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T&C Procedure For Air Condition System

J KR/CKM/T & C :______________________



1.0 General Procedures For Commissioning

The following procedure is a brief guide how to carry out the testing, adjusting and
balancing of chiller water system. Further necessary reference will be sought directly from
the appropriate commissioning codes.

After ensuring that all pre-commissioning and setting to work checks have been complete
satisfactorily the following steps for Commissioning shall be followed.

2.0 Preparation

a) Ensure system has been flushed, refilled and properly vented.
b) Confirm all automatic valves are manually overridden into the full flow condition.
c) Ensure pressurization unit are filled and operational.

3.0 Control System

a) All controllers and actuators shall be tested and adjusted for the modulating range
to ensure correct operation of all control systems.
b) Control sequences shall also be verified.
c) All safety controls shall be tested and if necessary under simulated conditions.

4.0 System Start-Up

Ensure that the system to be balanced is in its normal operating condition, i.e.; all
normally open valves are open and normally closed valves are close. (In case where port
automatic control valves are installed they should be set to full flow through the coil and
by pass valve should be isolated).

a) Have an authorized person start up the pump. (Main discharge valve should be
regulated to 50% to limits initial motor start current).
b) Once pump have run up to normal operation speed, check motor running current to
ensure it is within the full load capacity of the motor. Pump developed pressure
should be measured to ensure it does not exceed the system design.
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T&C Procedure For Air Condition System
c) Whilst monitoring the motor running current and system pressure open the main
valve to its fully open position or within motor running current and system pressure

5.0 Pump Test

a) All pumps shall be tested by taking pressure gauge readings, motor power
consumption and speed and comparing them with factory test result curves.

b) The motor starter heaters setting shall be recorded together with the voltage
and amperage on each phase, and the power factor.

c) All pumps mounting frame vibration isolators and holding bolts shall be
checked and adjusted as necessary to minimize the transmission of noise
and vibrations.

5.1 Checking Procedure

1. Unit type, capacity, motor rating, model no, no. of units, and layout is inspected in
accordance to contract specification.
2. Phase rotation angle is inspected via pahe
4. With pump running, gradually close main discharge valve fully and record
suction and discharge pressures.
5. Using shut off head, determine and verify actual pump operating curve and the
size of the size of impeller. Compare this data with the submitted data curves. If
the test point falls on the design curves, proceed to the next step; if not, plot a new
curve parallel with other curves on the chart, from zero flow the maximum flow.
Make sure the test readings were taken correctly before plotting a new curve.
Preferably one gauge should be used to read differential pressure.
6. Open the discharge balancing valve slowly to the fully open position; record the
discharge pressure, suction pressure and total head. Using the total head, read
the system water flow from the corrected pump curve established in step b.
7. If flow meter or calibrated balancing valves are installed, which would allow the
flow rate of the pump circuit(s) to be measured, perform the necessary work and
record the data. Compare this to reading recorded from the pump curve.
8. The total the pump flow rate should be within +-10% of the design requirement. If it
is low check pressure drops cross coil, heat exchanges, strainers etc and cross
reference to design figures for anomalies. If the duty is high it will need to be
regulated on the main balancing valve.

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T&C Procedure For Air Condition System

6.0 Piping Systems

a) All pipes, valves, fittings, etc. shall be tested to a hydrostatic pressure of 1
times the normal working pressure of the system, but in no case less than
100 psig. for a period of 48 hours. During this period pressure readings as
well as the ambient temperature shall be taken at intervals of 3 hours.

b) During the pressure test, all welding joints, bends, fittings and valves shall
be checked for any leaks or deformations for the entire piping system.
Expanded conditions of all pipings shall be carefully studied and any
necessary changes in hangers, anchors or guide locations shall be made.

c) All equipment not capable of withstanding the test pressure, shall be
disconnected when testing the piping with 100 psig., but shall be
reconnected and tested with actual working pressure and temperature.

d) The flow rates through all of the piping system components shall be verified
and adjusted until the proper temperature differentials are obtained at full
load operation.

e) All control valves shall also be tested for pressure drop and set for the
specified flow rates. When flow rate in the system has been properly set, the
spindle and yoke shall be clearly marked and its control handwheel

