AIR HANDLING UNIT | Pre-Commissioning Inspection Checklists

October 19, 2022 |

This AHU system commissioning inspection checklist can be used and completed throughout the project and its different stages:

  • delivery,
  • storage,
  • installation &
  • pre-commissioning

Once completed, the entire functional testing of the Air Handling Units can be conducted.

🟩 Delivery Inspection

Once the Air Handling Unit arrives at the site, usually delivered by a transport company, and before being accepted into storage, the following should be checked with the driver.

🔗If you want to know more on Air Handling Units see our article: 'AIR HANDLING UNITS | All we need to know'.

Any damage noted should be reported to the manufacturer/supplier within 3 days in writing, supported with photographs.

RefInspection/Task
1Supplier's consolidated delivery ticket is available, showing all equipment and ancillaries for inspection and being used to check against.
2A copy of the order that was sent to the supplier is available for reference and is being used to check against
3Equipment is packaged and crated in separate boxes, for maximum protection
4The unit nameplate and details match the purchase order
5Delivery protection is dry
6Unit/s are dry internally
7The external casing of the unit/s are undamaged
8All frames, if ordered are included
9All pipework connections are the correct size
10Pipework connections are undamaged
11All pipework handing’s are correct
12All ducting connections are the correct size
13All ducting connections are the correct size
14All ancillaries [valves, actuators, dampers, filters] are included in delivery as per the order and delivery note
15Spin the fan to ensure not damaged and out of line
16Check all coils for damage externally and internally
17Replace all protection that has been removed

🟩 Storage Inspection

🟧 Storage Area

If the equipment is to be placed into storage on site before installation, an inspection will be completed checking the following.

RefInspection/Task
1The area is internal and will not be affected by the weather. [if the unit is not rated for external use]
2The surface where the equipment is to be placed is flat.
3The equipment will be raised off of the floor to allow airflow and stop the risk of water ingress.
4The area is well covered and protected.
5The area is well ventilated and has no risk of high humidity.
6The area is clean & dust-free.
AHU System Pre-Functional Testing Checklist [MS Word]+[MS Excel]

Here is our open copy [MS Word] of the AIR HANDLING UNIT Pre-Functional Checklist, for making life a little easier...

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🟩 Storage of Air Handling Unit

Before the units are placed into storage, the following should be checked.

RefInspection/Task
1Units will not be stacked.
2Units will not have materials stacked on them.
3All ancillaries will be placed in a safe and secure location so items do not go missing or get damaged.
4All original packaging is intact and not removed.
5Pipework caps are not removed.
6Unit and all components placed on a flat surface.

🟩 Pre-Installation Inspection

Before the units are installed, the following should be checked.

RefInspection/Task
1The plinth/base is ready, flat, and level & can bear the weight of the installation.
2The room/area is dry and watertight.
3The area being installed is not prone to flooding or ponding of water.
4The room/area the unit will be installed into is clean and dust-free. If there is dust/construction work then the unit should be protected.
5If the unit is installed externally then ensure it can be fixed to the floor, check for internal mounting requirements with the manufacturer.
6If there is a buildup of snow it will not affect the unit’s operation or maintenance requirements.
7The installation of the unit will not impede the installation of the condensate trap/pipework.
8All connections, pipework/ductwork, etc., can be independently supported and not supported by the unit. The best practice is to install self-supporting brackets prior to the connection of the unit
9Ensure that all access doors are clear and not blocked from brackets or other services.
10Check to ensure that all connections kits containing – gaskets, bolts, cleats, screws are available to allow bolting up of the equipment.
11Remove all transport feet and bolts.
12Check that all required cabling can be run through the unit and on appropriate containment.

🟩 Maintenance/Access

RefInspection/Task
1There is enough space allowed around and above the unit once installed to perform maintenance, and remove components. [check the manufacturer’s maintenance instructions for requirements]
2All doors can be fully opened to gain access to the unit.
3Check that there is enough space for coils and fans to be removed and replaced. [Don’t forget that if the unit is mounted outside the surface will need to be hard and flat]
4If the unit is mounted at a high level, confirm that there is a safe manner to remove the parts and components and that there is enough space at a high level and at the floor level to allow this.

