Installation Testing and Comm of Chem Dos System

ABU DHABI FUTURE SCHOOL PROGRAM PHASE -2 PACKAGE 4 Method StatementMethod Statement for installation, testing and commissioning of Chilled Water System.

ClientAbu Dhabi Education Council

ConsultantDeewan Architects and Engineers

ContractorUnited Engineering Construction

Issued on19th September , 2013

Reference Number:ASEM-MTST-AC-06 REV01

METHOD STATEMENT FOR INSTALLATION, TESTING AND COMMISSIONING OF CHILLED WATER SYSTEM

TABLE OF CONTENTS

1. Purpose2. Scope3. Legislation and Code of Practice4. Reference5. Definitions6. Resources 6.1. Equipment 6.2. Safety of Equipment’s7. Safety Precautions 7.1. Construction Hazards 7.2. Personal Protective Equipment 7.3. Safety Training and Emergency procedures 7.4. First Aid8.Detailed Construction Sequence (Methodology) 8.1. Procedure9.Construction Program 9.1 Housekeeping 9.2 Protection of Executed Works 9.3 Responsibilities 9.4 Records10.Inspection and Testing11.Related Forms12.Attachments

ASEM-MTST-AC-03 Rev.0 Page 2 of 11


1. Purpose

This document describes the methodology and procedure of installation, testing and commissioning of Chilled water system for Abu Dhabi Future School Program Package-2, Phase 4 Project, and to ensure that all concerned persons are familiar with the sequence of activities, utilization of resources, and execution of the works in compliance with applicable Safety and Quality Procedures, and Project Documents and Specification.

2. Scope of Works

This document covers the following scope of works:

This method statement is intended to outline the activities and the methods used installation, testing and commissioning of Chilled water system. All activities will be carried out in accordance with the contract details and in full compliance to the Contract Specifications and Documents. All work within the rights-of-way of the standards and specifications will be done in compliance with requirements issued by authorities.

3. Legislation and Code of Practice

All related codes and standards referenced in the Contract Specification part E section 23 72 00.

4. Reference

Contract Specification Part- E section 21 05 00 clause 3.11. Contract Specification Part- E section 22 12 00 clause 2.4. Contract Specification Part- E section 22 08 00 clause 2.4.2. Approved Shop Drawings.

5. Definitions

Client : Abu Dhabi Education CouncilConsultants : Deewan Architects and EngineersContractor : United Engineering Construction L.L.C

6. Resources

6.1. Equipment / Tools

DESCRIPTION

Grinding/Cutting Machine Drill machine Crane Supports, anti-vibration rubber pads Nuts, bolt, gaskets, bolts Valves

6.2 Safety of Equipment’s

Necessary measures will be taken for the safety of the equipment and any other works affected by the works subject of this document. Relevant entities which might require protection include any such works in the vicinity of the area of work or on the service access or discharge path.The construction team will ensure that any such requirements are documented.



7. Health, Safety & the Environment7.1 Construction Hazards (tick as appropriate)

Corrosive OxidizingHighly

flammableExtremely flammable

Toxic Highly Toxic Irritating Harmful

Explosive Danger for the Environment

Constrained Space

Slippery Surface

Danger of Electrocution

Falling from Height

Other

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The hazards identified above will be controlled under the overall Project Safety Plan which is a separate document communicated to all parties on the project.

7.2. Personal Protective Equipment (tick as appropriate)

The works subject of this document requires that the following PPE be used:

Safety Precaution

Helmet Hi-VizEye

ProtectionFace

ProtectionMask

RequiredRespirator Required

Ear Protection

Gloves

RequiredSafety Shoes

RequiredProtective Clothing

Safety Harness

Equipment Guards

Lifejacket Other

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7.3. Safety Training and Emergency procedures

Before commencing any works, all employees will attend a site safety induction training to ensure all safety measures are understood and implemented and to cover specific procedures in case of emergency. If necessary, practical training exercises will be conducted on escape routes, signage, evacuation and rescue.

7.4. First Aid

Prior to the commencement of work, arrangements will be made for medical facilities and medical personnel to be available from prompt attention to the injured person. The contractor’s vehicle assigned to the job site will be used for transporting the injured person to the first aid station and to the nearest hospital when required.



