| Standard Operating Procedure | SOP No. | | --- | --- | | Start-Up Procedures & Verification for Heat Exchangers | 8.035 | | | Effective:6-14-99 | | DCR No.:98213 | Supersedes:New | | Revision No.:New | Revision Date:New | | | Page No.:1 of6 | ## 1 ## Purpose 1.1 Provide a standard procedure for start-up and commissioning of HVAC equipment. 1.2 Provide a standard procedure for coordinating selection, receiving, check out, and acceptance of new equipment. ## 2 Scope 2.1 This procedure applies to (but is not limited to) the following types of equipment: Air to Air Heat Exchanger and Water to Water Heat Exchanger. ## Responsibility 3.1 Project managers have overall responsibility for new equipment from procurement to start-up. To assure optimum selection of equipment and smooth commissioning, the project manager is responsible for coordinating the following activities: 3.1.1 Review of customer and specific job specifications. 3.1.2 Review of equipment selected with Service prior to ordering. Assure equipment is on approved list. 3.1.3 Review drawings, assure drawing schedules, and equipment details are correct. 3.1.4 Coordinate delivery and commissions schedule with all team members including (but not limited to): Site Foremen, Balance and Service (start-up), Customer, General Contractor, and Safety (as needed). 3.1.4.1 In most cases, start-up should be scheduled a month in advance. 3.1.4.2 If exact date is known, service should be notified with estimated time frame. 3.1.4.3 Communicate specific requirements to all team players in writing and verbally. 3.1.4.4 Provide appropriate job number to team members. 3.2 Therma Service/Start-up has responsibility for the following activities: 3.2.1 Therma will provide a qualified service mechanic to perform equipment start-up. 3.2.2 The start-up technician will perform the start-up tasks as specified in the commissioning Standard Operating Procedure for that equipment. 3.2.3 Service will provide estimated time required to Project Manager (PM) prior to start-up. Service will meet agreed upon schedules to assure customer satisfaction. 3.2.4 The start-up technician will fully complete a start-up sheet for each piece of equipment. A copy of this sheet will be provided to the Project Manager with the turnover documents: A second copy will be filed in service by customer name and address. 3.2.5 All time will be charged to the appropriate job number as specified by the Project Manager. If requested, Time and Material sheets shall be completed. 3.3 The Start-up/Commissioning Coordinator has responsibility for the following activities: 3.3.1 Provide a communication path between the Project Manager and the Field Foremen. 3.3.2 Schedule qualified personnel for start-up, balance, test, and room certification as required. 3.3.3 Coordinate punch-list completion with Project Managers. 3.3.4 Coordinate Start-up, Service, balance, and test report documentation. ## 4 Procedures 4.1 General: Service Technician is responsible for filling out start-up sheet FN 8.035.1 for Heat Exchanger. A start-up sheet will be completed for each piece of equipment. Each sheet requires the following information: 4.2 Job identification: The job name, job number, and job address are to be completed by the start-up/commissioning coordination. These will be provided to the service technician. 4.3 Section 5 - Equipment Description. 4.4 Section 6 - Equipment Pre-Installation Inspection. 4.5 Section 7 - Equipment Installation Inspection. 4.6 Section 8 - Operational Inspection. 4.7 Signature - As each section and page is completed, the Service Technician must print and sign his/her name and record the date. This document should also be signed off by an owner representative when required. ## 5 Equipment Description 5.1 This section should be completed by the Service Technician. Any design documentation specifying equipment should be recorded in this section. This includes: Specification number, Submittal number, Process and Instrumentation Diagram number, and Drawing number. Also, record which area this equipment will be serving. 5.2 Fill In the “design” column, record the following information as specified on the design documents. Unit Tag number (per drawings) Manufacturer (per equipment schedule and/or approved submittals) Model number (per equipment schedule and approved submittals). ## 6 Equipment Pre-Installation Inspection 6.1 For each of the following items: Check Yes, No or N/A for not applicable. If No is checked, describe the difference in the comment section and notify the Project Manager immediately. Initial and date each item as it is checked. 6.2 Nameplate data matches vendor specifications. When the equipment is delivered, verify it matches specifications. Complete Section 5. In the “actual on site” column, record the actual data as shown on the equipment and make sure that it matches the design criteria. 6.3 All parts are received and verify the packing slip(s). 6.4 Inspect for visible signs of damage, leak, or defective parts. Note any discrepancies and notify the Project Manager immediately. 6.5 Verify electrical service for correct voltage, current and thermal overload protection. 6.6 Operational and Maintenance (O&M) manual is available in the field. 6.7 Start-up technicians reviewed factory start up procedures in the Operation and Maintenance manual. 6.8 Connections: Size and location match drawing. Check Operation and Maintenance literature. 6.9 Exchanger is clean and free of foreign matter. Check prior to installation. ## 7 Installation Inspection 7.1 For each of the following items: Check Yes, No or N/A for not applicable. If No is checked, describe the difference in the comment section and notify the Project Manager immediately. Lock Out/Tag Out/ procedure should be observed before most of the following steps. 7.2 Unit is installed per design. Check Operation and Maintenance literature; some equipment needs to be level to 1/8” or better to allow proper drainage and operation. 7.3 Tag number is attached to the unit. Tag should be attached to service disconnect or near unit identification plate; if mounted in a ceiling system, tagging should reflect location above or below. 7.4 Service clearance is adequate for maintenance. Service clearance includes access to the equipment through the ceiling systems, over duct work etc. Filter access for removal and replacement are essential. 7.5 Orientation of inlet and outlet thermometers and pressure gauges are correct. 7.6 Primary media relief valve is installed. Check Operation and Maintenance literature and mechanical drawing details. May be in another part of system. 7.7 Secondary media relief valve is installed. Check Operation and Maintenance literature and mechanical drawing details. May be in another part of system. 7.8 Drains and air bleeds are installed. Check Operation and Maintenance literature and mechanical drawing details. 7.9 Sanitary design unit is completely drainable. Check Operation and Maintenance literature and mechanical drawing details. Sanitary or Potable water heat exchangers must be completely drainable for sterilization purposes. 7.10 Insulation is per specification. Check Operation and Maintenance literature and mechanical drawing details. 7.11 Bolts and studs are accessible. Check Operation and Maintenance literature and mechanical drawing details. Insulation may need to be removed for access for cleaning and sterilization. 7.12 Clamps, flanges and bolts are tight. 7.13 Unit has been leak tested. Check Operation and Maintenance literature and mechanical drawing details. ## 8 Operational Inspection 8.1 Use Operation and Maintenance literature and follow start up procedures; the form FN 8.035.1 is a general outline and is to provide a quality assured start up when used in conjunction with the Operation and Maintenance literature. If there are any discrepancies, notify the Project Manager immediately. 8.2 Record start-up operating parameters in Section 8 of the start-up sheet, FN 8.035.1. ## Document Approval Document Approval Service Manager 5-1 Date 899 Service Supervisor 5/19/99 Date Quality Assurance Manager 5-28-99