METHOD STATEMENT

SUBMITTAL
(MSS)

Project: A100-APOLLO DATA CENTER PROJECT

Client/Client Consultant: PIVOT / SUDLOWS

METHOD STATEMENT SUBMITTAL

FOR
START-UP COMMISSIONING OF AIR COOLED CHILLERS

Method Statement Submittal No: HWI-APO3-ME-MSS-0001-01

Rev. Checked Checked
Date Description Prepared Approved
No. Technical Safety
START-UP
00 26-11-24 COMMISSIONING OF AIR M/s Daikin REEFTECH Manu
COOLED CHILLERS

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TABLE OF CONTENTS
1. TESTING AND COMMISSIONING OF AIR COOLED CHILLERS...................... ...........3
1.1 Introduction......................................................................................................................3
2. SCOPE OF WORKS...............................................................................................................3
2.1 General Description.......................................................................................................3
2.2 Plant & Equipment Operations......................................................................................5
2.3 Materials & Tools..........................................................................................................5
2.4 Design Data...................................................................................................................6
2.5 Plan for Start-up commissioning...................................................................................8
2.6 Pre-requisites for start-ups............................................................................................9
2.7 Electrical Pre-Start Checks for Chillers.......................................................................10
2.8 Pre-Commissioning for controller...............................................................................11
2.9 Compressor commissioning procedure.......................................................................11
2.10 Chiller Load Testing Procedure...................................................................................11
2.11 Chiller Safety Test at Site............................................................................................12
3. JOB WRAP UP....................................................................................................................13
4. SAFETY AND HEALTH
ISSUES......................................................................................13
A. HSSE Risk Assessment................................................................................................13
B. Protective and Safety Equipment.................................................................................13
C. Information to Personnel..............................................................................................13
D. Emergency Procedure..................................................................................................13
5. SAFETY AND HEALTH
ISSUES......................................................................................14
A. Permit Requirements....................................................................................................14
B. Contractual Requirements............................................................................................14
6. QUALITY ASSURANCE..................................................................................................14
A. Inspection and Testing.................................................................................................14
B. Follow Up and Evaluation............................................................................................14
7. APPENDICES.....................................................................................................................15
A. Equipment Schedule.....................................................................................................15
B. Installation and Pre-commissioning check list.............................................................15
C. Power Quality Checklist...............................................................................................15
D. Compliance Statement.................................................................................................15
E. Start-Up Check
Form....................................................................................................15
F. Chiller Test Report Form..............................................................................................15
G. Chiller Safety Test Report............................................................................................15
H. Refrigerant MSDS........................................................................................................15

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I. Chiller maintenance
requirement...................................................................................15
J. Chiller Data Sheets........................................................................................................15
K. Pump Data Sheet..........................................................................................................15
L. HSSC Risk Assessment................................................................................................15

1. TESTING AND COMMISSIONING OF AIR COOLED CHILLERS

1.1 Introduction

The Modular Data Center Complex comprises of Air Cooled Screw Chillers to supply
chilled water to the Modular Data Center. Proposed stand-alone Chiller will monitor
and control the enclosed primary pumps along with the associated flow switches
supplied loose and installed locally.

 Air Cooled Screw Chillers- 04 Nos for POD-5. Model : EWAD980C-PS

 Vertical Inline Primary Chilled water pump 4 Nos: Wilo - IL 100/260-11/4
 Air Cooled Screw Chillers- 04 Nos for POD-6. Model : EWAD980C-PS
 Vertical Inline Primary Chilled water pump 04 Nos: Wilo - IL 100/260-11/4

The purpose of generating this method statement is to define the procedure to

implement the correct practices for Start-up, and Testing & Commissioning of Air Cooled
Chillers through the guidelines contained here to ensure that the job execution complies
with the requirements and serves the intended function to satisfactory level.

Employer Details :Pivot Asset Holding LLC.

Client Consultant :SUDLOWS
Design & Build Contractor :Huawei
Site Consultant :Ace International Consulting
Manufacture & Supplier :M/s Daikin
MEP Contractor :Laith Electro Mechanical

A work programme will be completed before commencement of works. The work

programme will identify the following which are therefore not part of this method
statement.

2. SCOPE OF WORKS

2.1 General Description

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This Method Statement covers all processes related to start up testing and Commissioning of
standalone Air cooled chillers. The Scope of Testing and Commissioning of the chiller shall be in
line with SECTION 23 64 26.13 Clause 3.4 and in accordance to detailed Method Statement.

Note:
 The sequence of plant operation and testing methods will be provided by PLC plant
manager manufacture supplier (Siemens).
 The Site Heat/Cooling Load testing shall be part integrated testing methods and
reports.
 Pump performance report shall be part of check list and water balance testing method
of statements. Pump start up required only covered by this documents.
 The water / power termination and quality report shall be part of relevant testing
methods of statements.

Supervision of installation & start up, testing & Commissioning of chillers point of contacts.

