A por AECOM Rus DOHA OASIS MIXED USE DEVELOPMENT METHOD STATEMENT FOR TESTING AND COMMISSIONING OF CHILLER ‘Tender No.: 5132635. DOS-RED-MS(TC)-USHP-1002 Revision No: 00 For Approval Project Phase Commissioning Reviewed by | Approved ty | Reviewed by: | Approved by: Rufina Aquino Satyendsa | Jin, | and Devendra simon | Abmed Soliman aga ‘Terrensfin Gaur on Ambrose Siddiqur Sami Rahman Zahid] Fakhoure SM Senior ict QAIQC [construction QAQC Manager| Technical | ep Manager & 5 a iy Director, |/ HSE Manager, Manager, | Manager, ‘Manager HSE Manager, : CONSPEL | CONSPEL | REDCO REDCO | nco fae ‘n0-blals [ovos¥ Controlled Copy No: * Copy Issued to: | AECOM ‘Controlled Copy No: * Copy Issued to: DoPMO_ | Pave t aaA” DoPMO §=ASCOM K=2e ‘This document sa controlled copy when the holders name is ned ink Document History Log: DOS-RED-MS(TO)-05HP- | jy 1002 Document No. [ ner. No] Issue Date | Purpose of Issue | Revised Selections | | Controlled Copy Issue Log: This document has been issued in a controlled manner to the following recipients (In the event of a revision, the parties listed below will automatically be issued with the updated version): Copy No. Company name QA Representative on M/S AECOM 2 | M/S DOPMO Pose 219a: DoPMO =ASCOM Ks 8.0 81 82 83 84 85 8 10. 11 12, 2B. 14. 15, 16. Contents Scope and Objective of Work... Reference Documents. Access / Egress . Logistics... Health, Safety & Environment... Definitions and Abbreviations. YN bb BR Responsibilities / Supervision Training, Testing and Commissioning. Test Criteria... Test Procedure Startup & Commissioning... Relevant documentation and Permit to Work System .. 10 Safety Task Briefing 10 ‘Work Inspection Request (WIR) 11 Required PPE. wd Housekeeping & Waste Management... Tools and Materials ..ccssnm QA/QC Approval and other documentary requirements... Distribution, Supporting Documents... ‘Main Contractor Safety Engineer's Approval... Attachments ‘DOS-RED-MISITC)OSHP-1002. Rev 06 Pave 319a PMO AECOM Ku" 1. Scope and Objective of Work This method statement will serve to provide a complete guide for the Testing and Commissioning of Chillers by Johnson Controls. The chiller model in question is Chiller Model : YKSSSRKASDHGS, The testing and commissioning of aforementioned chillers can be broken down into ~ _Nitcogen Pressure Leakage Test = Vacuum Test Charging York K oi Charging Refrigerant 2. Reference Documents © acs 2014 ‘© Project Specifications * IFC /Approved shop drawing © CONSPEL Qatar WLL Health, Safety and Environment plan. * Approved Material Submittal ¢ HSE Plan ¢ Task Risk Assessments DOS-RED-WS{TC)OSHP 1002, Rev 0 Pose ao 1S3. Recess / Egress [At this stage Main Contractor provided gates as shown on the figure below. Figure 1: Construction Site Gate locations 4. Logistics All tools and materials used for Testing and Commissioning can be carried by hand, 5. Health, Safety & Environment Throughout the project the following main control measures will be taken into account: The ite safety officer in cooperation with site team shall physically inspect the working area to confirm ‘that itis cleared of any hazard and / or obstructions that may hinder access or proper execution of the work. Continuing liaison with the Main Contractor representatives throughout the execution of the works, Paae 5118A DOPMO ASCOM Rit Use of adequate PPE during the execution of the works, minimum requirement as per the Main Contractors Obligations with items as determined by the attached Risk Assessment Ailhand and power tools to be suitable and appropriate forthe works tobe carried out. All tools to be in good working condition and safe to operate Supervision on site by competent and experienced people (i.e. foreman, supervisor, engineer etc) throughout the execution of the works. Works willbe carried out by rained and skilled tradesmen. “Amongst the personnel working onsite there will be people with Fist Aid Certificates and Fire Fighting Training. All drivers to hold a valid Qatar Driving License. Allrelevant permits to be issued, if required, to work within confined space, shafts floor opening, near slab edges etc. prior to the commencement of the work by the person in charge (ie. foremen, supervisors, engineers etc). The permits will be issued by the Main Contractor HSE department. First aid kit shall be available on site. Fire-fighting equipment willbe avallable onsite and in areas that are