INSTALLATION QUALIFICATION PROTOCOL FOR HVAC SYSTEM … IQ FOR HVAC SYSTE… · Equipment: HVAC SYSTEM FOR AHU-06 Page 10 of 30 INSTALLATION QUALIFICATION (IQ) SR.NO DESCRIPTION SPECIFICATIONS

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CUSTOMER:

M/s. NATCO PHARMA LIMITED.

K O T H U R

PROJECT: NEW PRODUCTION BLOCK

SUBMITTED BY:

PH AR M A EN G I N EER S

PLOT NO. 113/A/1 , LANE 8, PHASE II,

IDA CHERLAPALLI, HYDERABAD- 500040 .

Tel No.91-40 27261113 , 27261114

INSTALLATION QUALIFICATION PROTOCOL FOR

HVAC SYSTEM OF AHU-06

Page 2 of 30

INSTALLATION QUALIFICATION PROTOCOL APPROVAL

This document is prepared by the documentation team of M/S. PHARMA ENGINEERS

for

AHU TAG Number : ___________________________

PLANT /PROJECT : NEW PRODUCTION BLOCK

CLIENT : M/s. NATCO PHARMA LIMITED

Hence this document before being effective shall be approved by M/s. NATCO PHARMA

LIMITED

M/s. PHARMA ENGINEERS:

Name Designation Signature Date

Prepared By

Reviewed By

M/s.NATCO PHARMA LIMITED:

Name Designation Signature Date

Reviewed By

Approved By

Client: M/s. NATCO PHARMA LIMITED; KOTHUR

Supplier/ Manufacturer: PHARMA ENGINEERS, HYDERABAD

Equipment: HVAC SYSTEM FOR AHU-06

Page 3 of 30

INSTALLATION QUALIFICATION (IQ)

TABLE OF CONTENT

1. OBJECTIVE ............................................................................................................................... 4

2. RESPONSIBILITIES ............................................................................................................... 4

3. SCOPE OF SUPPLY OF COMPONENTS: .......................................................................... 5

4. VERIFICATION OF CALIBRATION OF INSTRUMENTS .......................................... 28

5. LIST OF DOCUMENTS ENCLOSED ................................................................................ 29




Page 4 of 30


1. OBJECTIVE

The objective of this document is to verify that the HVAC system (AHU TAG

NO) is installed with due considerations as specified in DQ of HVAC System

(TAG NO).

2. RESPONSIBILITIES

M/s. Pharma Engineers:

1. To install the system as per the specifications.

2. To provide the necessary test certificates as per technical specifications

specified in DQ.

3. To Complete the hvac system qualification.

4. To perform the duct leak test (for classified areas only) as per SMACNA

Standard 2012.




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3. SCOPE OF SUPPLY OF COMPONENTS: PURPOSE

This test is to verify that the AHU dimensions, position and sizes of utility

connections are in compliance with the design qualification and also with

as-built drawing.

PRE-REQUISITES

1. As built drawing

2. Measuring tape

3. Approved Design Qualification Document

TEST METHOD 1. Physically check the dimension of the AHU in length, width, and height

and confirm with design document.

2. Physically check and confirm the supply and return air duct sizes right

from the AHU up to terminal point for every room.

3. Physically check and confirm that the dampers are marked with air flow

direction and marking was mentioned for the quantity adjustment.

4. Physically check and confirm that required indications are mentioned on

the AHU like cable entry, safety indication, supply air, return air and

exhaust air location.

5. Physically check and confirm the condensate piping and slope being

maintained.

6. Physically check and confirm the location of fire/ smoke detectors and

confirm the good practice of installation.

7. Deviations or remarks may be documented along with summary of all test

results




Page 6 of 30


COMPONENT VERICATION:

AHU (SUPPLY UNIT) / AHU (RETURN UNIT) / EXHAUST UNIT / AHU CUM DEHUMIDIFIER

SR.NO DESCRIPTION SPECIFICATIONS AS PER DESIGN QUALIFICATION

CRITERIA FULFILLED (YES/NO)

1.

CONSTRUCTIONAL DETAILS:

AHU TAG Number

Unit Serial Number

Manufacturers name M/s. Flakt Woods (India) Pvt. Ltd.

Qty 01 No.

Model CCTU-030

Overall dimensions (L X W X H) (MM)

4864x1750x2055

Plenums Outer skin(MM) 0.8 mm PP GS sheet.

Plenums Inner skin(MM) 0.6 mm PP GS sheet.

