Method Statement of Air Leak Test for HVAC Duct System (Light Test)

Purpose

The purpose of the method statement is to explain the process of testing for the HVAC Duct system for air leaks (by light test) that will be performed within the framework of the buildings.

Scope

The Method Statement outlines the methodology for carrying out an air leak test using light in an HVAC Duct system associated with buildings.

The entire section of ductwork to be tested must be passed through a lamp with a power rating of at least 100 watts in order to conduct the light test. The lamp must be open so that it emits light uniformly and perpendicular to the duct walls in all directions. It is forbidden for any outer surface to be visible through any light coming from the duct interior.

References

Functional Requirements for HVAC and Industrial Building Utility Areas

Specifications for Ductworks

Specifications for Dampers

Devices for air terminals specifications

Specification for Sound Attenuators

Electric substation and compressor house specifications for buildings

HVAC Codes and Standards Guidelines

Legend & Symbols for HVAC

Method Statement for HVAC System Installation

Plan for HVAC System Installation Inspection and Testing

HSE Plan

Plan for Contract Quality

Heating, ventilation, and air conditioning requirements for buildings

The 1997 Handbook Fundamentals and the 2000 HVAC Systems and Equipment by ASHRAE, the American Society of Heating, Refrigeration, and Air Conditioning Engineers

CIBSE (Publication B3: Ductwork): Chartered Institute of Building Services Engineers the UK’s Heating and Ventilating Contractors Association; periodicals like the following: National Fire Protection Association 90A/90B

UL Underwriters Laboratories

Definitions and Acronyms

• HSE Health, Safety, and Environment
• PPE Personal Protective Equipment
• TRIC Toolbox Talk Risk Identification Card
• TBT Toolbox Talk

Roles and Responsibilities

The Project Manager

In charge of ensuring that the work is completed in accordance with the method, appropriate methodologies, standards, and specifications mentioned.

QA/QC Manager

In charge of overseeing and managing actions that adhere to the references’ quality standards. To the project manager he reports.

HSE Manager

The HSE Plan and management system are maintained by the HSE Manager. To the project manager he reports.

Construction Manager

Creates the duct schedule and work with the project manager to determine the methodology and resources needed to complete the duct. Additionally, he ensures that the Project Safety Procedures are implemented.

Site Quality Control Inspector

Conducts the initial inspections and follow up by creating and carrying out Inspection Requests in accordance with construction priorities. When asked, go along with the inspectors as they conduct routine inspections.

Supervisor

The supervisor is responsible for inspecting the HVAC system to ensure quality and check compliance with project papers and specifications. Ensure that the work is proceeding as planned and that the material is delivered on time to the site.

Give technical guidance and keep an eye on the “checkout test” related to pre-commissioning. Evaluate HVAC materials’ shipment damage and suggest a solution. The project manager is to whom he reports.

Shall ensure that the work group under his supervision adheres to safety regulations.

Foreman

He is directly in control of the workers, equipment, and tools utilized to duct the material. He is responsible for ensuring that all work performed under his supervision is done so in accordance with the project approved HSE guidelines.

HSE

In accordance with the safety rules and norms, all work must be carried out.

The work supervisor must ensure that team collaboration is implemented.

Every employee involved in the work must wear PPE.

All lifting equipment will have its certification status checked before use. 

All individuals participating in HVAC installation must be qualified and knowledgeable about the work that will be carried out.

A safety harness with a double lanyard must be linked to an approved safety lifeline when working at heights, and scaffolding or a man lift must be employed.

Under the supervision of the scaffolding supervisor, scaffolding must be built, approved, and disassembled.

If lifelines are used, each person linked to the line will be able to support a load of 2,275 kgs.

A lifeline may only have two people hooked to it at any given time. A lifeline needs to be regularly inspected after installation.

If a lifeline is going to be utilized, HSE needs to be informed.

All man lifts, vehicles, and cranes must be inspected and approved before being used on the job site.

Prior to usage, all lifting tools and equipment must be inspected, certified, and compliant with the color-coding system.

Prior to beginning work, TRIC and TBT must be completed.

HSE coverage must be provided continuously.

Methodology

A smoke test, light test, or duct test in accordance with ASHRAE code can be conducted to verify whether the duct is free of air leaks.

Low-pressure duct leakage testing is not permitted, according to SMACNA’s “HVAC Duct Construction Standards”. Because ducts are low pressure, a light test can be used to verify that the elements in the duct are connected before beginning the insulating process. If any leakage spots are found, they must be sealed using approved sealing material.

Take the following sequence:

• Prepare the duct by sealing all gaps.
• ducts should receive momentary earthing protection.
• Access door dampers can be utilized to provide light within the duct.
• A basic, 100–200-watt, portable lamp with protection can serve as the light source inside the duct.
• mechanical, flexible cable (30m–50m), and switchable ON/OFF capability.
• At the time of the test, all lights in the room where the testing will be carried out must be turned off.
• Access to the ducts will be made possible by scaffolding.
• Throughout the test, complete darkness must be maintained in the test area.
• Check at each connection point to ensure that no outside light is visible.
• If any flaws are found, the area must be marked before being fixed/sealed after completion of the test.
• The test must be redone after rectification.
• Each duct portion (supply and return duct) must be tested.

Procedure for Quality Assurance and Control

Prior to starting the installation work, an RFI must be sent to the QA/QC section in accordance with ITP. Prior to carrying out the light test, the supervisor, in collaboration with the QA/QC inspector, will inspect all essential requirements, ensuring that the work is prepared.

• Verify that all available and approved specifications and applicable documents are available.
• inspection of the Tools and Equipment
• Verify that all preparations have been made for carrying out the light test.

Attachments

• Inspection Request
• Risk Assessment
• SMACNA’s HVAC Duct Construction Standards

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