under the responsibility of CONSPEL Qatar WLL (Le. stores, workshop). Power Supply: Single-phase normal power supply where itis needed. Power supply will be provided by the Main Contractor. Control Panels are located around the construction Site. CONSPEL Qatar WLL extension leads willbe following such routes so as not to create a tripping hazard. All extension leads will be fied at height using cable stands, ALWAYS consult the CoSHH assessment and MSOS when working with glues, chemicals or other hazardous substances, NEVER work on lve electrical equipment or circuits. DON'T leave switch gear or distribution boards ‘open and unattended. Waste must he cleared and secured at the end of each working day Sufficient light shall be ensured before starting the work as per approved project HSE safety plan Additional task lighting will be provided by CONSPEL Qatar WLL i required. Additional task ting includes construction work lights (floodlights on poles) or similar. General access lighting. and emergency lighting willbe provided by the Main Contractor. In case the tradesmen will have to carry out the works near slab edges, floor openings, it shaft areas and on high level areas a Mobile Scaffold Tower will be erected, The use of ladders in such areas isnot permitted. The minimum distance to be kept between the ladder and the opening is 2 meters and always a hand hold to be available. Access near floor openings and lift shafts will be carried out under a Work Permit, ‘Bacument Na DOS RED WS/TCJOSHP 1002, Rev OO Poae 6 of19¢ A POEM AZCOM Reso 6. Definitions and Abbreviations Project client Client Representative Consultant/Engineer Main Contractor MEP Sub -Contractor Ms mp Pap Psp SSE aayac wik ir sos Cost PPE 7. Responsibilities / Supervision Doha Oasis Mixed Use Development Halul Real Estate Investment Company Doha Oasis Programme Management Office ‘AECOM Middle East Ltd REDCO Construction Al Mana CONSPEL Qatar WLL Method Statement Inspection Test Plan Project Quality Plan Project Safety Plan Health, Safety, Security and Environment Quality Assurance/Quality Control Engineer Work Inspection Request Material inspection Request ‘Material Safety Data Sheet Control of Substances Hazardous to Health Personal Protective Equipment Responsibilities for ensuring that the steps in this procedure shall be carried out are specified at relevant stepsiin the procedure: © MEP Project Director ‘* MEP Construction Director ‘* MEP Construction Manager © MEP HSSE Manager © MEP QA/aC Manager © Senior HSE Officers ‘© Site Engineer © QA/QC Engineer Site Foreman © HSE officer © Store Keeper ‘Document Wa DOS RED MS TCHISHP 1002 Rev (CONSPEL)} Pose ioa DoPMO =ASCOM Ke Main responsibilities for the aforementioned job positions please refer to the CONSPEL Qatar WLL POP plan ‘and HSE Plan. Additionally, CONSPEL Qatar WLL will provide the necessary means of communication between its own employees. The following means of communication will be utilized for this project + QHSE Meetings + Progress Meetings Coordination Meetings ‘© Employee Consultation (i.e. T8Ts, HSE Committee meetings etc.) 8. Testing and Commissioning 8.0 Test Criteria Nitrogen Pressure Test 1. Pressurized up to 150 psig using N2 with suitable amount of refrigerant as a trace gas for leak detection purpose 2. Flectronic leak detector to be used for leak detection Hold pressure for minimum 8 hours continuous Vacuum Test 1. To ensure the refrigeration circuit is free of moisture and water by dehydrate the chiller system to Smm Hg (5000 micron) or below. Charging York k Oit 1. Toensure the refrigeration circuit is free of moisture and water by dehydrate the chiller a system to 5mm Hg (5000 micron) or below. Charging Refrigerant 1. To ensure the refrigeration circuit is free of moisture and water by dehydrate the chiller system to Smm Hg (5000 micron) or below. 8.1 Test Procedure ‘Nitrogen Pressure (Leakage) Test Procedure 1. Increase pressure to $0 psig with N2 2. locate and repair leaks if found 3. increase pressure to 100 psig with N2 4. locate and repair leaks iffound s. Increase pressure to 150 psig with N2 ‘Bacurrent Na DOS RED WS{TC)OSHP 1002, Rev OO Pave B19AX DOPMO ASCOM K=Sux 6. Record start time and initial pressure reading 7. Hold test pressure for minimum & hours Record end time and final pressure reading 8 aa nt sign off pressure test record Note: Customer has to arrange nitrogen cylinders near chiller room & once it’s empty thas to pull out from chiller room Vacuum Test Procedure 1. Connect a suitable pressure type hose to the inlet of the vacuum pump. 2. Connect the vacuum gauge to %" port of i" service angle valve at top side of condenser or evaporator. 