M.O.C of Drain Tray SS 304

M.O.C of Frame work Aluminum Extruded Profile

M.O.C of Base of the unit 14G G.S Sheet Plain

2.

CENTRIFUGAL FAN:

Serial Number

Make KRUGER

Model BNB-P400

Air Flow 3000 CFM

Static Pressure 210 mm of WG

Type PLUG FAN / DIDW

Fan Pulley

V- Belt

R.P.M 3103 RPM

3.

MOTOR:

Serial Number

Make BB/CG/SIEMENS

K. W 5.5

Motor Pulley

No. of Poles 2 / 4

RPM 2900 RPM / 1440 RPM

Type Flame Proof / Non-Flame Proof




Page 7 of 30




4.

DEHUMIDIFIER BED CONSTRUCTIONAL DETAILS:

Manufacturers name AIRPAC FILTERS & SYSTEMS PVT. LTD.

Unit Serial Number

Air flow handling capacity of dehumidifier

2000 CFM

Revolution per Hour 20

5.

BED MOTOR

Serial Number

Make T.W.T.

Type Induction motor

Power 90W/440V

RPM 3

6.

REACTIVATION BLOWER

Type Backward

Blower Model RLO-315

Air Flow 667 CFM

7.

REACTIVATION MOTOR

Serial Number

Make Crompton Greaves

Type Tefc Sq cage Induction flange mounted

Rating 1.5 HP

RPM 2880

8.

FILTRATION SCHEME WITH IN AHU & ACD

FILTRATION IN ACD

REACTIVATION FILTER

Make Airpac Filter & Systems Pvt. Ltd.

Type of filter Flange type

Filter Media Synthetic

Compatibility of water wash Yes

Filter Test method EN 779

Filter classification as per EN 779

G-3

Average arrestance of synthetic dust

80 ≤ Am <90




Page 8 of 30




Equivalent particle size in terms of market language

20 micron-Un authenticated data

I.P.D of Filter (Approximate) 55 ± 10 Pa

F.P.D of Filter (Approximate) 250 Pa

Size of Filter / Rated Air flow 610 x 610 x 50 / 2000 CFM

Qty

Serial Number


Qty

Serial Number


Qty

NOTE: I.P.D & F.P.D values change based on AIRFLOW; hence customer should set the limits after commissioning.

9.

FILTRATION AHU

FIRST STAGE FILTRATION IN AHU

Make of Filter AAF






G-3


80 ≤ Am <90






Qty

Serial Number


Qty

Serial Number





Page 9 of 30




Qty

Serial Number


10.

FIRST STAGE FILTRATION IN AHU

Make of Filter AAF






G-4


90 ≤ Am






Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


11.

SECOND STAGE FILTRATION IN AHU

Make of Filter AAF








Page 10 of 30





M-5 / EU-5

Average efficiency at 0.4 micron 40 ≤ Em < 60






Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


12.


Make of Filter AAF






EU-6 / M-6







Qty

Serial Number


Qty




Page 11 of 30




Serial Number


Qty

Serial Number


13.


Make of Filter AAF






EU-7 / F-7




I.P.D of Filter for 150 mm thick (Approximate)

160 ± 10 Pa


120 ± 10 Pa



Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


Qty




Page 12 of 30




Serial Number


Qty

Serial Number


14.

THIRD STAGE FILTRATION IN AHU

Make of Filter AAF


Filter Media Micro Fiber Glass

Compatibility of water wash No



EU-9 / F-9

Average efficiency at 0.4 micron 95 ≤ Em




120 ± 10 Pa


180 ± 10 Pa


Size of Filter / Rated Air flow 610 x 610 x 150 / 1000 CFM @ 1.25 m/s

Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


Qty




Page 13 of 30




Serial Number


Qty

Serial Number


15.

TERMINAL STAGE FILTRATION IN AHU (PLENUM)

Make of Filter AAF






EU-13 / H-13

Average Efficiency at MPPS 99.95%


0.3 micron-Un authenticated data


350 ± 10 Pa


350 ± 10 Pa



Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


Qty




Page 14 of 30




Serial Number


Qty

Serial Number


16.

TERMINAL STAGE FILTRATION IN AHU (PLENUM)

Make of Filter AAF






EU-14 / H-14





350 ± 10 Pa


350 ± 10 Pa



Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


Qty

Serial Number


Qty




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Serial Number


Qty

Serial Number


17.