CHILLER SUPPLIER – CONTACT PERSONNEL

Project Manager Mallikarjun Chilal 056 53 40 252
Technical Supervisor Mayank Bhatia 056 179 74 98
Project Engineer Muhammad Fahim 056 401 26 49
Site Technical Mechanical Mayank Bhatia 056 179 74 98
& Electrical
Control System Technical Arvind Kumar / Atul 050 556 1706
Chauhan

The number of units to be commissioned is listed in equipment schedule APPENDIX-A

Verification of chiller installation provided in APPENDIX-B (Chiller Installation / Pre-
Commissioning Checklist) & APPENDIX-C (Power Quality Guideline) shall be duly filled
and signed by the site MEP contractor/client and forwarded to M/s Daikin as a pre
requisite for initial chiller start-up.

M/s Daikin shall provide a factory-trained representative to perform the following

services.

1. Check and record operational parameters for chiller & its possible protection
devices checks.
2. Operate chiller for run-in period.
3. Sign off and submission of final start-up and commissioning report of the chillers
4. Supervision and support for PLC integrations, Site Acceptance Test and
integrated System Acceptance Test.
5. Operations and maintenance training of owner’s maintenance personnel.

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6. Prepare and submission of Operations and Maintenance manuals/documents

relevant to the stand alone chiller.

2.2 Plant & Equipment operation

Chiller Plant Operation shall be consisting of the below:

 Chillers: Compressors Stage up and stage down are based on the built in chiller water
leaving & entering set points / reading.
 Pumps: Chilled Water Pumps will run as soon as the Chiller is enabled manually of
remotely
 And when the flow is verified through flow switch connected to the chiller, the
equipment will start running to maintain the set points water temp.

The entire plant operation (monitoring & controlling) can be carried out by the PL C located in
the chiller plant room / pump room (supplied, installed and commissioned by others).

Dual interface provision has been considered to enable monitoring of the Chiller Plant from
Building Management / PLC System. The plant data is communicated to BMS system via
Modbus RTU Gateway as per the data points described in APPENDIX-M (Refer for AWS Model).

Installation of peripherals devices and associated cabling work will be carried out by the MEP
contractor.

2.3 Materials and Tools

The following special tools will be used to carrying out start-up and commissioning of water
cooled chillers. Please refer to APPENDIX-N for calibration certificates of each tool.

 Pressure gauge
 Digital thermometer
 Digital vacuum gauge
 Digital Multi-Meter Torque wrench
 Insulation Tester (megger)
 General Hand tool

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2.4 Design Data

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2.5 Plan for Start Up Commissioning

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2.6 Pre-requisites for start-ups

 Ensure the shop drawings/schedules are in hand.

 Ensure the installation of equipment is complete.
 Ensure all HSE precautions have been met and complied with prior to commencement
of testing.
 Mechanical piping including chilled water, make-up & fill lines, refrigerant relief piping
(if necessary) must be inspected for any damages or incorrect connections.
 Ensure the following is defect free prior to commencing:
 Check the chiller foundation and ensure follow recommendations.
 Check area around the foundation and ensure service access to unit from all sides as
recommended in IOM comes with unit.
 Place the spring isolator depending upon unit weight able to absorb vibration without
compression. (Refer GA installation for location & weight distribution)
 Ensure chilled water piping is completed & field devices are installed as per IOM
 Chilled water chemical treatment has been carried out & matches Daikin
recommendation listed below:

Parameters Acceptable Range

Ph 9.0 to 10.5
TDS < 1500 PPM
Conductivity << 2250 µs / cm
Total Iron < 1.0 PPM
Suspended Solid < 20 PPM
Nitrite as sodium nitrite (ppm as NaNO2) 600 – 1200
Appearance Clear

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 Other supported equipment like pump, chemical dosing, make up water unit etc.
should be commissioned prior to chiller commissioning

2.7 Electrical Pre-Start Checks for Chillers

 Visual checks of electrical & control parts for damage. (If damage replace/repair)
 Tightness of cables in electrical should be checked if any loose connection]. Disengage
compressor fuses Open refrigerant valves viz, suction, liquid, discharge, liquid line
valve.
 Flow switch wiring & other field device fixed refer electrical wiring diagram came along
with unit.
 Phase to Earth’ and ‘Phase to Phase’ megger value shall not be less than 20 mega-
ohms.
 A suitable megger of 500V shall be used to carry out the test. (For 400V rated
equipment only, for equipment of MV & HV suitable megger value shall be used)

NOTE: After performing the tests specified above, discharge the

residual voltage stored in the winding by ear thing all the six motor
terminals momentarily using an electric wire. Continuity should be
measured between winding terminals. Turn on power measure
incoming voltage which should be in tolerance of ±10% of design
voltage for equipment & unbalance ≤2%.

 Verify phase rotation should be clockwise, if not rectification should be made.

 Check that all accessories and/or loose items have been fitted.
 Check site wiring corresponds to DAIKIN wiring diagram without exception.
 Compressor contactor wires may be removed to run control check prior to start-up if
judged necessary.
 Check circuit breaker settings to DAIKIN drawing.
 Check compressor motor overloads are set to motor FLA
 Check Starter Settings.
 Check control circuit for proper interlocks or jumpers for testing on auxiliary circuits in
accordance with wiring diagrams
 Check MCC panel contactors for correct sequence and settings. Proper settings shall be
applied on the contactor in the MCC panel. Under MEP Contractor scope
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 Turn on supply to unit, both 3 phase and control circuit (if required).
 Energize motor and check for correct direction before coupling compressor.
 Record revision of software in Micro panel.