3. Start the pump and observe that the pressure can be pulled down to below 1mm Hg (1000 micron). 4. Disconnect the gauge and connect to the chiller "service valve. 5. Start the pump for dehydration process. 6. When the vacuum reaches 5 mm Hg (5000 micron) or below, isolate the chiller and stop the pump, 7. Record the start time and initial vacuum pressure reading. 8. Hold the vacuum pressure for imum 8 hours with 1 mm Hg. (21000 micron) rise permitted, 9. Record the end time and final vacuum pressure reading, 10. Client sign off vacuum test record Note ~ Customer to provide 3 phase / single phase power supply for vacuum pump. Charging York K Oil Test Procedure 1. Connect a suitable 3/8” pressure hose pipe to Oil sump charging valve. 2. Charge York k ol in oil sump. Approximately 75 liters 3. Cillevel should be visible on oil gage. Charging Refrigerant Test Procedure 1. Customer has to provide permanent power supply 110Volt & 3Ph 415 Volts before charging refrigerant. Install 3ton chain block at overhead crane or A frame. (customer has to provide) Install weighing scale & lift refrigerant cylinder 1” above ground level. ‘Dacumant No DOS RED MSITC)OSHP 1002, Re. O0 Page 90f 18A BORO ARCOM. Riso 4. Record actual total weight of Refrigerant cylinder. 5. Charge Vapor refrigerant up to 35psig, 6. With the help of Refrigerant recovery unit charge refrigerant liquid as per design weight. 7. Customer has to provide water circulation in condenser via cooling tower. 8. Connect a suitable 3/4” pressure hose pipe to refrigerant cylinder & evaporator charging valve. 9. Charge refrigerant til chiller is fully charge as per design weight Note: Customer has to arrange Refrigerant Cylinders near chiller room & once it’s empty has to pull out from chiller plant. 8.2 Startup & Commissioning 1. Customer has to provide proper water flow for Evaporator & Condenser as per design flow. 2. Customer has to install Pressure gauges for water inlet & outlet pipe line for Evaporator & Condenser. Customer has to provide above 2000 tonnage load to commission each chiller. Customer has to provide contact person information for site related activities. 5. Customer should provide permanent power supply to chiller once start up is performed. 6. Starter panel has to be commissioned prior to chiller start up. aw 8.3 Relevant documentation and Permit to Work System Following the aforementioned works al elevant documentation will be completed by the site team and all relevant permits will be issued by the Main Contractor upon request. This include the following + Completion of the STARRT Card ‘+ Completion ofthe Hazard Identification Task Assessment © Working at Height Permit 8.4 Safety Task Briefing The Supervisor / foreman and with the presents of the assigned safety officer will conduct a safety task briefing for the work that's being assigned. All workers must be present during the safety briefings. They lentify all the potential hazards involved and what precautionary measures must be taken to minimize the hazards and protect the workers. Additional, the responsible foreman will appraise the skill and knowledge level of exposed worker/s, and provide any additional training from the HSE department. All ‘acumen’ No. DOS RED MSTTC)OSHPIO0E Rev O0 Pane to o779-z~ DOPMO =AECOM Ku" supervisors, foremen and safety officers must ensure that information, instruction, training and supervision are being implemented at al times during an assigned work activity. 8.5 Work Inspection Request (WIR) Work inspection request (WIR) to be raised after completion of work. Test Reports attached with the WIR for record of acceptance by the contractor and consultant inspectors. Required PPE CONSPEL Qatar WLL will supply to all employees free of charge Personal Protective Equipment in accordance with the QCS 2014 and ensure the correct use of such equipment. The employee should use the personal protective equipment in such manner so as to provide the protection intended and not to recklessly interfere with or misuse any equipment supplied in the interests of safety. The minimum site requirements are safety helmet, safety boots, overalls, Hi-Vi2 