Testing Procedure

1. Pipe material shall be recorded specification against tender specification.
2. Pressure testing is conducted for 24 hours (150 PSI). No pressure drop is
allowed and pressure test is conducted through zoning.
3. Pipe size installation shall be inspected as per approved drawings.
4. Inspect the bracket/hanger spacing (vertical and horizontal) as per contract
document drawing.
5. Welding and connection / fitting shall be inspected. Pipe less than 2 shall be
threaded and screw joint while pipe more than 2 shall be threaded, welded or
flanged joint.
6. Under ground pipe line bedding and trenches shall be inspected against
specification and drawing for load bearing and non load bearing requirements.
7. Corrosion protection (painting / galvanizing / cathodic protection / bitumen
wrapping) applied to pipe and bracket under and above ground shall be
8. Pipe sleeve through wall / slab shall be inspected based on specifications. Pipe
sleeve shall be anti-vibration and fire retardant.
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T&C Procedure For Air Condition System
9. All instrumentation and gauges installed shall be on approved tender and
drawing specification.
10. Valves ang other piping accessories installations shall be inspected as follows:
a. Balancing valve selection chart for valve suitability at rated flow and
b. Motorized valve regulator rating and required torque
c. Pressure gauge type rating and range for designated installation
d. Suitability and adequacy of air release valve location for effective air lock

7.0 System Balancing

a. Carry out an initial scan of all balancing valve and log result on relevant test
document. Investigate any abnormally low reading form blockage or air lock.
b. With the aid of a single line schematic and the obtained test data identify the
index valve. (Commonly furthest valve from pump).
c. Whilst monitoring the reading on index valve work back towards the pump
adjusting each valve on the respective branch in turn until reading are
proportionally balanced. (Ideally an overall reading of 10% between valves
should be obtainable).
d. Activity (c) should be carried out on all terminal valves until each individual
branch is proportionally balance. At this stage you will generally find some
branches higher than the pump % duty and some lower.
e. Connect a manometer to the index branch and take a reading. Whilst
monitoring this reading, work back towards the pump adjusting each branch
valve in turn until they are all in proportional balance with the index.
f. If are system has more than one riser the next step would be work back
from the index riser carrying out the same exercise as detailed in (d) & (e).
g. Once all terminal, branch and riser valves in balance the by pass valve on
the 3 port valve arrangements can be set. These should be regulated to
pose an identical resistance through the by pass pipe as that of the coil.
(Bypass valves can be set at any stage of the balancing procedure as they
will not affect the overall balance).
h. Pressure drops across AHU coils, heat exchangers, condensers, evaporator
etc should be taken where possible and logged as necessary.
i. Valve settings should then be recorded and the valve handles locked in

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T&C Procedure For Air Condition System


a) General

The cooling towers shall either be factory assembled in single fan modules or field
erected towers utilizing fully factory components. In addition, the cooling towers
shall be of approved brands with manufacturer's guaranteed capacity performance
without any allowance for up-rating the capacity under favourable operating
conditions of any kind.

Each cooling tower shall be capable of cooling the specified quantities of
condenser water under the conditions as listed in the Schedule of Design Data.

Each cooling tower shall be complete with basin, casing, fan, motor, infill and all
necessary supporting framework above the concrete plinths, structural foundation
for the cooling towers shall be provided for by Air-Conditioning Contractor unless
specified otherwise in tender drawings.

b) Performance

The selection of the cooling tower shall be based on inlet water temperature of
97F, outlet water temperature of 87.F and at a maximum wet bulb ambient
temperature of 82F.

c) Construction

- Casing &
Louvres: The materials for these shall be plastic or hotdip
Galvanised sheet steel.

- Eliminators: Drift eliminators shall be plastics (PVC) and shall have a
minimum of two distinct charges in air direction and limit
drift loss to less than 0.2% of the total water circulated.

- Distribution
System: The hot water distribution basin may be galvanised steel or
plastic. Distribution weirs and metering nozzles shall be
provided to ensure even distribution of water. Flow control and
shut-off valves of each discharge end of the pipe shall also be

- Basins: Unless otherwise specified, the collection basin shall
either be FRP or hot-drip galvanised steel and shall be
self cleaning with adequate capacity to hold the
circulating condenser water so that there shall be no
excessive overflow when the pump is stopped. The
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T&C Procedure For Air Condition System
basin shall be complete with quick fill inlet and valve,
make-up water valve operated by large diameter plastic

- Infill: The infill shall be of wave-formed sheets of self extinguishing
PVC. The infill shall be permanently positioned such that it
allows for expansion and contraction without cracking, warping
or sagging.