🟩 Pre-Commissioning Inspection

Once the equipment has been installed and before the functional testing and commissioning phase, the following will be checked.

🟧 General

RefInspection/Task
1Document the information of the unit from its nameplates and cross-reference with the specified information to ensure correct.
2Ensure the unit is level.
3Ensure all gaskets are installed and sealed.
4Ensure that all cleats are installed as per manufacturers’ instructions.
5All-access doors can be open and closed with no gaps or leakage.
6Check that all transport bolts and feet are removed.
7Roof canopy, if being used, is installed and fixed.
8All vibration mounts installed
9Seismic restraints, where required, installed.
10Unit and all components including valves and controls are labeled in line with the project naming convention.
11Operation and startup manual for the AHU available.

🟧 Electrical General

RefInspection/Task
1Unit and components are fully earthed in line with the manufacturer’s instructions.
2Earthing has been tested
3Emergency disconnect installed for each component in line with NFPA/local code requirements
4Electrical voltage from the site matches the unit required voltages.
5All cabling is installed and connected on the correct containment/raceways and not damaged.
6All cabling has been tested/torque tested.
7A local motor control panel [LMCP] has been installed
8The local motor control panel has been electrically tested
9All electrical cabling is labeled in line with the project naming convention.

🟧 Variable Speed Drive

RefInspection/Task
1A variable speed drive has been installed.
2Variable Speed Drive [VSD] has been electrically tested
3Variable speed drive has been functionally tested

🟧 Controls System/Motorized Dampers & Interlocks

RefInspection/Task
1Motorized dampers installed as per the drawings and open/close freely.
2All controls and panels have been installed to operate the motorized dampers
3Fire trip has been installed and operating/interlocked with the ventilation system.
4Freezing safety interlocks installed as per the design.
5Pressure differential measuring devices are installed across all filters
🔗To see our Ductwork Checklist, see our article: 'DUCTWORK | Pre-Commissioning Checklist'

🟧 Fresh Air Intake

RefInspection/Task
1The position of the intake louver is in line with the design requirements and positioned so as will not be affected by any exhaust air.
2Weather louver/roof cowl installed and weather tight with relevant mesh and is unobstructed.
3Weather louver installed with correct mesh.
4Weather louver mesh-free area meets the design requirements
5Plenum installed connecting the louver to the ducting.
6Plenum has drain installed with trap to remove any unwanted ingress of water
7Plenum has access hatch/s installed to allow future maintenance and inspections
8All fresh air ductwork is installed, correct size, and connected to the unit with correct fixings
9All attenuators are installed as shown on the drawings.
10All non-return dampers are installed as per construction drawings.
11All volume control dampers are installed as per construction drawings.
12Ductwork insulated and vapor seal in line with the specification.
13Test holes available in the duct to allow air readings

🟧 System Fire Dampers

RefInspection/Task
1If fire dampers were installed as per the drawings, confirm that they have been tested in line with the project requirements.

🟧 Filters

🟨 Panel Filters

RefInspection/Task
1Filter mounting frames are clean and dust-free.
2Panel filters are installed, clean, and are of the correct grade.
3Filters have the correct sealing gaskets installed.
4The filters are not jammed in the rails
5All components upstream of the filter are clean and dust-free
6Panel filters are locked in place
7Differential pressure sensors are installed and calibrated.

🟨 Bag Filters

RefInspection/Task
1Filter mounting frames are clean and dust-free.
2Bag filters are installed, clean, and are of the correct grade.
3Filters have the correct sealing gaskets installed.
4The filters are not jammed in the rails
5All components upstream of the filter are clean and dust-free
6Bag filters are locked in place
7Differential pressure sensors are installed and calibrated.

