Prior to the design of new or replacement Mechanical Systems, the following preliminary testing may be required to determine the current levels or airflow, water flow or equipment and system functionality. The Engineer of Record (EOR) shall survey the site upon project transfer and propose/define the extent of pre-design testing to complete the design. The list of tests below is a starting point of potential tests. More/less or different types of testing may be required based on project specifics. Review proposed testing extent with CPS (Design Manager). Once the extent is approved, the EOR shall arrange/oversee testing. Results of this testing may determine changes to the project scope of work. Similar pre-demolition testing may be required to be included in construction documents. All pre-design/pre-demolition testing shall be reviewed by the EOR and provided to CPS.
Airflow Testing
A preliminary Test & Balance of all air systems within the scope of work and adjacent spaces sharing equipment may be required. This will help determine the existing flows, verify each space meets applicable Codes, verify proper airflow to satisfy the design load of the space, and as define a baseline for re-balance of the system at the end of the project. Testing shall be sufficient to establish values so that areas outside of the project scope serviced by common equipment/ductwork can be re-balanced to pre-construction values upon project completion. Where existing drawings are insufficient and hard ceilings limit a sufficient survey, testing may need to include smoke/peppermint tests to establish diffusers/registers/grilles connected to systems/zones.
Water Flow Testing
A preliminary Hydronic Test & Balance may be needed when changes or replacements are being made to an existing dual temperature, heating hot water or chilled water system. This shall include all coils and other equipment utilizing this hydronic system throughout the facility. It is important to verify that all equipment is receiving proper flow of water to meet required loads, as a baseline for re-balance of the system at the end of the project, and to verify that the existing piping system is properly sized for the new flow rates as determined during the new design. This is of particular importance if the Boiler Plant or Chiller Plant are changing supply/return temperatures or temperature differential.
Controls Testing
The verification of proper controls communication is very important prior to finalizing the system design. A point-to-point verification of all control points of the equipment in the project scope of work will determine if the system is, and can be, functional without major additional work. In addition to the point-to-point testing, all controls shall be exercised and visually verified to be sure they are functioning as designed.
Fan Testing
For all fan systems within the scope of work, both static and dynamic testing shall be done to verify that the fan shaft, bearings, blades and the overall assembly is fully functional with no evidence of required repairs or replacement.
Steam System Testing
For all Steam Systems, a number of elements require testing to ensure the proper function of the system as a whole. This will include combustion testing of the boiler burners, flue vent testing, steam trap testing, and exercising of all steam valves. In addition, all condensate return pump systems shall be tested for proper operation and activation.
Boiler Testing
When boilers are damaged or greater than 30 years old, a boiler testing specialist may be required for hydrostatic testing, ultrasonic thickness testing, magnetic particle testing, supporting calculations, and field eddy current tube testing to establish required repairs and expected remaining useful life.
Natural Gas Piping Testing
Leak testing of Science Classroom gas piping distribution, solenoid valve actuation/system lock out and operational lights:
- Close all lab gas outlets and activate the room’s gas supply at the emergency shut off valve to determine if gas is available at each outlet. If gas is available, leak check accessible gas piping downstream of the room’s emergency shut off valve.
- If gas is not available, test to see if gas is available upstream of the room’s emergency shut off valve.
- If gas is not available upstream of the room’s emergency shut off valve, work back to the main to determine if it is shut off from the gas main or disconnected somewhere.
- If the room’s gas branch is shut off from the main but still appears to be intact, then pressure test the room’s gas branch piping. If pressure testing results are acceptable, then open valve to branch piping and verify that everything is functional.
- For systems that cannot be made functional, identify all repairs that are required to bring the room’s gas supply back into service.