HVAC Procedures and Forms Manual - HVAC Training

1 IHVAC Procedures and Forms ManualSecond EditioniiThis page intentionally left blank iiiHVAC Procedures andForms ManualSecond Editionby Herb Wendes, DEKKER, York and BaselTHE FAIRMONT PRESS, , GeorgiaivLibrary of Congress Cataloging-in-Publication DataWendes, Procedures and Forms Manual /by Herb 0-88173-387-3 (electronic version)1. Heating--Estimates-- Forms . 2. Ventilation--Estimates-- Forms . 3. Air conditioning--Estimates-- Forms . 4. Buildings--Mechanical equipment--Installation--Estimates. 5. Buildings--Energy .W4597 2001697 0029 9--dc2l2001040687 hvac Procedures and Forms Manual /Herb Wendes. 2002 by The Fairmont Press. All rights reserved. No part of this publication may bereproduced or transmitted in any form or by any means, electronic or mechanical, includ-ing photocopy, recording, or any information storage and retrieval system, without permis-sion in writing from the by The Fairmont Press, Indian Trail, Lilburn, GA 30047tel: 770-925-9388; fax: 770-381-9865 by Marcel Dekker, Madison Avenue, New York, NY 10016tel: 212-696-9000; fax: 212-685-4540 in the United States of America10 9 8 7 6 5 4 3 2 10-88173-387-3 (The Fairmont Press, Inc.)

2 0-8247-0923-3 (Marcel Dekker, Inc.)While every effort is made to provide dependable information, the publisher,authors, and editors cannot be held responsible for any errors or ixCHAPTER 1 hvac Testing and Balancing Procedures and Balance Test Procedure for Balancing ..3 Equipment Test Reports .. 11 Air Balancing Procedure ..12 Testing and Balancing Report Test Air Balance Report ..18 hvac Systems Recap Sheet ..20 Pitot Tube Traverse, Rectangular Duct ..22 Pitot Tube Traverse, Small Round Ducts ..24 Pitot Tube Traverse, Large Round Ducts ..26 Hydronic Balancing Procedures and Balancing Procedure ..28 Pump Test Report ..32 Water Balance Report, Pressure Differential ..34 Water Balance Report, Temperature Differential ..36 Chiller Test Reports ..38 CHAPTER 2 hvac Energy Auditing Procedures and Commercial Audit Procedures and Audit Depth Energy Audit Required for Thorough hvac Audit of System.

3 46 Average Annual Energy Performance in Btu s Per Square Feet ..48 Sample Audit and Forms ..49 Drawing of Suburban Office Building ..50 hvac Energy Auditing Report Cover ..51 Building and System Description ..52 Electrical Consumption History ..56 Equipment Schedules ..58 Electrical Consumption Test Reports ..62 Electrical Loads Per System ..66 Electrical Loads Project Recap ..68 Heat Loss Calculation, Load Calculation, Seasonal ..72viPeak Heating, Cooling and CFM Per Area ..74 Energy Cost and Btu Profiles ..76 Residential Consumption History ..78 Outside Wall Energy Evaluation ..80 Ceiling and Roof Energy Evaluation ..82 Windows and Doors ..83 Cold Floor Energy Evaluation ..84 CHAPTER 3 Indoor Air Quality Procedures and ..85 Specific Causes of Indoor Pollution ..86 Testing, Setting and Controlling Outside Air ..88 Carbon Dioxide Levels ..89 Indoor Air Quality Instruments and Testing.

4 90 Humidity ..90 Particulate Contaminants ..91 Formulas ..93 Indoor Air Quality Report ..95 Building Ventilation and Pressure Report ..96 CHAPTER 4 Engineering Calculation Procedures and Loss Calculation form ..98 Cool Load Calculation form ..100 Peak Heating/Cooling/CFM Per Area ..102 CHAPTER 5 hvac Cost Estimating Procedures and Metal Estimating ..106 Requirements of a Good Sheet Metal Estimator ..106 Efficient Estimating 112 Estimating Procedure Diagram .. 115 Scope of Complete Sheet Metal 116 General Estimating Forms for Both Sheet Metal and 117 Estimate Coversheet .. 117 Job Description and Budget Costs .. 118 Bid Checkoff ..120 Quotation Call List and Price Comparison ..124 Quantity Takeoff and Extension Summary Sheet ..128 Telephone Recap Sheet ..132 Bidding Record ..134viiCalculating Labor Costs Per Hour ..136 Company Markup Calculation Sheet.

5 138 Duct Takeoff and Extension Piece Duct Takeoff Sheet ..142 Per Pound Duct Takeoff Sheet ..143 Piping of a Good Piping Estimator ..144 Piping Takeoff Sheet ..150 Computerized 6 Hitting Home Runs in Technical with A Multitude of Problems ..158 Understand What Constitutes A Problem ..162 Multiplicity Thinking; Avoid Partial Acutely Aware of the Principles and of the Principles and Procedures ..165 Vibrations in High School Building, Sample Case History ..168 Become thoroughly Familiar with the Problem ..173 Examine Possible Causes and Suspend Judgment until Verified ..176 Establish and Evaluate Objectives ..178 Generate Multiple Options and Hold Back on Final Choice ..180 Information and Planning Options, Compare against Objectives, Make Decision ..183 Write it Down ..184 APPENDIX A Blank Full Size Blank Testing and Balancing Forms for Your UseTesting and Balancing Report Information Test Air Balance Report.

