

supported, where required.
12. Flexible electrical connections are provided.

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

Cooling Towers

CHECKLIST ITEM FINDINGS

1. All piping connections are properly installed.

2. All valves in the system are operational through their

full range, and are properly positioned.
3. Type, size and number of spray nozzles are verified.

4. Fan and pump rotation are verified.

5. Motors/fans are properly lubricated.

6. Motor, drive and fan alignment is verified.

7. Vibration isolators are installed for fan/motor.

8. Belt and drive-guards are installed as required.

9. Tower basin is filled, cleaned, and water treatment

system is functional.
10. All electrical connections and devices are complete and
operational.
11. Anti-vibration switch is installed and functional.

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

Chillers

CHECKLIST ITEM FINDINGS

1 Chiller factory performance test is complete with report

submitted.
2 Chiller is set in place and is hydrostatically leak tested.

3. Chiller safety and protection devices are tested and

report is submitted.
4. Crankcase heaters are energized.

5. All valves in the system are operational through their

full range, and are properly positioned.
6. All piping connections are properly installed.

7. Oil level and lubrication is checked.

8. Motor, drive and fan alignment is verified.

9. All electrical connections and devices are complete and

operational.
10. Vibration isolators are installed for fan/motor.

11. Belt and drive-guards are installed as required.

12. Chemical treatment of chilled water system is

completed.

Hydronic Piping

CHECKLIST ITEM FINDINGS

1 Piping system is installed, as per design.

2. Piping system is pressure-tested and accepted.

3. All valves in the system are operational through their

full range, and are properly positioned.
4. All required air vents and pressure relief valves are
properly installed.
5. Piping system is flushed, filled with water and
chemicals.
6. Strainers are clean.
7. All air is purged from system and pumps were run to
eliminate air trapped in system.
8. All required piping insulation is securely installed.

9. Balancing, isolating and control valves are installed

where required and operational through their full range
(0-100%).

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Document Responsibility: Inspection Department 27-SAIP-01
Issue Date: 29 September, 2004
Next Planned Update: 1 October, 2009 HVAC Inspection Requirements

Refrigerant Piping

CHECKLIST ITEM FINDINGS

1. Piping is insulated, as required by SAES-K-001.

2. System is pressure tested, dehydrated, evacuated and

charged.
3. Sensing bulb of thermal expansion valve is tightly
secured to suction line at the location recommended by
Manufacturer.
4. Sight glass, filter-drier, solenoid and charging valves
are installed, as per Manufacturer's recommendation.

CORRECTIVE ACTION REQUIRED:

CHECKLIST ACTION REQUIRED

ITEM NO.

__________________ _____________________
INSPECTOR'S NAME DATE OF INSPECTION

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