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Chiller installation method statement

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Met hod St at ement s Chiller inst allat ion met hod st at ement

Chiller installation method statement

March 17, 2014 | webmast er

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Below is a standard operating procedure which can

be used a a method statement for installation of
chillers on its foundation after it is delivered on the
sites. Before starting the activity of chiller installation
following tools/equipment shall be arranged:
Tool Box.
Lifting Equipment (Cranes)

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method statement
1/5

9/7/2014

Chiller installation method statement

March 14th, 2014
Below is a standard m ethod statem ent
which can be used as learning purpose and
to prepare further pr[...]

General Requirements
All the materials received at site shall be as per the approved technical material submittal for

METHOD STATEMENT FOR

INSTALLATION, TESTING AND
COMMISSIONING OF UPS

Chillers to be inspected upon receipt & approved by the engineer prior in proceeding with the
installation. Any discrepancies, damages etc., should be reported to the supplier for rectification

March 14th, 2014

1.0. PURPOSE: The purpose of this m ethod
statem ent defines the procedure to be
followed for Insta[...]

or replacement& to be removed from site immediately.

All construction preliminary inspection/testing works shall be carried out in accordance with the
specifications & to be done by qualified Mechanical Engineers and shall be checked and

METHOD STATEMENT FOR R.C.C.

COLUMNS AND SHEAR WALLS
CONSTRUCTION

approved by MEP Subcontractor Construction Manager along with QA/QC Engineer.

Material Transport/ Delivery

March 12th, 2014

Below is a general m ethod statem ent for
illustrative purpose, there shall be different
values for di[...]

Chillers are normally shipped & dispatched from factory as a hermetically assembled package,
factory piped, wired and tested. All openings except for the water box vent & drain holes are
covered or plugged to prevent contamination during shipment & handling.
Special care must be taken to ensure that units are offloaded from containers. Rough handling

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can result in damage to the unit.

Use appropriate type of vehicles in transporting the units and that they are protected against

BMS

mechanical & weather damage.

Cem ent & Clinker Testing

As soon as the units arrived at site, raise immediate inspection to the consultant & inspect

Civil Engineering

thoroughly for damage. Hence, in case of transit damage, supplier/ manufacturer must be

Civil Method Statem ents

informed immediately.

Concrete Testing

Ensure that the units have been inspected & accepted by the consultant as per the approved

Construction Method Statem ents

material submittal prior to offloading & site storage.

Drainage Pipes Installation

Storage on Site Store

Ensure that the storage location of the units has solid foundation, vibration free, dry, &
temperature range shall be -40F to 158F.
It is much recommended not to remove the plastic coverings or packaging materials during the
delivery to avoid any corrosion & deterioration.
Avoid any mechanical shocks and strokes during handling operations.
All packages for the equipment reaching the site shall be identified as per package list.

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Sequence of Installation for Chillers

Method Statem ent Tem plate

Method Statem ents

The entire assembly of the Water Cooled Centrifugal Chillers will be rigged from store to place of

Piping Method Statem ents

installation i.e. roof etc. Refer to Manufacturers Instruction Manual for rigging instructions for the

Piping Works

Chiller.

Plum bing Method Statem ents

All site safety rules & regulations shall be complied.

Pressure Testing

Supervisors will deliver tool box talks, relevant to these activities to all operatives involved in the

Project HSE Plan

installation and shall be recorded.

Pum p Installation

All operatives will be equipped with minimum personnel protective equipment; hard hat,

Quality Assurance

coveralls, safety boots, safety glasses.

Quality Managem ent

The persons using cleaning fluid, solvent cement& any other forms of chemicals have to wear

Risk

hand gloves.

Risk Assessm ent

Ensure only qualified personnel shall install, test & commissioned the equipment.

Risk Managem ent

During installation, display warning sign boards to be provided and barricade the area

Sam ple Form s & Form ats

whenever necessary. Close monitoring by the site engineers during installation is much highly

Tem plates

recommended.

Testing & Com m issioning

Only competent, experienced & trained personnel shall perform all the required activities stated

Water Supply Piping

in this method statement.

Welding Risk

Ensure that all operatives fully understand the method of these activities.

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Chiller installation method statement

Preliminary Checks Before Chiller Installation

Before commencement of Installation activity, the supervisor/ engineer must ensure that:

Working At Height

TAGS

All Installations & Pressure Testing of Pipe/ Duct works have been completed & approved by the

& Access Cont rol Syst em Accessories AC Duct ing

consultant.

Met hod St at ement ac duct inst allat ion AC

Determine whether the units occur damages during the storage & shifting of location.
Permission to start or Civil Clearances prior to installation has been given by the main
contractor.
All relevant Approved Shop drawings for the installation of the equipment shall be available &
approved by the consultant.
Installation activities shall only commence when all associated works by the Civil has been
completed.
Safe access shall be provided by the Main Contractor thru Work Permit in coordination with the
Safety in charge at site.

