Operation qualification protocol for air handling unit & air distribution system

Operation qualification protocol for air handling unit & air distribution system

Purpose:

The purpose of this protocol is:

Verifying the operational attributes of the Heating Ventilation and Air Conditioning system is critical to serve the intended purpose.

To establish the suitability of the draft SOP prepared for the operation of System.

To document the observations for future reference.

Requalification:

Operational Qualification to be repeated in case of:

Replacement of any major component/instrument.

Major modification in the existing equipment.

During monitoring if equipment is found to be malfunctioning (Broken or not working properly).

Shifting of the equipment from one location to another location.

System Description

  • The Air Handling Unit GF-02 consists of:
  • Air Circulation System
  • Air Cooling System
  • Air Distribution Network
  • Air Filtration System
  • Control System
  • Safety System

FUNCTION: The AHU is designed to circulate the air in the area after passing it over cooling coils to maintain the required environmental conditions and pass it through a series of filters to maintain the desired cleanliness level in the area. The air intake and out-take of the system are designed to maintain a certain degree of pressure gradient, temperature, and Relative Humidity in the area as per the requirement.

The major components of the air-handling unit are briefly described below:

Air Circulation System

Blower: A blower is provided in the unit to supply air in the working area. This blower is directly driven by a motor. The blower takes the air from the atmosphere and/or from the rooms as return air and delivers it to the working areas through an air distribution network

Air Cooling and Heating System

Cooling Coil: –The air Temperature and RH should be controlled by the cooling coil. It has Coated Al.fins and Chilled water circulated through the coil by copper tubes. The Dry air passes through the coil before entering in room via the ducting system.

Hot water Coil: –The air Temperature and RH should be controlled by HW coils. It has Coated Al.fins and Chilled water circulated through the coil by copper tubes. The Dry air passes through the coil before entering in the room via a ducting system.

Air Distribution System

Air Distribution Network. An air distribution network is provided to supply the air, delivered by the blowers, into the working areas. By using the same network, return air flows back to the air handling unit to maintain certain pressure gradients and other parameters like Temperature & RH.

AIR FILTRATION SYSTEM

10 micron Pre Filters: – Fresh air filters having filtration efficiency up to 90% down to 10m are provided in the Fresh air intake of the AHU to filter out dust particles from the service area air.

0.3 micron HEPA Filters: – HEPA filters having filtration efficiency up to 99.99% down to 0.3m are provided in the Air Handling Unit for bleed air.

10+5 micron combo Pre Filters: –Combo pre-filters having filtration efficiency up to (90% down to 10 m + 95% down to 5m) are provided before cooling the coil in the return air of the Air Handling Unit to filter out the dust particles.

3-micron Fine Filters: – Fine filters having filtration efficiency up to 99% down to 3m are provided after the cooling coil and blower to remove fine particles from the treated air.

CONTROL SYSTEM

Instrumentation and Control System: – To control of various parameters, Proportional thermostat have been provided.

The Air-Handling unit caters to:-

AREA DETAILS

Name of the area/Area (SQFT)/Height (FT)

The Air Handling unit is designed to provide and maintain the following conditions in the area where it caters

AHU Capacity of air filtration – ______________ CFM.

Temperature – NMT 25 ºC

R H – NMT 60 %

Operational Qualification Procedure

Pre Requisite of OQ Test

Equipment should be installed properly as defined in the Installation Qualification Protocol of the equipment.

Utilities should be provided to the equipment.

Required identification tags should be available at site in appropriate place.

Test Equipment

The following test equipment is required for the Operational Qualification Test.

Magnehelic Gauge –For checking the Pressure Drop across the AHU Filters.

Multi Meter / Clamp Meter -For checking the Electrical Supply and Current rating of the motors.

Qualification of Execution Team

The execution team should be qualified to conduct Operational Qualification of the equipment.

Date of Training:

Inspection checklist

The SOP shall be drafted and verified for operation during Operational Qualification testing. If any changes/modifications are found SOP shall be revised considering all changes.

Prior to the Qualification test, the Personnel shall be trained by the competent Engineer from the supplier / user on the operational features of the equipment / system and method of qualification protocol.

The trained personnel shall carry out the Operational Qualification for key functionality and safety features. Record the observations in the individual test data sheets. Checkpoints designed for the purpose of OQ are also aimed at verification of existing and drafted SOPs.

Report the deficiency from the specified function, if any in the protocol.

Operational Qualification

Instrument Calibration

Magnehelic gauges

Key Functionality

The critical components of the Air Handling System shall be checked to ensure that these are operating to meet the desired design specification, as given by the supplier.

The following attributes are considered critical

Primary Checks of Blower and Motor Assembly

Operation of Blower Motor Assembly

Operation of Cooling and Heating system

Flow of air through filters

Safety Function

Operational Checks

Primary Checks

Check for the Supply Blower and Motor of the Air Handling Unit

1.Check the Supply Blower and Motor assembly for proper fitment on base frame – Blower and Motor should be properly fitted on base frame and tightened with bolts and nuts.

2.Check the motor shaft rotation, manually- Motor shaft should rotate smoothly when rotated manually.

3.Check the Blower rotation, manually- Blower should rotate smoothly when rotated manually – Motor should be tightened with shaft key and hub screws.

4.Check the Blower shaft key and hub screws – Blower should be tightened with shaft key and hub screws.

Check for Air Handling Unit Dampers

Open and close the Fresh Air damper of the Air Handling Unit for its operation, manually- Damper should open and close smoothly.

Note: Adjust the damper in full open condition after the checking.

Open and close the supply air Volume control Damper of the Air Handling Unit for its operation, manually – Damper should open and close smoothly.

Note: Adjust the damper in full open condition after the checking.

Operational Checks

Check for the Power supply.

Switch on the main power supply to the control panel Located at the Ground Floor –Power supply indicator should glow in the control panel

Switch on the control panel power supply to the Air Handling Unit -Air Handling Unit blower motor should start.

Check for the Supply Air Blower

Check the supply air blower for any abnormal sound – There should not be any abnormal sound in the supply air blower.

Check the direction of the rotation of the blower- Blower should rotate as per the arrow mark indicated on the blower.

Check for the AHU Filtration System

Check the differential pressure of the 10+5 m filters – Differential pressure of the filters should be between 4-12mm of wc

Check the differential pressure of the 3 m filters – Differential pressure of the filters should be between 12-15mm of wc.

SOP VERIFICATION: SOP No. /Title  

The System was operated as per the SOP and details are recorded as under:

Operated By/Checked By/Changes required in draft SOP (If any): 

SOP to be corrected (Yes/No)  /Verified By/Date

Deficiency (if any) and Corrective Action Report

Acceptance Criteria  

Operational Qualification shall be considered acceptable when all the conditions specified in various test data sheets.

Any deviation from the acceptance criteria of the specific checkpoint shall be reported and decision should be taken for the rejection, replacement or rectification of the equipment/component.

Whether the acceptance criteria of the protocol and specific checkpoints are met.

SUMMARY AND CONCLUSION:

Forms and Records (Annexures)

Not Applicable

Distribution

Master copy – Quality Assurance

Controlled copies- Quality Assurance, Production, Quality Control, Engineering

History

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