- Hardware: All hardware used in the construction of the tower shall be
supplied by the cooling tower manufacturer. In general all bolts
and nuts shall be galvanised and nails used shall be non-

d) Fan & Motor

The fan shall be multi-bladed with fixed or adjustable pitch. The fan blades shall be
heavy duty cast aluminium and houses within a fan cylinder design for streamline
air entry.

Fan motor shall be totally enclosed air cooled suitable for operation on
415V/3ph/50Hz supply. Motors shall be furnished with special moisture protection
on windings, shafts and bearings. Each motor shall be of 2 speed with 4/6 poles. A
time switch shall automatically lower the speed at night. All steel components or
structures used for installation of the mechanical equipment of the cooling tower
shall be dip galvanised or other corrosion protection devices.

e) Water Treatment Plant

The treatment plant shall be a complete package incorporating proportional
metering equipment, chemical tanks, 7 days timer c/w back-up battery and other
accessories. The plant shall be suitable for continuous automatic water treatment
for trouble free operation of the Air-Conditioning system. The plant shall be
installed and commissioned strictly in accordance to the manufacturer's instruction.

The chemicals used shall be Corrosion Inhibitor & Anti-Foulant and Microbiological
Growth Control Agent. All chemicals must be approved by the Ministry of
Environment for discharge into open drains or atmosphere.

f) Others

The cooling tower which stands at more than 1.5m high should be equipped with
service ladder.

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T&C Procedure For Air Condition System
8.1 Checking Procedure

1. fan is checked for cracks
2. check for noise of motor
a. check lubrication for gear
b. check and adjust belt tension
3. check reservoir interior and strainer
4. check sprayer for clogging by dust
5. check paint of steel material for corrosion
6. Water treatment to control scale and corrosion due to concentration of impurities in
water as it evaporates
a. By bleeding
i. Overflowing
ii. Bleeding from return line to Cooling Tower
b. By cleaning manually algae and slime on the surface of the material
8. Water flow to cooling tower balancing valve is inspected prior to 1
start up.
9. Water quality and is inspected and piping network is flushed prior to 1
start up.
10. Phase rotation angle is inspected via phase rotation meter for correct fan motor
rotation prior to 1
11. Belting tightness is inspected during 1
12. Fan vibration and dynamic balancing is inspected during 1
start up.
13. Abnormal noise and vibration from Cooling Tower unit during 1
running is
14. All bolts and nuts for the fan, etc are made sure to fully secure.
15. Fan static pressure during 1
run is inspected against contractual specification.
16. Supply and outlet temperature for cooling tower is inspected.
17. Gearbox lubrication oil level is inspected.
18. Cooling tower filter condition is inspected
19. Emergency stop button installation is inspected.
20. Infill condition and cleanliness is inspected
21. Infill water seepage is inspected.
22. Basin cleanliness is inspected.
23. Motor starting method is inspected against contract specification.

9.0 Switchboard

a) All thermal overloads on starters shall be checked and adjusted for the actual load
and the settings recorded.
b) All circuit breakers overload settings shall be checked and recorded.
c) Each motor shall have its voltage and current draw recorded.

Testing Procedure

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T&C Procedure For Air Condition System
1. As built drawing for starter board control scheme for switch gear rating, wire sizing
and professional approval as well as licensed fabricator prior to fabrication of unit
is inspected.
2. Wiring installed is inspected via Mega tester conducted by licensed wiremen
3. Control logic is inspected in accordance to contract specification.
4. Physical wire sizing and type to all power units and motors is inspected in
accordance to IEE regulation.
5. Current leakage protection, earth leakage protection, over loading protection,
switch gears rating, transformers rating, MCCB, MCB, contactors rating is
inspected in accordance to IEE regulation.
6. Incoming power adequacy for starter board power consumption is inspected with
other Discipline.
7. Power factor reading, installed capacitor bank is inspected if necessary.