FRESH AIR FILTRATION IN AHU / PRECOOLING

Make of Filter

Type of filter

Filter Media

Compatibility of water wash

Filter Test method


Average efficiency at 0.4 micron


Size of Filter / Rated Air flow

Qty

Serial Number

18.

BLEED AIR FILTRATION IN AHU

Make of Filter

Type of filter

Filter Media

Compatibility of water wash

Filter Test method


Average efficiency at 0.4 micron


Size of Filter / Rated Air flow

Qty

Serial Number




Page 16 of 30




19.

COOLING, HEATING WITH IN AHU / ACD

COOLING COIL IN TFA


Quantity 1 No.

Fluid Chilled water

Coil size (fin ht. x fin Length) 635 x 860 mm

No. of Rows 6

Tube MOC Copper

Tube Diameter 1/2”

Fins MOC Aluminum

20.

COOLING COIL IN AHU


Quantity 1 No.

Fluid Chilled water


No. of Rows 6

Tube MOC Copper


Fins MOC Aluminum

21.

HEATING COIL IN AHU


Quantity 1 No.

Fluid Hot water


No. of Rows 2

Tube MOC Copper


Fins MOC Aluminum

22.

STEAM COIL IN ACD


Quantity 1 No.

Fluid Steam


No. of Rows 6

Tube MOC Copper





Page 17 of 30




Fins MOC Aluminum

23.

DETAILS OF VOLUME CONTROL DAMPERS FOR AHU:

Make M/s. Flakt Woods (India) Pvt. Ltd.

MOC Aluminum extruded aero foil design

Supply Air 325x550 mm–1 No.

Return Air 325x550 mm–1 No..

Fresh Air 300x600 mm– 1 No.

Bleed Air 300x300 mm– 1 No.

24.

DETAILS OF FUSIBLE LINK FIRE DAMPERS FOR AHU:

Make M/S. System Air India Pvt. Ltd.

Type Multi-blade low leakage with opposed blade

Blades & Casing 1.6mm thick GSS / 1.6 mm thick GI sheet

Fire Rating @ IP555 120min Fire Rating

Melting point of fusible link 74 deg. C

Limit switch Mounted on frame of damper

Supply Duct 550x325 mm

Return Duct 550x325 mm

Exhaust Duct 550x325 mm

25.

DETAILS OF MOTORIZED FIRE DAMPERS FOR AHU:

Make M/S. System air india pvt. Ltd.

MOC GI

Thickness 16G

Rating @ IP 555 120min Fire Rated

Supply Duct 550x325 mm

Return Duct 550x325 mm

Exhaust Duct 550x325 mm

26.

ACTUATOR FOR FIRE DAMPER:

Make M/S. Belimo

Model NFA-S2

Location Return Air Duct, Supply Duct




Page 18 of 30




27.

PIPPING & MANIFOLD DETAILS

CHILLED WATER MANIFOLD:

Pipe Size 32 mm

Pipe Material MS

28.

PIPE INSULATION

Make kflex

Material Elastomeric Nitrile rubber

Fire performance Class ‘O’ (FM APPROVED)

Thickness 25 mm

Temperature range (maximum& minimum)

105°C & -40°C

Thermal conductivity at 20°C 0.036 w/m degK

29.

3Way Valve with Actuator Make Honeywell

Valve Model Number V5013P1010

Actuator model number ML74208088-E

Size 25 mm

Qty 1no.

30.

Ball Valves Make L&T

Size 32 mm

Qty 6 Nos.

31.

Balancing Valves Make Advance

Size 32 mm

Qty 1No.

32.

Strainer Make Creative/zoloto

Size 32 mm

Qty 1No.

33.

Drain Valve

Make Zoloto/L&T

Size 20 mm

Qty 1No.




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34.

Air Vent Valve Make Anergy

Size 15 mm

35.

Test port

Make Anergy

Size 8mm

36.

HOT WATER MANIFOLD:

Pipe Size 25 mm

Pipe Material MS

37.

PIPE INSULATION

Make kflex

Material Elastomeric Nitrile rubber

Fire performance Class ‘O’ (FM APPROVED)

Thickness 25 mm

Temperature range (maximum& minimum)

105°C & -40°C

Thermal conductivity at 20°C 0.036 w/m degK

38.

2 WAY VALVE WITH ACTUATOR

Make Honeywell

Model Number V5011P1004

Actuator model number ML74208088-E

Size 25 mm

Qty 1no.

39.