🟧 Supply Air Fan

RefInspection/Task
1Electrical connections and cables are complete, fully tested, and torqued in line with project/manufacturer requirements
2Motor protection installed and operating [Overload]
3Motor protections calibrated
4Voltage from electrical systems is correct for the unit requirements [within +/-10%]
5Fan housing is clean and dust-free
6Fan, blades, and motors are clean and dust-free.
7Fan belt tension is correct
8Fan belt condition is good
9Ensure the fan wheel is centered on the intake section
10Check the tightness of fixings [torque]
11Check flexible connections between the motor/impeller and unit to ensure are in good condition and leak-free.
12Impeller is balanced
13Fan/motor rotates in the correct direction with no obstructions [by hand]
14Fan/motor rotates in the correct direction with no obstructions [electrically bump unit on]

🟧 Cooling Coil

RefInspection/Task
1The cooling coil is clean, in good condition, and the fins undamaged.
2Ensure that the pipework is connected and the correct size
3Ensure that the flow and return pipework handings are correct. [Water Inlet – downstream of the airflow direction Water Outlet – upstream of the airflow direction]
4The installation of the pipework will not put stress on the equipment connections or create vibrations.
5The materials used between the equipment and the chilled water system will not cause Electrolysis.
6Pipework that is to connect to the unit has been weld tested.
7Pipework that is to connect to the unit has been pressure tested.
8Pipework that is to connect to the unit has been cleaned and flushed.
9Equipment has been backflushed.
10The system has been bled and air removed.
11The chilled water system has been hydraulically balanced.
12Pipework is insulated and vapor sealed
13Insulation is labeled
14All pressure gauges installed, and display scale as per design requirements.
15All valves/control valves are installed and incorrect direction
16All commissioning devices are installed

🟧 Heating Coil

RefInspection/Task
1The heating coil is clean, in good condition, and the fins are undamaged
2Ensure that the pipework connection is the correct size
3Ensure that the flow and return pipework handings are correct. [Water Inlet – downstream of the airflow direction Water Outlet – upstream of the airflow direction]
4The installation of the pipework will not put stress on the equipment connections or create vibrations.
5The materials used between the equipment and the heating water system will not cause Electrolysis.
6Pipework that is to connect to the unit has been weld tested.
7Pipework that is to connect to the unit has been pressure tested.
8Pipework that is to connect to the unit has been cleaned and flushed.
9Equipment has been backflushed.
10The system has been bled and air removed.
11The heating water system has been hydraulically balanced.
12Pipework is insulated and vapor sealed
13Insulation is labeled
14All pressure gauges installed, and display scale as per design requirements.
15All valves/control valves are installed and in the correct direction
16All commissioning devices are installed

🟧 Refrigerant Dx Coil System

RefInspection/Task
1The refrigerant coil is clean, in good condition, and fins are undamaged
2External condenser installed
3Ensure that the gas and suction pipework is connected and the correct size
4Ensure that the gas and suction pipework handings are correct.
5The installation of the pipework will not put stress on the equipment connections or create vibrations.
6The materials used between the equipment and the refrigeration pipework system will not cause Electrolysis.
7Pipework that is to connect to the unit has been pressure/vacuum tested.
8The system is charged with the correct amount of refrigerant.
9Pipework is insulated and vapor sealed
10Insulation is labeled
11All solenoids installed and operating
12All sight glasses installed
13All valves/control valves are installed and in correct direction

🟧 Droplet Eliminator

RefInspection/Task
1Ensure is unobstructed and can be removed for maintenance/cleaning.
2All pipework/condensate is connected to the drain [see condensate section]

🟧 Steam Humidifier

RefInspection/Task
1Unit is electrically connected with testing completed to electrical components.
2Humidifier internals is clean and clear of debris.
3Condensate pipework is installed [see condensate section].
4Coldwater feed is connected to the humidifier standalone unit.
5Connections between the standalone unit and the humidifier are using the specific manufacturer’s hoses
6The hoses and pipework that is connected are installed in line with the manufacturer’s requirements. No tight bends, or kinks.
7Metal clamps are used to connect the pipework between the humidifier and the standalone unit.
8Controls valves fitted and operating to allow cold water into the system.
9Check that the humidity sensor is calibrated.

