METHOD STATEMENT

Installation of Air Cooled

Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA

Doc. Ref. Rev. Prepared Reviewed Approved
MS Description Date
No. No. By By By
Method Statement for the Installation of Air Cooled BMECO,
MS-ME-001 00 Chillers 5-Sep-14 PMO PMO Head

1   Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA

 TABLE OF CONTENTS
1.0 Introduction

1.1 Purpose.

1.2 Scope

1.3 References

1.4 Definitions

1.5 Responsibilities

2.0 Requirements

2.1 Material Requirements

2.2 Tools / Equipment Requirements

2.3 Manpower Requirements

3.0 Safety

3.1 Safety Procedures

4.0 Procedures

4.1 Handling, Storage, and Transport

4.2 Installation

4.3 Testing

5.0 Quality Control Procedures (QCP)

6.0 Inspection & Test Check Sheets

7.0 Risk Assessment

2  Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
1.0 INTRODUCTION

1.1 PURPOSE:

The purpose of generating this Method Statement is to define the procedure step by step to implement the
correct practices for Installation of Air Cooled Chillers incorporating the contract specifications, drawings,
regulations (specifically PEO’s and the authorities’ having jurisdiction), the approved material manufacturers’
instructions and recommendations as applicable to describes works.

1.2 SCOPE:

This Method Statement is applicable to all activities related to the installation of Air Cooled Chillers. This
limited to the Chillers solely without the incorporation of the associated starters, controls, or required
monitoring points of the BMS. The scope extends to cover all the INSTALLATION works starting from the
handling & Storage up to the pump room readiness for testing & commissioning. The specific testing &
commissioning of the Chillers along with their electrical & Control instruments shall be covered by other
documents.

1.3 REFERENCES:
 Contract Specifications: Section Sec. 22 Part (2)
 Shop Drawings: Drawings No. MH-400, 401.
 Material Submittals: MAR-2.1
 Related Method Statements: MS-ME-002, 007
 International Codes & Standards: ASHRAE, AHRI Standards

1.4 DEFINITIONS:

Client : M/s Private Engineering Office (PEO)

Consultant : M/s Dar Al-handasah (Shair & Partners).

Management : M/s Hill International

Contractor : M/s Al Ali Engineering Co.

Sub Contractor : M/s Bojamhoor Mechanical & Electrical.

QCS : Qatar Construction Specifications (Standard Specifications)

BS : British Standard

EN : European Norm

3  Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
 PM : Project Manager

PE : Project Engineer

ITL : Independent Testing Laboratory

IR : Inspection Request

ITP : Inspection & Test Plan

HSE : Health, Safety & Environment

PPE : Personal Protective Equipment

QC : Quality Control.

BMS : Building Management System

GI : Galvanized Iron

VFD : Variable Frequency Drive.

DB : Distribution Board.

SMDB : Sub Main Distribution Board.

MCC : Motor Control Center

AV : Automatic Air vent

MS : Method Statement

WSD : Workshop Drawings

MAR : Material Approval Request (Submittal)

MIR : Material Inspection Request.

MEP : Mechanical, Electrical, and Plumbing.

1.5 RESPONSIBILITIES:

1.5.1 Project Manager :

Responsible for the overall project. The Project Manager will be based on site and will be responsible for
the Management of the project, both on and off site, through delegation of duties in accordance with the
organization chart and for the effective implementation of the overall Project Management System.

1.5.2 The MEP Coordinator:

4  Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
 Responsible on behalf of The Contractor to coordinate, check and follow up all MEP related sub -
contractors progress and installation works in proper sequence of activities with main contractor to achieve
targeted completion.

1.5.3 MEP Project Manager :

Responsible for the overall MEP Activities of the project. The MEP Project Manager will be based on site
and will be responsible for the Management of the project, both on and off site, through delegation of
duties in accordance with the organization chart and for the effective implementation of the Project
Management System.

1.5.4 MEP Project Engineer:

Responsible for the execution of particular MEP activities (as Applicable to his specialty domain) in
accordance with the Project Specifications, Safety and Approved Method Statement.

1.5.5 The Store keeper:

Shall be responsible for to ensure issuance of materials to the site with reference to Material Inspection
Records (MIR’s) and suitable manner of storing the material as pre the manufacturer recommendation.

2. REQUIREMENTS:

2.1 MATERIAL REQUIREMENTS:

The following list describes the materials required to be abundantly available on site as applicable and
required for the pertinent works to be carried out:

- Air Cooled Chillers.

- Vibration Isolators.
- Steel Angles and Supports.
- Gauges & Thermometers.
- Flanges, & Pipe Fittings.
- Flexible Pipe Connectors.
- Identification tags.
- Nuts, Bolts, and Washers.
- Drop in Anchors.