1.0 AHU

AHU Room
1. Fan outlet air orientation shall be inspected for optimum fan performance.
2. Drain pipe requirement and orientation including water trap installation shall
be inspected based to contract specification
3. Plinth orientation and dimension including vibration isolation method and
requirement shall be inspected accordance to contract specification.
4. Fresh air intake louvers requirement shall be inspected for size and Volume
Control Damper (VCD) accordance to specification.
5. AHU room insulation material and requirements shall be inspected
accordance to contract specification.
6. AHU roof / ceiling installation shall be inspected for material, strength and
rigidity to avoid the danger of ceiling collapsing due to suction effect.

AHU Unit
1. Model installed is inspected
2. AHU refrigerant circuit is inspected for sign of leakage with leak detector
3. Condenser correct water inlet and pullet piping orientation is inspected as
per manufacturer requirements
4. AHU insulation is inspected as per contract and approved drawing
5. Face velocity of Water Cooled Package (WCP) unit in accordance to
contract requirements. Typically 550 fpm maximum.
6. All bolts and nut for WCP panel, fan, etc are fully secured.
7. Condenser air purging is performed prior to unit 1
start up.
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T&C Procedure For Air Condition System
8. Water pressure inlet and outlet of condenser is inspected as per
manufacturer recommendation and contract specification.
9. Water flow through condenser balancing valve is inspected prior to 1
10. Water quality is inspected and piping network is flush prior to 1
start up
11. High Side and Low Side pressure is inspected accordance to manufacturer
12. Phase rotation angle is inspected via phase rotation meter for correct
compression rotation prior to 1
start up.
13. Thermostat installation, setting, devices protection are inspected during 1

start up.
14. Off coil temperature is monitored for first 2 days of running.

AHU unit 1
test run
1. Abnormal noises and vibration are inspected from the WCP unit during 1

2. Fan static pressure is inspected during 1
run against contractual
3. Supply air temperature and room temperature, relative humidity and return
air temperature are inspected after system has been running in stable
4. Compressor oil lubrication level is inspected.
5. Condition of filter drier is inspected.
6. Crankcase heater operation is inspected during off cycle.
7. Anti recycles timer in each compressor start is inspected.
8. Timer delay for each motor startup is inspected
9. Superheat condition of the evaporator is inspected in accordance to
manufacturer recommendation.
10. Motor starting method and running ampere is inspected against
manufacturer recommendation and contract specification.

2.0 Ductwork

All air duct sizes (internal dimension) and their installation shall be as indicated in
the tender drawings.

The ducts shall be fabricated from good quality galvanised steel sheets. All ducts
shall be free from sharp edges and with tight seams and corners to minimise
leakage. All transformation due to changes in duct sizes shall be done gradually
with a slope of 1:7.

The duct shall be cross-braced and reinforced where necessary to ensure rigidity
and freedom from mechanical noise induced by vibration.

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T&C Procedure For Air Condition System
The duct shall be supported with 40mm mild steel angles and flats, spaced at 2.5m
intervals to form a rigid, vibration free support. Means shall be provided for
adjusting the duct height. Screwed mild steel rods of 9mm diameter may be used
for this purpose. The hangers shall be fixed to the building structure by means of
shear type fasteners or other means approved by J KR.

Elbows shall be long radius type and changes in slope shall be gradual to maintain
uniform velocities, low noise level and turbulence. All elbows and tees shall be
fitted with double thickness turning vanes. All takeoff branch shall be fitted with
splitter damper

Where duct pass through walls and are in view, cover plates shall be provided.
Such cover plates shall be of extruded aluminium angle, pop rivetted to duct wall or
sheathing to approval.

The gauges of sheet metal, type of transverse joint and types of bracing shall be in
accordance with the following table:-

Max. Size Thickness Type of Transverse Type of Bracing
of Duct of Sheet Joint Connection
Metal (mm)

Up to 0.560 S.Drive, Pocket or Bar None
300mm Slips, on 2375mm centres

325 to 0.800 S.Drive, Pockets or Bar None
600mm Slips on 2375mm centres

625 to 0.800 S.Drives, 25mm Pocket or 25mm x 25mm
750mm 25mm Bar Slips of 2375mm x 3mm angle centres.
1200mm from

775 to 1.000 S.Drives, 25mm Pocket or 25mm x 25mm
1000mm 25mm Bar Slips of 2375mm x 3mm angle
centres. 1200mm from

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T&C Procedure For Air Condition System

Max. Size Thickness Type of Transverse Type of Bracing
of Duct of Sheet Joint Connection
Metal (mm)

1025 to 1.000 40mm Angle connection, or 40mm x 40mm
1525mm 25mm Bar Slips with 35mm x 3mm angle
x 3mm bar reinforcing on 1200mm from
2375mm centres. joint.