🟧 Cold Water Feed

RefInspection/Task
1Pipework pressure tested
2Pipework insulated and vapor sealed
3All valves fitted and operating [isolation, non-return]

🟧 Condensate drain/siphon

RefInspection/Task
1The condensate is installed to the correct fall.
2Ensure is protected from any frost with insulation and/or heating cable.
3There is a trap installed and is installed in line with manufacturers’ requirements. [Check manufacturer’s instructions for calculation/requirements]
4If there are multiple coils installed on a unit, ensure the condensate pipework configuration is installed in line with the manufacturer’s requirements.
5Check that the size of the condensate is correct.
6Ensure the trap is filled to the correct level.
7Ensure the drain pan is clean and free of debris

🟧 Electric Heater

RefInspection/Task
1Operation of the heating coil is fan controlled/interlocked
2Fan delay incorporated into the controls logic, allowing the fan to run [15 mins] after the heater has deactivated/switched off.
3Heater elements are clean and not obstructed by debris
4All electrical testing was completed including torque tests of connections.
5All safety components are connected and operational including all thermostats to cut power to the heater if needed.
6All controls cabling is connected and installed in line with the manufacturers/design drawings.
7Power is available to the electric heater/control panel for operation.

🟧 Supply Air Ductwork

RefInspection/Task
1All supply air ductwork is installed, correct size, and connected to the unit with correct fixings
2All attenuators are installed as shown on the drawings.
3All volume control dampers are installed as per construction drawings.
4Ductwork insulated and vapor seal in line with the specification.
5Test holes available in the duct to allow air readings
🔗To see our Fire Damper Checklist, see our article: 'FIRE DAMPER | Pre-Commissioning Checklist'

🟧 Return Air Ductwork

RefInspection/Task
1The position of the extract louver is in line with the design requirements and positioned so as will not affect the fresh air intake.
2Weather louver/roof cowl installed and weather tight with relevant mesh and is unobstructed.
3Weather louver installed with correct mesh.
4Weather louver mesh-free area meets the design requirements
5Plenum installed connecting the louver to the ducting.
6Plenum has access hatch/s installed to allow future maintenance and inspections
7All extract air ductwork is installed, correct size, and connected to the unit with correct fixings
8All attenuators are installed as shown on the drawings.
9All non-return dampers are installed as per construction drawings.
10All volume control dampers are installed as per construction drawings.
11Ductwork insulated and vapor seal in line with the specification.
12Test holes available in the duct to allow air readings

🟧 Return Air Fan

RefInspection/Task
1Electrical connections and cables are complete, fully tested, and torqued in line with project/manufacturer requirements
2Motor protection installed and operating [Overload]
3Motor protections calibrated
4Voltage from electrical systems is correct for the unit requirements [within +/-10%]
5The fan housing is clean and dust-free
6Fan, blades, and motors are clean and dust-free.
7Fan belt tension is correct
8Fan belt condition is good
9Ensure the fan wheel is centered on the intake section
10Check the tightness of fixings [torque]
11Check flexible connections between the motor/impeller and unit to ensure are in good condition and leak-free.
12Impeller is balanced
13Fan/motor rotates in the correct direction with no obstructions [by hand]
14Fan/motor rotates in the correct direction with no obstructions [electrically bump unit on]

🟧 Heat Recovery Unit

🟨 Plate Heat Exchanger

RefInspection/Task
1Electrical connections and cables are complete, fully tested, and torqued in line with project/manufacturer requirements
2Condensate is connected where required.
3Components are clean and undamaged
4Ensure any bypass dampers can operate correctly and are not obstructed.
5Ensure any pressure and temperature sensors are calibrated.

🟨 Thermal Wheel

RefInspection/Task
1Electrical connections and cables are complete, fully tested, and torqued in line with project/manufacturer requirements
2Condensate is connected where required.
3Components are clean and undamaged
4The wheel is able to turn without being obstructed
5Belts are tight
6Motor alignment is correct
7Ensure any pressure and temperature sensors are calibrated.

🟧 Extract Air Ductwork

RefInspection/Task
1All return air ductwork is installed, correct size, and connected to the unit with correct fixings
2All attenuators are installed as shown on the drawings.
3All non-return dampers are installed as per construction drawings.
4All volume control dampers are installed as per construction drawings.
5Ductwork insulated and vapor seal in line with the specification.
6Test holes available in the duct to allow air readings

🟧 Controls

RefInspection/Task
1Ensure all sensors and instruments are installed as per the control logic/manufacturers wiring drawings  
2All sensors are calibrated

⬜ Air Handling Unit Commissioning Checklist [PDF] & [.doc]

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⬜ AHU [Air Handling Unit] Pre-Functional Checklist [Microsoft Word]

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