Maintenance Acoust ic Lining blank performa

blank proforma bms system BMS Testing
Procedure Building Management System
Building Management System BMS control

measures Electrical Method Statement for

hazard hvac HVAC Method Statements
inst allat ion Installation of GI Conduits &
Accessories

method Method

Of Statement Method

Statement met hod

st at ement for Inst allat ion Met hod
St at ement Templat e MST MST For BMS

of pipe flushing pressure pumps risk Risk

General Installation Procedures for Chillers

Assessment safe work method sample

check list sample checksheet Sample

Prior to moving the chillers at site, ensure that the foundation requirements have been done.
Foundation details & requirements for the chillers shall be as per approved shop drawings or as
recommended by the manufacturer as follows:
1. Rigid non-warping mounting pads or a concrete foundation is available prior to shifting chillers
at site.

statement

Format Electrical
swms
template test Testing & Commissioning
Testing & Commissioning Method
Statement water
DOWNLOAD METHOD STATEMENTS

2. Ensure that the foundation will be able to support the chiller at its full operating weight.
3. For proper unit operation, the chiller must be level within 1.6mm over its length & width when set
into place on the mounting surface.
After ensuring that the foundations for the chillers are satisfactory, shift the chillers by means of
cranes to its exact location.
Ensure that the lifting cables are capable of supporting the entire weight of the chiller. Failure to
properly lift the unit could result to serious injuries & damage of the unit.
System evacuation, dehydration and charging with refrigerant shall be carried out by skilled &
experienced personnel only.
Ensure isolator pads or spring isolators are available in the chiller feet/ legs prior to lowering the
unit to its foundation.
Ensure that all piping connected to the chiller must be properly isolated & supported so that it
does not place any stress on the unit.
It is much recommended to avoid piping from 3 feet minimum to the equipment to allow
proper fit-up upon arrival of the unit at job site.
Pipe the evaporator into the chilled water circuit.
Pipe the condenser into the cooling tower water circuit.
Locate pressure gauge taps in a straight length of pipe. Place tap a minimum of one pipe
diameter downstream of any elbow, orifice, etc.
Install air vents & drain valves on the water boxes. Each water box is provided with 3/4 NPTF

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(National Pipe Thread Female) vent & drain connection. Plastic plugs are factory installed in
both openings. Remove & discard the same before installing the water box vents & drain valves.

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Install pressure relief valves in the condenser & evaporator water circuits to avoid water box

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damage due to hydro-static expansion.

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Whenever are applicable, install pressure relief valves at the drain connections on the
evaporator and condenser water boxes.
Install a strainer in the entering side of each piping circuit to avoid possible tube plugging in the

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9/7/2014

Chiller installation method statement

chiller with debris.

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Install flow sensing device. Use either flow switches or differential pressure switches in conjunction

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with the pump interlocks to verify evaporator and condenser water flows.
Install by pass valve system to avoid circulating water through the auxiliary shell when the unit is
shut down.
Pipe the evaporator & condenser as per the approved shop drawings. Ensure that the correct
pipe sizes are to be connected to the evaporator & condenser circuit.
Ensure that the evaporator water piping is clear; check if the chilled water pump is operated
but before initial chiller start-up. If any partial blockages exists removed the same to prevent for
possible tube damage resulting from evaporator freeze-up or erosion.
For condenser & large evaporator connections, arrange the water piping so that the water
supply enters the shell at the lower connection, and exists from the top connection.
Units shall use grooved- pipe connections and flanged connections for 300 psi water boxes, use
welded flanges.
Piping joined using grooved type couplings, like all types of piping systems; require proper
support system to carry out the weight of the pipes & equipment.
Ensure that system refrigerant differential pressure must be maintained above 21 kpa at all times.
Failure to do so could result in operating problems.
Ensure that the discharge piping that allows pressure relief devices to safely vent refrigerant to
the atmosphere if over pressure occurs.
Make sure that the minimum pipe size for the vent must be equals the size of the discharge
connections on the pressure relief device.
When connecting the vent line to the chiller do not apply threading torque to the outside pipe.
If the unit is not factory insulated, install insulation around the evaporator bulb wells and ensure
that the bulb wells and connections for the water box drains and vents are still accessible after
insulation is applied. Ensure that the sensor modules and interconnecting four wire cables must
be raised up above the field installed insulation. Do not insulate over the wiring or sensor
device. Insulation shall be as per approved material submittal.
Install the controller hardware/ equipment which are used to interface with the internal chiller
data & functions provide by the controls. Note that there are four connections on the controller
that support the communication interface.
Install the control panel & ensure low voltage & high voltage areas are in proper route & field
wiring.
Install the display. The display is boxed and shrink-wrapped behind the control panel during the
shipment. Follow the procedure for installation of display as follows
Unwrap control panel & display arm.
Plug the power cable and the Ethernet cable into the bottom of the display.
Adjust the display support arm so the base plate that attaches to the display is horizontal.
Position the display with the LCD screen facing up, on top of the display support arm base plate.
Align the four holes in the display support arm base plate.
Attach the display to the display support arm base plate.
Ensure all Electrical requirements have been wired & connected as follows:
Power supply wiring to the starter
Starter to motor wiring
Starter to control panel wiring
System Control Circuit wiring
Water pump interlock circuits & flow switches & other devices.
Temperature Sensor circuits
Other unit control options present
Any field supplied control devices
Ensure that all wires & cables are of the correct sizes as voltage/ampere requirements of the
units.
After installation of the chillers, raise inspection to the consultant for acceptance prior to

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9/7/2014

Chiller installation method statement

proceeding with testing & commissioning.

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Filed under HVAC Met hod St at ement s, Met hod St at ement s | Tags: Chiller, Chiller inst allat ion met hod st at ement ,
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