Installation qualification protocol for air handling unit and air distribution system
OBJECTIVE
The objective of this protocol is to provide an outline for the inspection of static attributes, written procedure and guidelines and respective acceptance criteria for the Installation and Operational Qualification of Air handling unit .
The Air-Handling unit caters to:-
AREA DETAILS – Name of the area /Area (SQFT) /Height (FT).
Installation Qualification
Each installed components and sub component complies with the engineering design and manufacture recommendations.
- To ensure that appropriate interconnections are made for utilities / equipment that all the features are defined before the start up of operational qualification.
- The system meets the current good manufacturing practice requirements.
- To prepare tentative standard operating procedures.
- Calibration of instruments
- Functional keys.
- Design parameters
- Alarms & interlock systems
- Verification of standard operating procedures.
- Sequential operation
- Effect of power failure on the equipment
SYSTEM / EQUIPMENT DESCRIPTION
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
RH — NMT 60 %
Description:
Air handling unit is a recirculation system, in double skin modular construction. AHU will have extruded aluminum frame with sandwiched panel of G.I. sheet duly pre coated from outside & 43 mm thick PUF filled in between.
Fresh air enters through 10µ fresh air filter. Air then passes through mixing section with (10 +5) µ pre-filter, 6 rows deep chilled water coil (CH W) coil & 2 rows deep Hot water (H W) coil is placed on condensate tray, Sandwiched type in SS-304 construction with proper drain point. The air will then pass through 3µ fine filter installed in AHU supply plenum.
FA damper are provide with 10µ G-4 pre- filter, EA damper are provide with (0.3µ)H-13 HEPA filter.
Filtered air after 3µ filter will be supplied to the room via leak proof GSS Ducting through ceiling mounted Supply air Hepa (0.3 µ) H-13 and air will return through return air Riser via return duct to mixing chamber.
Both ends of the GI ducts will have flanges & flanges will have neoprene gasket. GI ducts will be thermally insulated by Polyethylene foam insulation. Air volume control dampers shall be installed at (fresh, return) air inlet, (supply, bleed) air outlet of AHU and Supply air Hepa & Risers. Fire damper should be installed on supply & return air duct near to AHU.
RESPONSIBILITY
Engineering and Maintenance Department
Preparation of the IQ protocol in conjunction with user .
Checking the protocol for adequacy and accuracy prior to the approval.
Providing guidance, wherever required to the related departments.
Quality Assurance Department
Providing guidance and check the protocol document.
Head Operations
Checking the protocol for adequacy and accuracy.
Providing required details to the Engineering / Maintenance.
Collection of data and preparation of final design.
Execution of the protocol and preparation of IQ summary report.
User department
Approval of protocol.
EXECUTION TEAM
Quality Assurance : Monitoring and reviewing the validation activities
Engineering : Execute the validation activity and provide necessary support for the proper installation of the equipment.
Production : Participate and provide necessary support for the validation activity
The following components were checked if they are according to the design specification:
Design Verification : Room Data Sheet & Floor Plan Drawing
INSTALLATION VERIFICATION
It was checked and proved that the Air Handling unit and the documentation correspond to the order. In addition, changes and supplements were identified and documented. This review is the basis for further functional reviews, maintenance and modification control.
The IQ protocol defines test procedures, acceptance criteria and the documents that are necessary to prove that the Air Handling unit was installed correctly and corresponds to the specifications of the manufacturers as well as client and that it is suitable for the planned application. The completely executed and finally approved protocol confirms that the Air Handling system is corresponds to all acceptance criteria.
The Installation-Qualification is valid as documented evidence, that the Air Handling Unit corresponds with all checkpoints of design plans, all components of manufacturer’s documentation, rules of technique and the defined requests, The basis for the installation qualification was the detailed design, room tables and the technical Manufacturers documentation.
The following appendices, in the qualification protocol attached, were used for execution of the installation qualification to prove the Air Handling Unit corresponds with the defined requests.
The following drawings were compared on site to the existing installation:
- Fresh air filter (G-4)
- Pre Filter (G-4 +F-5 ) Combo
- Fine Filter (F-7)
- Bleed Air Filter (H-13)
- Supply Blower – Motor
- Cooling coil
- Heating Coil
- Supply/Return Air dampers
- Fire Dampers
- Duct work
INSTALLATION CHECK
The listed drawings shall be compared on site to the existing installed and any discrepancy shall be marked by redlining in the drawing. After the completion of the walk down, the checked drawings have to be signed with date and signature and have to be attached to these protocols.