Ball Valves Make L&T

Size 25 mm

Qty 5 Nos.

40.

Balancing Valves Make Advance

Size 25 mm

Qty 1No.

41.

Strainer Make Creative /Zoloto

Size 25 mm

Qty 1No.




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42.

Drain Valve Make Zoloto/L&T

Size 20 mm

Qty 1No.

43.

Air Vent Valve Make Anergy

Size 15 mm

44.

Test port Make Anergy

Size 8mm

45.

PRE-COOLIG COIL MANIFOLD

Manufacturers name M/s. Hyderabad Coils

Serving to AHU- FRESH AIR

No. of Rows 4

Coil size (fin Width. X fin height)

24” X 24”

Fins/ Inch 12 FPI

Fins MOC Aluminum

Size of manifold 40 NB

Pipe Material of manifold MS

Make of Ball Valves L&T

Qty 2 Nos

Make of Strainer Marck

Size 40 mm

Qty

Make of Balancing Valve Advance

Size 40 mm

Qty

46.

POST HEATING COIL MANIFOLD

Manufacturers name M/s. Hyderabad Coils

Serving to AHU- FRESH AIR

No. of Rows 2

Coil size (fin Width. X fin height)

24” X 24”




Page 21 of 30




Fins/ Inch 12 FPI

Fins MOC Aluminum

Size of manifold 40 NB

Pipe Material of manifold MS

Make of Ball Valves L&T

Qty 2 Nos

Make of Strainer Marck

Size 40 mm

Qty

Make of Balancing Valve Advance

Size 40 mm

Qty

47.

HEATERS

Make

Type

Capacity

48.

THYRISTOR HEATING MODULE

Make M/s Pharma Engineers

Unit Serial Number

Qty 01 No’s

Type Double Skin Thermal Break Type

Model TH-45

Location At service floor

Overall dimensions (L X W X H) (MM)

Capacity 45 KW

Plenums Outer skin(MM) 0.8 mm PP GS sheet.

Plenums Inner skin(MM) 0.6 mm PP GS sheet.

Panel thickness(MM) 43±0.5 mm

49.

HVAC ELECTRICAL PANEL (CENTRALIZED)

Make M/s. PHARMA ENGINEERS

Type Compartmental

Location

Cable Entry Top




Page 22 of 30




50.

HVAC ELECTRICAL PANEL (STAND ALONE)

Make M/s. PHARMA ENGINEERS

Type

Location

Cable Entry Top

51.

VARIABLE FREQUENCY DRIVE

Make Danfoss

Serial Number

Model VLT HVAC basic Drive FC101

VFD Capacity (KW) for supply unit

3.7 K. W

VFD Capacity (KW) for return unit

3.7 K. W

52.

INSTRUMENTATION DETAILS

MAGNEHELIC GAUGES

Make Dwyer, U.S.A.

Location AHU prefilter

Range 0-25mm

Qty 1 No’s

Serial Number

Location AHU fine filter

Range 0-50mm

Qty 1 No’s

Serial Number

Location AHU plenum HEPA Filter

Range 0-50mm

Qty 1 No’s

Serial Number

Location Rooms




Page 23 of 30




Range 0-60 Pa

Qty 5 No’s

Serial Number

53.

SENSOR DETAILS

TEMPERATURE & RH SENSOR

Make

Model

Location

Qty

Serial Number

54.

DPT SENSOR

Make

Model

Location

Qty

Serial Number

55.

VELOCITY SENSOR

Make

Model

Location

Qty

Serial number

56.

DUCTING: Material Galvanized steel sheet

Manufacturer JINDAL / TATA/SAIL/UTTAM/ESSAR

Fabrication standard/Year IS 655/2012

Duct leak test standard (only for Classified AHU’s)

SMACNA 2012

Duct seal class C

Duct leak testing pressure 2” W.G




Page 24 of 30




Thickness of Galvanized sheet

Up to 750 mm - 24 G

751 to 1520 mm - 22 G

1521 to 2285 mm - 20 G

Type of Gasket Rubber based gasket

Supporting Rods 8 mm G.I threaded rod

Duct joint MS angle frames for Classified AHU TDF for unclassified AHU

Bonding/sealant Silicone based sealant

57.

INSULATION: Make THERMOBREAK

Type Cross linked polyolefin foam

Thermal Conductivity ‘K’ valve, 0.032 W/mK @ 23° C

Density Kg / m3 25

Temperature range -80 Deg.C to +100 Deg.C

Finishing material Aluminum foil

Fire performance Class “0”

Thickness 19mm For Supply & 13 mm For Return Ducts

58.