5  Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
 2.2 TOOLS / EQUIPMENT REQUIREMENTS:

The following list describes the Tools and/or equipment required to be abundantly available on site as
applicable and required for the pertinent works to be carried out:

Tools:
 Heavy duty truck.
 Heavy duty crane.
 Manual Ram / Winch for pull mechanism.
 Lifting slings and shackles.
 Measuring Tapes.
 Spanner Set.
 Spirit Level.

Equipment:

 Cutting Machine.
 Grinder.
 Drilling Machine.
 Mechanical Toolbox

2.3 MANPOWER REQUIREMENTS:

An Adequate number of Pipe Fitters, A/C Technicians, Electricians, and Helpers should be made available
to carry out the works. Each chiller shall be assigned with a minimum of 8 Skilled Technicians and 10 –
12 Helpers. The overall works in the Chiller Yard shall be always overseen by a general supervisor qualified
to implement and fulfill the QA/QC, HSE requirements. The Supervisor shall be responsible to rectify and
amend the works as required.
3. SAFETY:

 All safety precautions for the installation and testing of below grade pipes shall be reviewed and
implemented as per the project safety plan.
 Dust masks, goggles, gloves, safety shoes, helmets, and all PPE shall be worn during all storage &
handling, installation, testing procedures.

6  Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
  Work area should be checked and cleared from any safety hazard prior to starting erection or
installations.
 Work area should be maintained clean and neat throughout all activities duration.
 Any sign of hazard that would come up during activities shall be evaluated according to the attached
risk assessment.
 Proper precautions shall be taken during welding or any other hot application.
 The measures and procedures described in the following Risk Assessment (Section 7 of this documents)
are aiming at reducing the associated activities’ risk and shall be strictly adhered throughout the
installation.

4. PROCEDURES:

4.1 HANDLING, STORAGE, AND TRANSPORT:

HANDLING & STORAGE

 Unit shall be stored and handled in accordance with manufacturer’s instruction.
 The Chillers while unloading shall not be dropped, but slowly lowered to the ground with the help of
mobile/tower crane with proper support as per the manufacturer recommendation.
 When the material delivered / received at site, each Chillers unit shall be checked such as number
of quantities, model number, compressors, motors, evaporators, condensers, refrigerant pipes, etc and
notify supplier of any non compliance. After completion of above concerned, the units kept ready for
QC inspection.
 Ensure that the delivered material NAME PLATE should mentioned the following items such as Model
number, Capacity, Type compressor, Motor Speed, type of refrigerant, ampere rating (Power), and
Country of Origin etc. The chillers capacity, size and weight are shall be as per below mentioned
details.
 Before unloading of chillers any of visible damage must be reported immediately.
 Protective shipping cover in place until the machine is ready to install.
 Ensure that the Chiller original factory performance test certificates shall be submitted before shipment
of chiller.
 Upon satisfactory of QC inspection the chillers shall be stored properly.
 The MIR shall be raised for Company inspection and after completion of inspection the Chillers shall
be stored properly with protective covering.

7  Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
  Store keeper will be responsible for the proper storage and maintenance of records as required.
 Manufacturer’s storage instructions shall be followed for all applicable items.
4.2 INSTALLATION:
Pre-Installation Procedure of Chillers.
 The area in front of accesses to be cleared at ground floor level and to be levelled & compacted.
 Check and ensure that utility building drawing is approved by Company and same will be available
prior to start work at site.
 Check & ensure that the Chillers foundation (Height, Width & Length etc) as per approved builders
work drawing prior to marking the support locations.
 Check the foundation surface and it shall be smooth finish to avoid any dust accumulation.
 Ensure the area around the foundation to access the Chillers from all sides of the unit as per approved
builders work drawing and manufacturer recommendation.
 Mark the support locations as per approved floor coordination drawings in the chillers foundation
slab.
 Ensure that the chillers are inspected and approved MVR by Company as per approved material
submittal.
 Check and ensure that the necessary work permit (Hot & Cold work permit) will be obtained from
the main contractor and safety officer prior to commence of the work at site.
 Ensure that Chiller foundations are concrete and painted prior to the installation.
Chillers Temporary Storage
 For off loading chillers from transportation vehicles by placing a heavy duty crane and then packing
cover are removed to expose the rigging hooking points on the chiller and the chiller are unbolted
from shipping skid, lifting sling are hooked with the help of proper arrangements as per attached
manufacturer’s machine rigging guide drawing. All chillers will be off loaded one by one in temporary
storage area near chiller yard.
 follow manufacturer instruction during the lifting.
Installation of Chillers Support
 After confirmation of the pre-installation details, to start marking the supporting structure in the
foundation as per attached manufacturer recommendation details.
 Level machine by using jacking screw.
 To drill the exact location as marked in the foundation and to fix the jacking screw.
 Carefully wax jacking screw for easy removable from grout.