General Verification:-
Layout :The drawing reflects “as built” conditions
Room Data Sheet :The drawing reflects “as built” conditions
Grills Location Drawing :The drawing reflects “as built” conditions
Component: Fresh air Pre Filter
Manufacturer : Air Tech.
Location : AHU
Filter Class / Efficiency : 10 µ
Model / Type : Flange type
Dimensions of Filters(mm): 305 x 305 x 50 mm
Number of Filters: 1 Nos
Installation: Installed in Fresh air Module
How verified :Physical Inspection along with Unit Drawing
Component: Pre Filter (Combo)
- Manufacturer : Air tech.
- Location : Coil protection in mixing chamber
- Filter Class / Separation Efficiency : 10 µ +5 µ
- Model / Type : Flange type Filter & Dimensions (mm) : 610 x 610 x 380 ,305 x 610 x 380
- Number of Filters : 1 Nos Each
- Pressure difference measuring : 4-5 mm
- Installation : Installed in Return Plenum at clean condition
- How verified :Physical Inspection along with Unit Drawing
Component: Fine Filter:
- Manufacturer : Air tech.
- Location : Supply Chamber in AHU
- Filter Class /Separation Efficiency :3 µ
- Model / Type :Flange type Filter
- Dimensions (mm) :610 x 610 x 305 ,305 x 610 x 305
- Number of Filters :1 Nos Each
- Pressure difference measuring : 7.5-8.5 mm
- Installation :Installed in Supply Plenum at clean condition
How verified :Physical Inspection along with Unit Drawing
Component: Bleed air Filter
Manufacturer :Air Tech.
Location :AHU
Filter Class /Efficiency : 0.3 µ
Model / Type :Flange type
Dimensions of Filters(mm) :305 x 305 x 305 mm
Number of Filters :1 Nos
Installation :Installed in Exhaust air Module
How verified :Physical Inspection along with Unit Drawing
Component: HEPA Filter
Manufacturer :Air Tech.
Location :AHU
Filter Class /Efficiency : 0.3 µ
Model / Type :
Dimensions of Filters(mm) :
Number of Filters :1 Nos
Installation :Installed in Terminally
How verified :Physical Inspection along with Unit Drawing
Component: Fan – Motor
Make :Punker
Type :PLUG Type (non spark proof)
Capacity :2718 cfm
Total Static Pressure :115 mm of wc
Fan/ Blower speed(RPM) :2754
Motor
Make :CG / BBL / ABB / Siemens or equivalent make
Type :TEFC 3Ph / 4Pole
Rating :3.7 kw,2 Pole EFF-2
Component: Damper
Location :Supply, Return, Fresh & Bleed air damper
Model / Type :Opposed blade low leakage GI damper
How verified :Visual Inspection
Component: Ductwork
Material :GI sheets
Manufacturer of Sheets :Jindal / Tata
Zinc Coating Thickness :Coating of 120g/Sqmtr
Duct joints :All joints are with angle iron flanges and neoprene rubber gaskets.
Type of sealing at joints :Silicon sealant at all the longitudinal & transverse joints.
Sheet thickness :20/22/24 SWG
Installation :
Completed under clean condition
How verified :Ducting Layout & Visual Inspection
Component: Outlet Terminal Box
Manufacturer :MKP
Type :Swirl Diffuser
Installation :
Completed
How verified :Ducting Layout & Visual Inspection
DOCUMENTATION REQUIREMENT
The purpose of documentation is to provide basis for further validation (OQ) and generated documented evidence that the equipment / system was manufactured as per the desired design criteria.
- General : Purchase order
- :System specification
- Instrumentation calibration : Calibration certificate for the
- Magnehelic Gauge
- Other certificates : Certification Manifold valves, Ducting, & Insulation
- Lists : Equipment and instrument list with Component descriptions.
- Electrical component parts list with descriptions. Spare parts list.
DEVIATION REPORT
All discrepancies between specification and Acceptance criteria fulfilled yes / no on site concerning the installation equipment, piping, supply and supervision facilities which are discovered during the Acceptance criteria fulfilled yes / no of this protocol have to be documented in this divergence report.
This page may be copied (as often as you need it in case of more than one discovered divergence).
Deviation No.: ______________________
IQ SUMMARY AND CONCLUSION:
SUMMARY ———————-
CONCLUSION————————
Forms and Records (Annexures)
Not Applicable
Distribution
Master copy – Quality Assurance
Controlled copies- Quality Assurance, User Departments
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