6 191 Air Systems Recap ..192 Pitot Tube Traverse, Rectangular Duct form ..193 Pitot Tube Traverse, Small Round Ducts form ..194 Pitot Tube Traverse, Large Round Ducts form ..195 Pump Test Report ..196 Water Balance Reports ..197 Chiller Test Report ..199B. Energy Audit Forms for Your for Energy Auditing and System Description ..202 Electrical Consumption History Per Month ..203 Fan Test Test Report ..205viiiChiller Test Report ..206 Electrical Loads per System ..207 Electrical Loads Project Recap ..208 Heat Loss Calculation ..209 Cooling Load Calculation ..210 Peak Heating, Cooling and CFM Per Area .. 211 Energy Consumption History ..212 Outside Wall Energy Evaluation ..213 Ceiling and Roof Energy Evaluation ..214 Windows and Doors ..215 Cold Floor Energy Evaluation ..216C. Indoor Air Quality Air Quality Ventilation and Pressure Report.

7 219D. Engineering Calculation Forms for Your Loss Calculation ..220 Cooling Load Calculation ..221 Peak Heating, Cooling and CFM Per Area ..222E. hvac Cost Estimating Estimate Report Description and Budget Costs ..224 Bid Checkoff Sheet ..226 Quotation Call List and Price Comparison ..227 Quantity Takeoff and Extension Sheet ..229 Telephone Recap and Markup Sheet ..231 Bidding Record ..232 Calculating Labor Costs Per Hour ..233 Company Markup Calculation Sheet ..234 Per Piece Duct Takeoff Sheet ..235 Per Pound Duct Takeoff Sheet ..236 Piping Takeoff Sheets ..237F. Hitting Home Runs in Technical Management Forms ..238 Problem Work Sheet ..238 Cause Work Sheet ..239 Objectives Work Sheet ..240 Options Work Sheet ..241 Information and Planning Work Sheet ..242 APPENDIX B Charts and and Symbols ..244 Association Abbreviations ..245 Air Flow and Pressure Formulas.

8 246 Changing Fan CFMs and Drives ..248 Air Heat Transfer in State of Air Formulas ..250 Air Density Correction Factors ..252 Converting Velocity Pressure Into Feet Per Minute (Standard Air)..253 Converting Velocity Pressure Into Feet Per Minute (Various Temperature) ..254 Hydronic Chart ..256 Motor Amp Draws, Efficiencies, Power Factors, Starter Sizes ..257 Conversion Factors ..258 Fuel Heating Values ..259 Steam Formulas ..260 Electrical Formulas ..261 Refrigeration Temperature/Pressure Chart ..262 Properties Of Saturated Steam .. page intentionally left blank xiIntroduction to Second EditionHitting Home Runs in Technical ManagementThis second edition of hvac Procedures and Forms has been expanded to include a new sectiontitled Hitting Home Runs in Technical new chapter covers the management of problems, trouble shooting and decision making in theHVAC industry in a more effective, systematic, and thorough manner.

9 Included are the principles andprocedures of the home run process, an actual complete case history, and Forms which complement theprocedures and help guide you through the five other sections of the Manual provide a quick reference and guide on Procedures ,charts and Forms in some of the most critical areas of operations in the hvac industry, testing,balancing, energy auditing, indoor air quality, load calculations, and cost Manual is written for contractors, building engineers, and technicians, as well as for bal-ancers, maintenance personnel, and servicemen. It is a valuable guide for managers and supervisorsfor planning, scheduling, controlling, monitoring, and resolving problems quickly and effectively inmechanical systems. The comprehensive procedural sections guide the manager or technician effectively throughtesting, trouble shooting, auditing, air quality, and problem solving operations.

10 The Forms are concise, comprehensive and optimally organized for easy gathering of data andfor reference. They prompt the user for essential information needed in the different areas ofwork. They serve as a check-off list to insure completeness and effectiveness of Procedures and Forms in this Manual were created by the author over a period oftwenty-five years. He personally applied the Procedures and the Forms successfully in the field andoffice. He tested, modified and developed them and proved them to be meaningful and of engineers, technicians, balancers, maintenance personnel and contractors have ap-plied the Procedures , used the Forms , and provided positive feedback. They have been used inschools and for Training it would take many years to develop valid, workable, analytical Procedures andforms, and because this information is now compiled in a single reference the user will save count-less hours in performing the technical operations, and in assimilating and organizing the data, onvirtually all types of mechanical systems and Testing and Balancing Forms11 Chapter 1 hvac TESTING AND BALANCINGPROCEDURES AND FORMSAIR BALANCE TEST REPORTSTest reports are an absolute necessity in balancing.