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Duct Leak Test

Objective: To ensure that there is absolutely no leakages from the Air-conditioning Ducts. Pre Requisite: Ensure that all Duct Joint Flanges are provided with Proper Gaskets and Galvanized Nutbolts with plain and spring washers. Visually inspect the ducts externally and internally. No damage of ducts or dents should be visible. If any duct is found damaged, the same shall be replaced with a new duct before carrying out the leak test of ducts.

Procedure: Clean all ducts (from inside) of debris, dust etc. Select a length of duct work to be tested and calculate the area of duct Blank off and seal all joints properly in the selected length of duct. Inspect carefully to ensure that no opening has been overlooked. Select a test pressure not in excess of the pressure class rating of the duct. (Usually the actual operating pressure as shown in table.) Calculate the allowable leakage using leakage factors for the duct surface area. Place the leakage tester on level ground adjacent to the duct selected under test. Provide Dead ends at both ends of the Duct length being subjected to leak testing. Ensure one of the dead ends has the provision for connecting the Leakage tester. Attach the duct adapter plate to the duct and connect the flexible hose to the duct adapter plate and fan outlet spigot, using hose clamps. Switch the tester power supply ON by means of its power supply using POWER ON/OFF switch provided on control panel. Slowly increase & adjust the flow meter of blower of leak test machine to achieve required duct static pressure (Pressure can be monitored in Magnehelic guage), for the tested pressure corresponding leakage flow rate/factor shall be obtained. Refer table & chart below. Adjust blower capacity until steady-state conditions at the test pressure are achieved.

Leakage Class

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5

Visually inspect the duct for leakages especially through Seam joints, Flanges, Nuts and bolts etc. Record the airflow (across the orifice) at the steady state condition. This airflow is the CFM leakage of the tested section of the duct. Observations: Record the Observations in the Observation Table given below.

Trouble Shooting Observations: Profuse leakage through Flange joints. Profuse leakage through Duct Seam joints. Slight leakage through Duct Seam joints. Leakage through Nut bolts. Suggested Corrective Action Check Gasket. If found discontinued, replace gasket and provide an overlap of at least 25 mm at Gasket joint. Check Nut and bolts. Tighten if found loose. Replace to new duct piece Apply Silicon Sealant on affected portion of Seam joint. Tighten Nut bolts and ensure that each Nut-bolt has been provided with a plain and a spring washer.

Conclusion

Approval Test Conducted by Checked by Approved by

Name/ Designation/ Organization Signature Date * - Ducts shall be identified in terms of Area classification and supply or Return duct e.g., Supply air duct. * - Identify the Ducts in the Drawing (which are subjected to leakage test) and a copy of relevant portion of drawing shall be enclosed. 8 Precautions: Total length of the duct to be tested as per SMACNA standards.

Heat exchangers shall consist of most energy efficient metal plates pressed into a "Herring Bone" pattern and securely clamped between nitrile rubber gaskets by the pressure end plates of the mild steel framework. Plates shall be stainless steel for fresh water or titanium for sea/well water. The plates shall be suspended from the top bar of the framework and located on the bottom guide bar. No part of the mild steel framework shall be in contact with the heat transfer fluids. C6.16.2 Heat transfer plates shall be clamped by lateral bolts between a stationary frame plate and a movable pressure plate such that opening of the plate heat exchangers can be done without removing any connecting pipes. C6.16.3 Heat exchanger shall be designed to give a high heat transfer efficiency to achieve close approach temperatures as low as 3C. C6.16.4 Heat exchanger frame shall be of mild

steel and shall be suitable for bolting to a horizontal deck. The frames shall be arranged such that when the tie bars are loosened, full access to all plate surfaces is provided for cleaning and maintenance. The entire framework and all parts of the units shall be factory treated to prevent corrosion such that the heat exchanger shall be capable of corrosive environment. All holding down bolts shall be of high tensile carbon steel with plastic tube protection. Each shall be equipped with bearing boxes and a locking washer enables the bolts to be opened from the fixed cover. No welded parts are allowed. C6.16.5 Inlet and outlet ports shall be rubber lined or metal lined constructed on the fixed frame plate only. C6.16.6 The heat transfer plates for fresh water application shall be of stainless steel and in a corrugated pattern with thickness of 0.6 mm minimum, and pressing depth of about 3.20 mm with pressure rating a minimum of 1000 kPa or other rating to suit system design as specified. Maximum plate pack length shall not exceed 45% of the total framework length. Double gaskets shall be provided around the bypass port on each plate, with a drain hole between the gaskets to facilitate leak detection. C6.16.7 Distribution area shall be with regular pattern and the flow pattern shall be "counterflow". Gasket shall be on every plate to eliminate interleakage between media. C6.16.8 The heat exchanger units shall be pressure tested in the factory prior to delivery. The plate heat exchanger shall have a working pressure not less than 1000 kPa and shall be tested with a minimum pressure of
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1.5 times the working pressure for 24 hours suitable to the system design application as specified. The manufacturer shall guarantee the heat exchanger free from leakage for 5 years. C6.16.9 The heat exchanger for chilled or hot water application shall be properly insulated with optimum efficiency and robust insulation against heat loss. The insulation panels shall be of the double skin aluminium/stainless steel cladded type with handles suitable for easy removable for plates access for inspection and maintenance. An insulated stainless steel drip tray shall also be equipped for chilled water application.