2.8 Pre-Commissioning for controller

A. Controller programming to be done and parameters to be set as per job specific as per
design data provided above.
B. Manual control test: Put controller in manual mode and verify operations of:
 Condenser fan motor
 Loading & unloading solenoid coil
 Measure heater ampere
 Software settings for the Chiller
2.9 Commissioning procedure
a) Ensure that all the pre-start up checks are carried out successfully.
b) Engage the compressor fuses
c) Start the compressor and record compressor ampere, oil level and operational
parameters.
d) Record all readings in the final performance check list. (APPENDIX- F)
2.10 Chiller Load Testing Procedure
Refer to integrated testing method of statements for chiller load testing. All chiller
performance will be recorded by Daikin representative in accordance with iSAT originator
requirement. And shall be handed over to the concerned duly signed.

2.11 Chiller Safety Tests at Site

Chillers for this project will be tested for below safety tests at site.

A. High Pressure Alarm test.

The scope is to test the high-pressure alarm in built in the Chiller / Chiller control panel. To
build high pressure in the condenser section, the fans on the condensers are manually
switched off from the control panel. Pressure will build up in the condenser which will be
reflected in the microtech panel. Once the pressure reaches the high pressure cut out

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pressure, the alarm will be activated and chiller will trip due to high pressure. The microtech
will reflect the error code.

B. Low Pressure Alarm test.

The scope is to test the low-pressure alarm in built in the Chiller / Chiller control panel. To
build low pressure the liquid line valve to the evaporator is closed, the evaporator pressure will
start decreasing. The alarm will be activated and chiller will trip due to low pressure at the
low pressure cut out pressure. The microtech will reflect the error code.

C. Loss of flow test.

The scope is to test the “loss of flow” or “no flow safety” of chiller. Once the chiller is running
smoothly, the water flow to the chiller is manually stopped via the pumps. The chiller will
sense “no flow “via the flow switch located across the evaporator line. The alarm will be raised
and chiller will be “OFF” due to loss of flow. The microtech panel will reflect the error code.

D. Rapid Restart Test

Scope is to verify the performance of rapid restart feature. During the chiller in operation the
electrical supply upstream the machine is shut down manually by the operator, and then
restored back after few seconds, in order to simulate the power failure. Once the electrical
power comes back and flow is established , the time count starts and the circuit having less
operating hours is expected to start before within 30 sec.

3. JOB WRAP UP

1. Clean up the job site.

2. Job Documentation shall be completed as per the appendices form attached, which
shall be filled and duly signed by all stake holders.

4. SAFETY AND HEALTH ISSUES

A. HSSE Risk Assessment

See Appendix L.

B. Protective & Safety Equipment

 All workers involved shall be equipped with adequate PPE.

C. Information to Personnel
Communication shall be made through:
• Safety Induction
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• START Program
• Tool Box Meeting
• Job Training
• Supervisors / Foremen
• Notices / Memos

D. Emergency Procedures
 First aiders and first aid facilities are available at the site offices / welfare facilities
located at the site office facilities to deal with emergencies on site.
 In the event of an emergency, call the first aider listed at site office / store / Operative
rest area
 Give your name, location and the nature of the accident to the operator. The exact
location will be described on the permit to work.
 Fire points are located at all required areas (refer to the site fire and emergency plan)

Daikin Management Contact List:

Designation NAME Mobile/Land
CHILLER SUPPLIER – CONTACT PERSONNEL
Project Manager Mallikarjun Chillal 056 534 0252
Technical Supervisor Mayank Bhatia 056 179 74 98
Project Engineer Muhammad Fahim 056 401 26 49

5. SAFETY & HEALTH ISSUES

A. Permit Requirements

PTW and JCR approval to be obtain prior to start of any testing and commissioning works.
B. Contractual Requirements

As per site regulations:

 Safety Induction for New Employees
 PPE Requirements
 Inspection of Machinery
 Emergency Procedures
 Welfare Facilities
 First Aid Requirements
 Defensive Drivers Training
6. QUALITY ASSURANCE

A. To follow Quality Requirements (internal monitoring of works).

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B. Inspection & Testing

Testing and inspections performed as described in mater commissioning program.
C. Follow Up & Evaluation
Internal checklists shall be adopted.

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7. APPENDICES

A. Equipment Schedule
B. Installation and pre-commissioning check list.
C. Power Quality Check list,
D. Compliance Statements.
E. Start-up Check Form.
F. Chiller Test Report Form
G. Chiller Safety Test Report
H. Refrigerant MSDS
I. Chiller maintenance requirement
J. Chiller Data Sheets.
K. Pump Data Sheet
L. HSSC Risk Assessment.
M. Data Points
N. Instrument Calibration Certificate
O. Inspection Test Plan (ITP)
P. GA installation details
Q. Run test report and Quality Check Lists of all the Chillers

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