Name of On-Site First Aider/s:

First Aid Box Location:

Location of Nearest Hospital:

First Aid and Medical Supplies available at site:

Potable Water Ice Cubes

10x6cm Sterile Gauze Pad 4x6cm Gauze Roller Bandage

10x10cm Sterile Gauze Pad 8x10cm Gauze Roller Bandage

Large Sterile Gauze Pad 10x12cm Gauze Roller Bandage

Burn Dressings 5cm Elastic Bandage

7.5cm Elastic Bandage 10cm Elastic Bandage

Triangular Bandage Barrier Device for CPR

Adhesive Skin Tape Adhesive Leucoplast Tape

Emergency Blanket Safety Pins

First Aid Scissors Tweezers

Disposable Gloves Instant Cold PackNon-prescription Medicines (Aspirin, Ibuprofen, Acetaminophen) First Aid and Burn Spray, Deep Heat Spray

8. Detailed Construction Sequence (Methodology)

8.1. Procedure

8.1.1 CHILLED WATER PIPE INSTALLATION:

a) Storage :

i) All material while unloading shall not be dropped, but slowly lowered to the ground.

ii) For pipes, rubber inserts shall be placed for all pipe supports.

iii) Pipes shall be stacked on a flat surface with adequate supports.

iv) All pipes to be capped off and to be removed for installation.

v) Any items found damaged or not suitable as per project requirements shall be removed from site. If required to store temporarily, they shall be clearly marked and stored separately to prevent any advertent use.

b) Preparation :

i) Check and ensure all drawings used for installation are latest and approved for construction.

ii) Mark the pipe routing and support locations in the trench as per approved drawings.

iii) Check the co-ordination of piping layout with other services and decide pipe route with minimum bends/offsets.



iv) Check and ensure sufficient clearance around pipe for applying insulation / cladding as applicable.

v) Clean and apply primer / red oxide on all seamless black pipes.

c) Installation :

i) Drill the holes in walls or slabs (Incas of hollow core slabs holes to be made after approval of hollow core slabs manufacturer) for fixing supports.

ii) Fix the anchors and threaded rods with clevis hangers / structural supports as applicable. Threaded rod length shall be sufficient to allow for levelling of piping.

iii) Cut the pipes accurately to measurements determined at site.

iv) Prepare the pipe ends according to the type of joints i.e. Threaded joints, welded joints .

v) Threading shall be done as per fittings / coupling manufacturer’s recommendations.

vi) End preparations for welded joints shall be done as per approved welding procedure.

vii) After the end preparation clean the pipe ends and ensure no material and dust is left inside.

viii) Qualified and approved welders with certificates shall be engaged for welding works.

ix) Install the pipe sections at heights as per approved drawing in a neat and tidy manner.

x) Insert the rubber inserts between the pipe and support.

xi) Sleeves of suitable sizes shall be provided at wall crossings.

xii) Install the valves in locations as per approved drawings.

xiii) Install the piping connections with valves and accessories wherever equipment’s are installed as per approved drawings and technical specification.

xiv) Fix the blind plugs / temporary valves on all drain, air vent, pressure gauge, thermometer and test points trappings approved drawings.

xv) Check and ensure proper supporting is provided as per approved drawings.

xvi) While installation is going on of the pipe work, the insulation will be fitted to the pipe work. But all fittings and joints will be left exposed until the pressure testing and inspection is completed.

xvii) Raise the inspection for chilled water piping installation to consultant. Obtain signoff for hydraulic pressure testing.

Pressure Testing:

i) The chilled water piping shall be tested according to the system working pressure and PN ratings of the pipes, pipe fitting and valves used in the piping.

ii) The piping may be tested in sections or in total, depending on site requirements.

iii) Estimate the piping volume and make arrangement for required quality of clean water.

iv) Arrange for temporary piping / hose pipe connections for filling and draining the water.



v) Fix the temporary valves at air vent / drain points and pressure gauges.

vi) Fill the piping system with clean water.

vii) If leakages are observed, arrest the leakage immediately. If leakages are major, isolate the leaking portion with nearest isolating valve and / or stop the water filling.

viii) Rectify the leakages and again fill with water.

ix) Ensure no leakages throughout the entire piping system.

x) Observe for the leakages and pressurise the system using hydraulic test pump.

xi) During pressurisation observe the joints and entire piping system for leakages.

xii) Observe the pressure gauges readings for 4 hours and ensure there is no drop in gauge pressure. System pressure to be 1.5 times than the actual working pressure.