Vest, Safety glasses and protective gloves. Other task specific PPE will be used when required subject to the attached Risk ‘Assessment forthe specific task. Additional types of PPE are stated below: © Far Defenders Dust masks © Leather Aprons © Face Shields © Full Body Harness with Lanyards The Site HSE Officer shall physically inspect the working area to confirm that its cleared of any hazard and or obstructions that may hinder access or proper execution ofthe work. * Qualified personne! to be on site to implement the work # First Aid kit shall be avaliable onsite. + General management of protection/operation hazard is tobe observed. + Safety barriers or warning tape shall be provided as required around hydro test area. + Power: Single-phase normal power where itis needed © Plant: Not applicable, Document Re DOS RED MRTOOSAP TODS Ree Foxe gD (CONSPEL}}A ROMO AZCOM Rios 10, Housekeeping & Waste Management CCONSPEL Qatar W.L.L has a moral and legal obligation to limit the envionment impact ofits operation at all times, CONSPEL Qatar [Link]. will carry out its activities in such a manner that: * No environmental harmful emissions or discharges occur. + Allresidues and waste products and materials are disposed of in an environmentally safe and healthy manner and must therefore ensure that all emissions, discharges, residues and waste do not + Pollute the air, ground or water * Provide safety or healthy threat to employee or others © Allwaste produced must be removed from site by a licensed contractor Housekeeping willbe carried out by the tradesman in regular intervals. The working area wil be Kept in a clean and tidy state for the whole duration of the work. A complete housekeeping and cleaning of the working area will be carried out at the end of each day. Once the works are completed all wastes will be removed from the working area and transferred to the waste skips provided by the Main Contractor. Care will be given the process of removal so as to minimize any manual handling. Hazardous waste will be collected separately and transferred to the stores and disposed temporary into 200It drum installed in the store for that purpose. 11. Tools and Materials, Nitrogen Pressure (Leakage) Test 4. General hand tools 2. Nitrogen pressure regulator 3. Pressure gauge 4. Pressure type hose 5. Electronic leak detector Vacuum Test 1. General hand tools. 2. Vacuum pump. 3. Pressure type hose. 4. Vacuum Gauge. ‘Charging York K Oil 4. General hand tools. 2. 3/8” hose pipe. 3. York K Oil Page ta FoA PeeMOASCOM Rese 1. General hand tools. 2. 3/0” hose pipe. 3. Weighing Scale, 4. 2ton belts Qty 2nos. 5. Chain block 3t0n, 6. R134a Refrigerant. 12. QA/QC Approval and other documentary requirements Follow the approved method statement, ITP, HSE Plan and material approval. Inspection will be carried out as per the attached check list. 13. Distribution Copies of this MS will be circulated to the following people for information & action: a. Site Engineer b. QA/QC Engineer HSE Engineer 14. Supporting Documents This MS to be read in conjunction with the a. Attached Risk Assessments b. C5 2014 Specification Project Specification 4. Project Quality Plan @. Project HSE Plan ‘Dacument No DOSRED MSITC)OSHPTOOR Rev OO Pose sofA Doo ARCOM! Re 15. Main Contractor Safety Engineer's Approval ‘Approval Status Approved Approved subject to compliance with the following notes Not approved - with reason 16, Attachments a. Check List for Pre-commissioning of chiller b. Report Forms © 1m 4 Task Risk Assessment Test Certificate ‘Docurient No DOS RED MSTICIOSHE. TOOT Rev OO Pore 14 e719A DOPMO ASCOM K=su= Pre-Commissioning Checklist Poses 79Project Name: Doha Oasis Mixed Use Development Employer: Halul Real Estate Investment Company Page: Page 1 of 1 Z Checklist for Pre- Commissioning for Chiller Consultant: AECOM Middle East Limited CIRRef. Contractor: REDCO Construction - Almana Date 7 Level: ii ‘Area: [ Location: i a i Pann I CONSPEL : ProjectSite Engineer | nate | axacengeiinsp. | Remarks 1 | Site inspection of shipping damage 2 | Chiller pressure test | Chiller dehydration & vacuum test 4 | Compressor oil charge & test run oll pump % | Compressor motor lubrication charge © | Disconnect the driveline coupling 7 _| Refrigerant initial charge (80% of full charge) 8 | Control / safety interlock wiring check & field test 2 (between chiler/ chiller motor / motor starter) 