1550 to 1,250 40mm Angle connections, 40mm x 40mm
2275mm or 40mm Pocket or 40mm x 3mm
Bar Slips on 1125mm diagonal
maximum centres with angle or
35mm x 3mm bar 40mm x 40mm
reinforcing. x 3mm angle
600mm from

2300mm 1.800 40mm Angle connections, 40mm x 40m
and or 40mm Pocket or 40mm x 3mm
above Bar Slips on 1125mm diagonal
maximum centres with angle or
35mm x 3mm bar 40mm x 40mm
reinforcing. x 3mm angle
600mm from

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T&C Procedure For Air Condition System
2.1 Ductwork

(a) External insulation of ducts

All conditioned air ducts shall generally be insulated with 7.0mm thick PE foam having a
thermal conductivity of approximately 0.034W/mK at 0
C mean temperature and
approximately 0.036Wm/K at 23
C mean temperature. The insulation material shall have
a density of 30-36kg/m
and chemically crosslinked closed-cell type according to water
absorption level of 1.05% after 7 days and less than 2% after 28 days ( DIN 53434 ). In
addition, water vapour diffusion resistance factor shall be more than 1300 ( DIN 52615 ).
The insulation material must be qualified as a building material by J abatan Bomba dan
Penyelamat, Malaysia.

All ductworks below the roof or in any vertical shaft shall have 10.0mm thick PE foam.

All ductworks within the plantroom and conditioned air ducts exposed to weather shall be
insulated with PE foam reinforced with galvanised wire mesh and finished with hybrid

The complete surface of duct and insulation material shall be coated with adhesive before
pressing together. Insulation shall be carried out at all flexible connections and points
subject to condensation. The end of joints in the insulation shall be coated with adhesive
and cemented together to ensure continuity of the insulation.

All insulation material shall have performance guarantee against any condensation on the
material for a period of not less than 2 years.

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T&C Procedure For Air Condition System
(b) Duct Acoustic Insulation:

The ductwork acoustic insulation shall be in general conform to the requirements
listed below:

a) The acoustic insulation shall be of thick long textile glass fiber duct liner coated
with a fire-resistant black composite surface and acrylic coating together with
factory applied edge coating or approved equivalent. The thermal conductivity of
the insulation materials shall not be greater than 0.040 W/m
C at a mean
temperature of 24

b) All supply and return air ductwork shall be internally lined with acoustic
insulation for the complete lengths of 6 metres down-stream of the air handler,
whichever is longer.

c) Absorption coefficient of duct liner shall not be less than those stated below for the
thickness indicated when tested in accordance with ASTM C 423 using a Type A

Octave Band Absorption Coefficients

Thickness NRC 125 250 500 1000 2000 4000

25mm 0.60 0.10 0.28 0.50 0.70 0.82 0.83

50mm 0.80 0.22 0.49 0.83 0.89 0.89 0.91

d) Thickness
1 In ductwork: minimum 25mm unless otherwise noted on drawings.
2 Plenums: minimum 50mm
3 Supply duct and return duct: minimum 25mm unless otherwise noted on
4 Minimum density: 24kg/m
in ducts
in plenums

e) All portions of the duct designated to receive acoustic insulation shall be
completely covered internally with duct liner. Transverse joints shall be neatly
butted and shall have no interruptions or gaps. The duct liner shall be cut to
assure tight overlapping corner joints. Top pieces shall be supported by the side
pieces. The up-stream transverse edges shall be properly coated with suitable
adhesive to prevent air erosion.

f) The insulation material must offer outstanding durability on exposure to air velocity
and superior acoustical and thermal performance in system operating at velocities
up to 30.5 m/s (6000 fpm) and temperature up to 121
C (250

g) The liner shall meet the life safety standards as established by NFPA 90A and
90B, FHC 25/50 and combustion rating shall be in accordance with ASTM E84 or
approved equivalent.