8.1.2 METHOD FOR INSULATION OF CHILLED WATER PIPES:

a. PRE INSTALLATION

1. All materials and documentation relevant to a particular section of works will be checked by the Construction Department prior to the commence of work ensuring that these are of the correct type as reviewed by the Client. Before commencement of permanent works, pre-inspections will be carried out on all materials prior to them leaving the storage area.

2. Prior to the commencement of any permanent works, areas and access will be inspected to confirm they are in a suitable condition for permanent works to commence.

b. METHOD FOR INSULATION

a. Site supervisor to be issued with the latest revised construction drawings and signed-off pressure test certificates for the area by the construction department.

b. Site supervisor will requisition approved materials required for the specific installation to be carried out and adhere to the following guide lines.

c. Insulation Schedule. Refer to latest revised construction drawing and technical specification.

d. Supervisor to ensure that there is ample clearance around pipe fittings and plant to enable the e. Care is to be taken that surface sections of the installation to be insulated are free from damage,

surfaces cleaned, painting has been completed, and is not wet or damp.

f. All joints will be wrapped with wide adhesive tape.

g. The Supervisor is to ensure that there is no insulation joints located within sleeves or at hangers.

h. Insulation process has to start after hydraulic testing of water.

i. Pipes to be cleaned and to be ready for insulation.

j. Apply tube insulation over the pipes considering pipe outer diameter and specified thickness.

k. Join the insulation with approved aluminium tape.

l. Apply foster coat as per manufacturer standards, then wrap it with woven glass canvas and apply the second coat of foster. Proper coats of foster to be applied on pipes to avoid any irregularities.



m. Apply water barrier coating wherever it is required according to project specification and requirements.

n. Aluminium cladding (jackets) to be provided where applicable as per technical specification.

o. Insulation of pipes passing through fire barriers are fire resistant and all gaps around will be caulked with fire resistant material.

p. Where sheathing is applied to insulation, the seams will be angled away from view whenever practical.

The supervisor in charge and the QC officer will continuously monitor the activities to ensure that all components indicated on the approved drawings have been installed and that the installation is in accordance with the contract requirements and manufacturers recommendation.

All completed installation work will be protected to avoid damage until final inspection and sign off by the Client.

8.1.3 FLUSHING OF CHILLED WATER PIPING NETWORK:

a) Preparation :

The following preparation checks / works shall be carried out prior to commencement of flushing and cleaning of chilled water system.

i) Check and ensure the system is hydrostatically pressure tested and verify test certificate.

ii) Check the provision of air vents at location as per approved drawings.

iii) Check and ensure sufficient quantities of chemicals are available as per requirement.

iv) Place warning signs and warning tape as required.

b) Flushing & Cleaning:

i) Fill the system with clean water and drain the water after 30 minutes.

ii) Refill the system with clean water and run the chilled water pump for 2 hours.

iii) Open the drain valves in the main lines and drain the water completely.

iv) Clean the strainers

v) During the above flushing process the drain valves shall be kept open while the pump is running, until the water appears clean.

vi) Close all the drain valves

vii) Refill the system with clean water and add cleaning chemicals in required quantities as per Specialist supplier’s instructions.

viii) Samples of solution shall be collected from various parts of the system to ensure the chemical solution has reached all parts of the system.

ix) Run the pump and circulate the water (with chemicals added) for a minimum period of 24 hours as per specialist supplier’s recommendations.



x) Samples to be tested in 3rd party laboratory.

xi) After the cleaning process is completed as described above the cleaning solution shall be flushed out.

xii) The entire system is re-filled with fresh and clean water and treated with corrosion and scale inhibiting treatment chemicals as approved. Specialist contractor shall collect samples and conduct tests until satisfactory results are obtained as required.

c) Inspection:

1 The inspection request shall be raised for Main Contractor and Consultant to witness the flushing and cleaning process.