9 | Motor starter pre-test and checking 10 Motor insulation test (eager test) co Chilled water pipe flushing work (prior connecting to chiller) |” 12 | Condenser water pipe flushing work (prior connecting to chiller) 13 | water filing into chiller & check for leakage from water box (Evaporator & Condenser) 14 | Site inspection of shipping damage 15 | Chiller pressure test 16 | Chiler dehydration & vacuum test 17 | Compressor oll charge & test run oll pump 18 | Compressor motor lubrication charge 18 | Disconnect the driveline coupling 20 | Refrigerant iniial charge (80% of full charge) ‘ ” / * - “e Based on template: 005-0004 V1.0Project Name: Doha Oasis Mixed Use Development Employer: Halul Real Estate Investment Company Page: Page 1 of 1 [21] Control / safety interlock wiring check & field test (between chiller / chiller motor / motor starter) 22 | Motor starter pre-test and checking | 23 | Motor insulation test (Megger test) ma Chilled water pipe flushing work (prior connecting to chiller) 28 | Condenser water pipe flushing work (prior connecting to chiller) 26 | water filling into chiller & check for leakage from water box (Evaporator & Condenser) 27 _| Site inspection of shipping damage 2 | Ch F pressure test 28 | Chiller dehydration & vacuum test 30 | Compressor oll charge & test run ol pump 31 | Compressor motor lubrication charge 32__| Disconnect the driveline coupling 33 | Refrigerant iniial charge (60% of full charge) 34 | Conitoi/ safely interiock wiring check & field test (between chiller / chiller motor ! motor starter) '38_| Motor starter pre-test and checking 36 | Motor insulation test (Megger test) 37 Chilled water pipe flushing work (prior connecting to chiller) 38 | Condenser water pipe flushing work (prior connecting to chiller) 39° | water filing into chiller & check for leakage from water box (Evaporator & Condenser) 40 | Site inspection of shipping damage 41_| Chiller pressure test 42_| Chiller dehydration & vacuum test TR Sey ALANA St ae ssod on emlte: DOS-00V_1.0Project Name: Doha Oasis Mixed Use Development Employer: Halul Real Estate Investment Company Page: Page 1 of 1 43 | Compressor oil charge & test run ol pump T 44 | Compressor motor lubrication charge 48 | Disconnect the driveline coupling 46 | Refrigerant initial charge (60% of full charge) 47 | Control / safety interlock wiring check & field test (between chiller / chiller motor / motor starter) 48 | Motor starter pre-test and checking 49. | Motor insulation test (Megger test) 80 ‘ Chilled water pipe flushing work (prior connecting = to chiller) 51 | Condenser water pipe flushing work (prior connecting to chiller) ®2 | water filing into chiller & check for leakage from water box (Evaporator & Condenser) ‘Additional Comments: rc ne Spectr Rep TPA Represeniave Subcinador NG Suboonreci: Gi Engr Reese | Sem signe | REDCO Representative seam SECON Ste AECOM Dison Lead AEOOM Diane zoom ana RRS AMana ce = ‘Based on template: DOS-Q0xx V_1_0Project Name: Doha Oasis Mixed Use Development Employer: Halul Real Estate Investment Company Page: Page 1 of 1 Checklist of Commissioning for Chiller Consultant +: AECOM Middle East Limited CIR Ref. Contractor : REDCO Construction - Almana Date Level: Area: Location: 7 ina Sad onsPeL PrelesSte Ena® | owacengrmep, | Remarks 1] Motor dry run test 2_| Resinstall the coupling for drive ine ‘3 | Check water fw (evaporator / condenser / motor cooling) vs design condition “4 | Functional check for safety tipping on "low" water flow condition (evaporator & condenser) Chiller intial running test (include refrigerant charging & fine calibration) subject to site condition (steady cooling load shall be provided for chiler testing work) © | Chiller running test upon completion of refigerant ‘charge (Sufficient cooling load shall be provided for the test) ‘Additional Comments: Specialist Engr-Rep ‘TPA Representative Subcontractor QA/QC ‘Subeontractor CM Engr. Representative Stamp & Signature REDCO Representative REDCOIRM Stamp & Signature ‘AECOM Site Engineetinepector AECOM Discipline Lead ‘AECOM Discipline | Pactage Pm AEcoM GWAC AZCOMES mA h GRO seesA Report Forms TED WS{TCIOSHP 1002, Rew 00 Poses ofisajb HIGHTECH Am ORM AOM R= a DOHA OASIS MIXED USE DEVELOPMENT IR VALUE TEST FOR CHILLERS q Project DOHA OASIS PROJECT CIRNo. [tocation: [System Reference: ltevel Drawing Reference: et. 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