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T&C Procedure For Air Condition System
h) The airstream surface coating should contain an immobilized, EPA registered,
anti-microbial agent so it will not support microbial growth as tested in accordance
with ASTM G21 and G22 or approved equivalent.

i) Duct liner shall be adhered to the ductworks with a minimum 90% coverage of
adhesive. All exposed leading edges and transverse joints shall also be coated
with adhesive and shall be neatly butted without gap. In addition, adhered pin
press-on head fasteners shall be used to secure the duct liner to the duct.

Where gaps in insulation cause condensation on the outside of the ductwork, ducts
shall be dismantled and reinsulated to S.O.'s approval.

Good quality canvas with 50mm thick fibreglass insulation shall be used to connect
the duct with fan outlet.
10.2 Air grilles and diffusers

All air grilles and diffusers sizes indicated in the tender drawing do not include border
widths. Ceiling diffusers, unless otherwise specified, shall be four-way throw type. Side
wall grilles shall be of rectangular universal type with adjustable horizontal and vertical
deflection fins. All air grilles and diffusers shall be fabricated from best quality galvanised
steel sheets unless otherwise stated in the tender drawings. All grilles and diffusers shall
be fitted with adjustable opposed multi-blade volume dampers controlled by linkages. All
external fresh air grille shall be weather/rain proof and fabricated from extruded aluminium
c/w opposed blade damper and insect netting.
Grilles and diffusers of size 500mm and below shall be of 1mm thick, and size 525mm and
above shall be 1.25mm thick. Damper blades shall be 1mm thick and not wider than
50mm. All air grilles and diffusers shall be of high quality finish and shall be to the approval
of J KR Cawangan Mekanikal.

2.3 Fire dampers

Fire dampers shall be supplied and fitted through the fire wall as shown in the tender
drawings within the thickness of the various fire break walls, partitions and floor slabs. The
fire dampers shall comply in all respects with the requirements of the J abatan Bomba and
shall have not be less than 1 hour fire resistance.

The damper shall be constructed from not less than 3mm mild steel plate with welded
joints and flanged ends for connecting to the G.S.S. ductwork, the blade shall be of not
less than 3mm similar steel plate arranged to swing freely and automatically into place
when released by fusible link mechanism.

Internal small angle iron guide stops shall be fitted to ensure an efficient seal when the
damper blade is in the closed position.

After fabrication, the whole of the damper and blade shall be chemically derusted and
finished with at least two (2) coats zinc chromate paint.

Fusible links shall be arranged to break at 57 C and be connected and anchored to
welded internal lugs by means of non-corrodible multicore wire. The position of the fusible
links when assembled shall be chosen so that they may be easily inspected and adjusted
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T&C Procedure For Air Condition System
through access panels cut in the G.S.S. ductwork. In all cases the ductwork access panels
coincide with the removable portions of the false ceiling wherever they occur.

Spaces between the duct perimeter and the fire rated wall shall be fitted with intumescent,
Latex- based fire stop sealant rated per UL1479. The material shall have minimum fire
resistance rating of 2 hours. The fire stop shall be applied throughout the depth of the fire
rated wall.

2.4 Non-return dampers

All non-return dampers shall be of light gauge and of sturdy construction with spindle
running freely in oil impregnated bronze or other approved type of bearings. Damper
blades shall be tipped with 7mm thick hard felt to ensure silent operation. Non-return
dampers shall be provided on all external wall openings of exhaust fan systems and also
in ducts on suction sides of duplicate fan installations. over with 24 gauge 63% perforated
galvanised steel sheet.

Testing Procedure

1. Sheet metal, material and thickness is inspected according to contract document
and approved working drawings
2. Insulation thermal conductivity is checked
3. Ducting dimension and insulation is inspected.
4. Ducting joint is inspected
5. Duct brackets and hanger placement is inspected
6. Vapor Barrier type and joints is inspected in accordance to specification and
approved working drawings.
7. Diffuser and air grille material requirements, size, thickness, coating and number
installed are inspected as per contract documents and approved working drawings.
8. Fire damper rating and installation is inspected as per BOMBA standard, contract
documents and approved working drawings.
9. Splitter damper installation is inspected as per contract document and approved
working drawings.
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