8  Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
  Grout the base of sole plates and there must be no voids in the grout beneath the plates.
 To remove jacking screws from levelling pads after grout has hardened find attached carrier drawings.
Installation of Chiller on Foundation
 After suitable placing of heavy duty crane near chiller yard area.
 Chiller # 1 will be lifted with heavy duty crane from hooking points on chiller.
 The chiller will be lower down into sole plate on foundation matching with center lines marked on
foundation.
 Similar method to be use to install chiller # 2.
 Pump down unit and chiller panels will be installed as per the location shown in the approved HVAC
foundation drawings.
 Ensure that the electrical power connection shall be done as per approved shop drawing and
manufacturer details.
 Control wiring shall be installed and terminated as per approved shop drawing and manufacturer
details.
 QC inspection shall be carried out as per the installation checklist.
 Inspection Request (IR) shall be raised for the Consultant to installation of chilled water pipes with
all valves and accessories as per approved shop drawings
 After successfully placing of all the chillers equipment are demobilized from the respective area.
MARKING, LABELING, AND IDENTIFICATION
 Proper Identification tags of the Chillers, Valves, Direction of Flow shall be used.
 Color bands shall be used for piping identification (Primary, Secondary) Direction stickers shall
be generally used for the purposes of marking & Identification.
 Distances between marking labels shall be as specified in the contract documents.
5. QUALITY CONTROL PROCEDURES (QCP):

Check installations to ensure that works are carried out as per approved Method statement, approved
shop drawings and agreed quality standards. Below mentioned checks will be performed parallel with
the progress:

Check installations to ensure that the works carried out as per approved method statement,
approved shop drawings and agreed quality standards.

Check materials used are as per approved submittals.

Check all the supports and supporting structures are installed without any deflections.

9  Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
 Check levels, dimensions and location as per approved shop drawings.

Check the location and size of Chillers is coordinated with Other Services.

Ensure all installation are checked and approved by the Consultant Engineer.

Check overall workmanship of finished works.

Check housekeeping, cleaning and protection of works.

On completion of the activity

Ensure inspection requests issued at least 24 hrs prior to inspection.

 Ensure inspection performed as per This Method Statement, and the references and quality
procedures mentioned herein
 Review all documentation for completeness and correctness.
 Ensure ITP or Check Sheet is fully complied and fulfilled.
 Ensure all Test I Inspection certificates available and complete.
 Ensure NCR’s (if any) are closed.

Final Acceptance

All related documents are signed-off and approved as per the instructions, quality assurance, HSE,
and Risk Assessment mentioned herein.

6. INSPECTION & TEST CHECKSHEETS:

The Following Checklist shall serve an inspection & test plan describing the overall procedures followed
and required by the supervising engineer to inspect and test the works done. Fulfilling the below
inspection parameters’ requirements shall be considered acceptable for the approval of the installation
and acceptance of performed works.

10   Method Statement – Installation of Air Cooled Chillers

Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
CHECK SHEET FOR:
Form No. : MS-ME-001
CHECK LIST FOR INSTALLATION OF AIR COOLED CHILLERS Rev- No. : 00

SUB CONTRACTOR CONTRACTOR

Section of Work: Installation of Air Cooled Chillers Location : Chiller Yard - Roof

Checked by Checked by Date

SUB CONTRACTOR CONSULTANT
Sl.No. CHECKS TO BE PERFORMED CONTRACTOR
MEP QA/QC
ENG’G
1. Check that drawings are used for installation are current
and approved.

2. Check that the chillers installed at site are as approved

material submittal and MIR approved, (name plate,
capacity, model no.).

3. Verify the chillers, pump down unit and panels factory

wooden packing is removed prior to installation.

4. Inspect the chillers, pump down unit and accessories are

new and undamaged prior to installation.

5. Verify the civil works/foundations are completed as per

approved drawings and approved by Company prior to
installation of chillers, pump down unit and panels.

6. Ensure that Chiller plinth are complete/painted prior to

installed. Verify the Chiller support is installed as per
manufacturer recommendations as per approved method
statement and details.

7. Verify the Chiller support grouting is completed as per

manufacturer recommendation and details according to
approved method statement.

8. Verify the area and locations are safe to proceed with

installation of chillers, pump down unit and panels.

9. Verify the plinth marking is done for the chillers prior to

installation of chillers as per approved method
statement.