2 Work Inspection Request (WIR) shall be retained as records.

d) Important Notes:

1. All the process of the chilled water flushing will be done by MEP contractor because of having highlyProfessionals and experienced team for chilled water flushing.

2. Please note that a temporary pump will be used until clear water is achieved, once clear water is achieved after several draining of the system then the chemical will be added in water then the permanent chilled water pump will be on for the circulation.

3. All the flushing will be done as per Technical specification and chemicals in the water shall be added as per approved quantity in material submittals.

8.1.3 INSTALLATION OF CHEMICAL DOSING SYSTEM:

1. Shift the component for auto dosing system to the installation point.

2. Remove the packing and ensure that the system is free from transportation damages.

3. For wall mounted controller panel the exact location of panel and fixing holes to be marked based on approved

shop drawing.

4. Install the dosing tank on the plinth and fix properly.

5. Provide drain point from the dosing tank to the nearest common drain.

6. Mount the dosing pump on top of the dosing tank / wall.

7. Ensure that the suction valve of the dosing pump and the flexible tubing are in straight position.

8- Install the low-level switch in the dosing tank as per supplier recommendation.

8. Install the conductivity probe in a bypass loop across the return and supply header.

9. Ensure that the probe in continuous contact with moving water.

10. Ensure that the probe Tip does not touch any metal parts.

11. Provide valves across the bypass loop in order to isolate the loop and take the probe for cleaning.

12. Provide one separate ½” taping in the suction or return header for injection point of scale & corrosion inhibitor

dosing system.

13. Provide valves in these tapings for removing the injection valves for maintenance.

14. Tighten all connection as required.

15. Check and adequate space is available for maintenance.



16. Inspection request shall be raised for the consultant inspection.

8.1.4 TESTING AND COMMISSIONING OF CHEMICAL DOSING SYSTEM:

1. Check installation of auto dosing system.

2. Check availability of power.

3. Check electrical connection to the dosing pump and conductivity controller.

4. Fill the dosing tank up to 50 liter mark with clean potable water.

5. Remove the discharge pipe of the dosing pump.

6. Give power to the system and prime the pump.

7. Connect the discharge end and make sure the suction and delivery tubes are kept straight.

8. Check installation of the conductivity controller.

9. Check if the conductivity probe is properly installed and in contact with the system water.

11. Supply power to the conductivity controller.

12. Set conductivity of the controller (based on water analysis).

13. Cross check with a manual conductivity meter the conductivity shown in the controller.

14. Switch the dosing pump to auto mode.

15. The dosing pump will start injecting chemicals if the value is below the conductivity set point.

16. Fill the dosing tank with the recommended chemicals.

9. Construction Program

As per main program

9.1 Housekeeping

The work area shall be maintained neat and tidy as reasonable practical at all times.

9.2 Protection of Executed Works

Executed works in areas were other works are still being carried out shall be protected as per the contract requirements.

9.3 Responsibilities

PositionOverall Resp. Supervise Perform Short Description

Project Manager Construction Manager Project Engineer Site Manager Site Engineer Land Surveyor Safety Engineer QA/QC Engineer MEP Coordinator General Foreman Foreman Charge hand



Labourer Helper

9.4 Records

In accordance with the Quality Management System, the following records will be maintained as documentary evidence of the establishment of this method statement:

Records to be retained Responsibility Minimum Retention Period

Disposition

Work Notification( If required)

Site Manager As per ContractRequirements

Request for Inspection( RIW )

QA/QC Engineer As per ContractRequirements

10. Inspection and Testing

In Process works shall be monitored for quality of workmanship and fabrication against approved shop drawings and standards by the relevant supervisor.

All works shall be inspected for conformance to specification. The inspection formats shall be used in accordance with the requirements of the main contractor UNEC. Raise the inspection for installation, testing and commissioning of chilled water systems.

11. Related Forms

As per required forms

12. Attachments

Risk Assessment


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