SUPPLY AIR TERMINAL MODULE Make

Module MOC

Grill MOC

Thickness of sheet

Damper

59.

TERMINAL HEPA FILTERS IN ROOM Make of Filter AAF






EU-14 / H-14







Page 25 of 30






Room Name

Hood Size

HEPA Filter Size / CFM

Qty

Serial Number

60.

SUPPLY AIR TERMINAL ANTI SMUDGE FOUR WAY DIFFUSERS

Make

Diffuser MOC

Damper MOC

Room Name

Diffuser Size

Qty

61.

SUPPLY AIR TERMINAL GRILLES

Make

Grill MOC

Damper MOC

Room Name

Grill Size

Qty

62.

SUPPLY AIR TERMINAL MODULE

Make Module MOC Grill MOC Thickness of sheet Damper Room Name Hood Size Qty




Page 26 of 30




63.

RETURN AIR TERMINAL ANTI SMUDGE FOUR WAY DIFFUSERS

Make

Diffuser MOC

Damper MOC

Room Name

Diffuser Size

Qty

64.

RETURN AIR TERMINAL GRILLES

Make

Grill MOC

Damper MOC

Room Name

Grill Size

Qty

65.

RETURN AIR RAISERS

Make

Riser MOC

Damper Make

Damper MOC

Riser Grill MOC Riser Filter Make Type of filter Filter Media

Compatibility of water wash Filter Test method Filter classification as per EN 779

Average efficiency at 0.4 micron Equivalent particle size in terms of market language

Room Name Riser Size




Page 27 of 30




Filter Size / CFM Qty Serial Number

ACCEPTANCE CRITERIA Dimensions and supply connections of the system should comply with DQ document and as built drawings. However, the acceptance is up to the judgment of experts if any deviations in the readings REMARKS (IF ANY): Test Conducted By Test Witnessed By




Page 28 of 30


4. VERIFICATION OF CALIBRATION OF INSTRUMENTS

S.no. Instrument Type Location Instrument Tag Number

Calibrated on Calibration

Due

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

REMARKS (IF ANY):

Submitted By Checked By




Page 29 of 30


5. LIST OF DOCUMENTS ENCLOSED

S.No Drawing Name Enclosed (Yes / No)

1. Testing Certificate For Ahu

2. Testing Certificate For Blower

3. Testing Certificate For Motor

4. Testing Certificate For Dehumidifier Bed

5. Testing Certificate For Dehumidifier Bed Blower / Motor

6. Testing Certificate For Reactivation Blower / Motor

7. Testing Certificates For Ahu Filters

8. Testing Certificate For Chilled Water Coil

9. Testing Certificate For Hot Water Coil

10. Testing Certificate For Steam Coil

11. Testing Certificate For Volume Control Damper

12. Testing Cerrticate For Fire Damper

13. Testing Cetificate For Actuator For Fire Damper

14. Testing Certificate for Chilled Water Manifold and All Related Fitting And Accessories

15. Testing Certificate for Hot Water Manifold and All Related Fitting And Accessories

16. Testing Certificate For Steam Manifold And All Related Fitting And Accessories

17. Testing Certificates For Pipe Insulation

18. Testing Certificates For Actuators For Control Valves

19. Testing Certificate For Thyristor Module

20. Testing Certificates For Control Panel

21. Testing Certificate For Variable Frequency Drive

22. Calibration Certificate For Magnehelic Gauge

23. Calibration Certificate For T&RH Sensor

24. Calibration Certificate For DPT Sensor

25. Calibration Certificate For Velocity Sensor

26. Testing Certificate For Ducting

27. Testing Certificate For Duct Insulation




Page 30 of 30


28. Testing Certificate For Terminal Module

29. Testing Certificate For Terminal Filters

30. Testing Certificates For Diffusers

31. Testing Certificates For Grilles

32. Testing Certificates For Risers

33. Testing Certificate For Riser Filter

34. Duct Leak Test Report

REMARKS (IF ANY):

Submitted By Checked By

Documents

INSTALLATION QUALIFICATION PROTOCOL FOR HVAC SYSTEM … IQ FOR HVAC SYSTE… · Equipment: HVAC SYSTEM FOR AHU-06 Page 10 of 30 INSTALLATION QUALIFICATION (IQ) SR.NO DESCRIPTION SPECIFICATIONS