11   Method Statement – Installation of Air Cooled

Chillers
Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
10. Verify the Chiller and panels’ orientation is correct as
per approved drawings according to piping connections
and cable entries.

11. Verify the all Chiller installation is completed as per

locations details and approved shop drawings.

12. Verify the Chiller panels installation is completed as per

locations, details and approved shop drawings.

13. Ensure the Chillers power and control connections are

completed as per approved shop drawings, details and
manufacturer recommendations.

14. Verify the Chillers, pump down unit and panels are
covered and protected properly particularly in the
piping connections portion until the permanent
installations.

15. Check IF lifting procedure as per Manufacturer

recommendation.

12   Method Statement – Installation of Air Cooled

Chillers
Project: HEALTH CARE CENTER @ INDUSTRIAL AREA
Prepared By: Reviewed By: Approved By:
 Likelyhood ( Probability )

Same Incident occurred more Same incident occur several Same incident Occurs
Same incident has occurred
than once in similar industry times in similar industry. Frequently in the similar
Severity of Consequences Never occurred in similar industry
(1- Often Happens at least industry. Continuous or will
(once every five years)
5 timesper year) (5-12 times per year) happen frequently.

Safety and Health Environment Production and Cost 1 (Rare) 2 (Possible) 3 (Likely) 4 (Often) 5 ( Frequent)
• Minor  injuries  which  may  require  • • Incident  event   without  causing 

1 - Insignificant
Insignificant Environmental 
self  administered first  Aid.  Impacts.  production los. 
• Insignificant impact  to  • Temporary nuisance  from  noise,  • Financial  Loss  ( compensation, fines, 
sorrounding comunities.  cost  to repair,  plant  damages  ) of less 
1 2 3 4 5
odours,   dust  other  air  emission, 
vibration  and visual  impacts.  that  QR 5000. 
• Result  in the generation  of non‐ 
hazardous  waste. 

• Injuries  requiring  treatment  by  • Minor  environmental impact  due  • Incident  event   without  causing 

medical  practitioners.  to contained release  of pollutants.  production los. 

2 - Minor
• Personnel  unable  to perform  • Significant  use of water,  fuels  ,  • Financial  Loss  ( compensation, fines, 

2 4 6 8 10
assigned  duties.  ( Restricted Work  energy  and other  natural  resource.  cost  to repair,  plant  damages  ) of less 
Cases)  • Minor  spillage  of Chemical  that  QR 10000.  to QR 50000 
(less  than  100  liters)  to onshore 
areas. 
• Minor  spillage  of chemical  (less 
than 10litter) for Offshore  
• Serious  injuries  requiring  • Incident  /event   without  causing 

3 - Moderate
Treatment by medical  practitioner  • Significant  short  term  impact  to  production loos  or delay  up to one 
or immediate evacuation to  flora/fauna and water  resources.  week. 
• Spillage  of Chemical  more  than  •
3 6 9 12 15
hospital.   Potential  for long  term  Financial   loss  ( compensation, fines, 
or permanent disabling  effecf.  100 liters  resulting  to localised  cost  to repair  plant  damage)  of QR 
(e.g.  Fracture,  chronic  back  impacts.  50000to  AED500000 
injuries,  sprain,   burns,  etc).  • Spillage  of chemical  more  than 10 
liters  to Offshore  areas. 

• Single  fatality  or permanent toal  • Continous  and serious  damage  to  • Production  loss  or delay  fro over  one 
disability.  from  an accident  or  flora/fauna and water  resources.  month. 
4 - Major

occupational Illness  ( Poisoning,  • Spillage  of chemical  resulting  to  • Financial  loss  ( compensation, fines, 

widespred contamination. 
4 8 12 16 20
cancer)  cost  to repair  plant  damage)  QR 
• Major  destrcution  of significant  500000to  AED  10M. 
habitant. 
• Major  environmental impact  due 
to uncontained release.  which 
required  outside  assistance. 
• Multiple  fatality  or permanent  • Long  term  impact  to environment  • Loss  of the  ability  to produce. 
5- Catastrophic

total disabilities from  an accident  (Flora/fauna and ground  water  • Severe  financial  penalties  or legal 

or occupational illness  ( Poisoning,  resources.  liabilities. 
•
5 10 15 20 25
Cancer)  • Spillage  of chemical  resulting  to  Finacial  Loss  greater  that  10M. 
long  term  environmental effect. 
• Widespread distruction  to a 
significant area  of land,  rare  flora 
and  fauna  and   or ground  water 
resources. 

Low 1-4 No action required (ALARP Level), unless escalation of risk is posible.

Risk Medium 5-10 Activity can proceed subject to proper management and/or modification

High 12-25 Activity must proceed unless risk is reduced to acceptable level