METHOD STATEMENT FOR INSTALLATION OF HVAC CONTROL SYSTEM..

1.          Scope of Work

This method statement explains the method for installation of HVAC control systems. HVAC Control System includes

1.1       Cable Tray and Conduiting.

1.2       Field Instrument Devices with Idendification Tag.

1.3       HVAC control panels-DDC

1.4       Control cables & Termination.

2.          Reference Documents

2.1   Approved Drawings

2.2   Catalogues & Vendor Documents.

2.3   Standards & Specification for Control System.

2.4    Material Submittals for HVAC Control System

3.          Definition and Abbreviation

3.1      SAES                             Saudi  Aramco Engineering Standards

3.2      SATIP                             Saudi Aramco Technical Inspection Procedure

3.3      SAIC                              Saudi Aramco Inspection Checklist

3.4      NEC                               National Electrical Code

3.5      IEC                                 International Electro-Technical Commission

3.6      RFI                                 Request for Inspection

3.7      MRR                              Material Receiving Report

3.8      ITP                                 Inspection and Test Plan

3.9      COMPANY                    LUBEREF or its Designated Representative

3.10   CONTRACTOR                        SAMSUNG Engineering Const. Ltd

3.11   SUBCONTRACTOR     Any individual or Corporation under contract to the

CONTRACTOR who perform the entire and/or some portion of the work or services on a project which the CONTRACTOR has agreed upon.

4.          Responsibilities...

4.1 Electrical / Instrument Engineer

·         He shall be overall responsible for the complete activity, including, but not limited to:

a.    Assigning workman crew.

b.    Sequence of activities to be carried out in the work as per the method of stating.

c.    Stage inspection & Surveillance.

d.    Notification to the client/consultant engineer/QC for inspection and daily work activities.

e.    Provide day to day guidance and delegate works as necessary.

f.     Ensure that the equipment and tools required for carrying out the activities   are available on site and used in a safe manner.

g.    Produce all necessary records for the confirmation of work completed and pass to QC inspector as required.

4.2   Electrical / Instrumentation Supervisor

·         He shall be overall responsible for the activity, including, but not limited to:

a.    Assigning workman crew.

b.    Sequence of activities to be carried out in the work.

c.    Ensure that the quality levels for the works are maintained.

d.    Ensure that the equipment and tools required for carrying out the activities   are available on site and used in a safe manner.

4.3  QA / QC Inspector

a.    Verification of material approval and vendor certification..

b.    Carry out day to day surveillance so as to ensure that the work is carried out as per the standards.

c.    Maintain records of quality control check lists / reports for the site work inspection.

5.         Control Measures..

5.1   Quality Control

a.            Ensure availability of the latest released for construction drawings and Specifications.

b.            Ensure that the tools / equipments used for testing purpose are calibrated  and certificates available.

5.2.      Safety

a.    All equipments and accessories have been certified for their capacity and integrity.

b.    Safety and risk assessment shall be performed for every job or task which has the potential for harm.

c.    All personnel are issued with Personnel Protective Equipment with FRC.

d.    Provide Hand gloves and educate workers for safe operation.

e.    Provide safety harness and educate workers to attend safety training who are working at height.

f.     Always try to keep the work area clean.

5.3       Material Receiving, Storage & Inspection

a.    Upon receipt of the material, it shall be inspected with respect to project specification, approved construction drawings, data sheets and delivery note.

b.    Visual inspection shall be carried out to check the condition of the panels. Be sure to note and report any damage on the MRR documents.

c.    Care should be taken while choosing a location for panel storage. It should be stored indoors on adequate location, elevated off the ground, well-ventilated and dry surface. To prevent damage to cable tray, never pull cable tray from truck trailer by chaining to bottom rung and dragging out of the trailer.

d.    Cable tray is made of either corrosion-resistant metal, such as aluminum or stainless steel, or metal with a corrosion-resistant finish with one of the following process:

i)      Hot-dip galvanizing after fabrication

ii)     Hot-dip mill galvanizing

iii)    Electro deposited zinc

iv)   Other coatings as appropriate for the application

e.    Cable tray must be protected or stored in a well ventilated, dry location. Small accessories shall be stored to prevent loss.

f.     Cable tray shall be properly supported, elevated off the ground, and stacked by width and type.

g.    After receipt and inspection, all instruments shall be clearly marked with tag number and it shall be stored in an environmentally control building or outdoors with protection   against   weather   elements,   in accordance   with the   manufacturer guidelines for instrument protection.

h.    Electronic  instruments   shall  be  stored  inside  on the  platforms  or blocks at least 150mm  above grade and covered  with tarpaulins  to protect them from the weather.

i.      Any document coming along with the instrument box shall be kept & documented by Samsung.

j.      Small accessories of panel should be stored to prevent loss.

6.         Sequence of Activities...

6.1        Procedure (General)

a.    Check approval of construction drawings.

b.    Check the size and route of Cable conduit & Cable tray for control cable pulling as per the approved construction drawing.

c.    Install the supports of Cable conduit & Cable tray as per the standard.

d.    Check the Cable conduit & Cable tray ends are free from sharp edges.

e.    Install the conduits and provide Locknuts & end bushings.

f.     Provide junction box/pull box where necessary and as per standards.

g.    Visual Inspection for Cable conduit & Cable tray installation.

h.    Pull the cable and make sure that there is 70% free space available inside conduits.

i.      Check for insulation resistance and continuity of the cable after installation.

j.      Check the panels are free from damages.

k.    Install the control panels in the correct location as per the approved construction drawing.

l.      Visual Inspection for Panel Installation.

m.   Check the conduit/cable entry (gland / connector) to the panels is as per standards.

n.    Provide end bushings with ground for conduit/gland entry to the panels.

o.    Make sure that the panels are properly grounded.

p.    Make sure that the field devices are installed in the correct location and of the correct type.

q.    Provide approved cable lugs of proper size for cable termination.

r.     Check the terminated lugs are fastened enough.

s.     Provide cable tags for cable identification.

t.      Visual inspection for panel termination.

u.    The system is ready for function test & commissioning.

6.2       Installation Procedure (Cable Support Installation)

a)    In order to install the cable tray supports, first find the required elevation from the floor to the bottom of the cable tray and establish a level line as per approved construction drawing.

b)    Bore concrete for anchoring and hanger support. Ensures that the anchors are properly fixed and aligned.

c)    For wall and single strut cantilever bracket, secure the brackets to the structure making sure they are level and aligned with each other.

d)    Welding shall be done for supports as necessary.

e)    Fabricated cable trays supports need to be retouched with appropriate paint after cutting, drilling, or deburring or if the coating gets damaged.

6.3       Installation Procedure (Cable Tray Installation)

a)    After the supports are in place, the installation of the cable tray can begin at any place that is convenient. It is not necessary to start at one end of the run. It is ideal to lay out the system so that splice joints fall between the support and the quarter point of cable tray. This maximizes the rigidity of the cable tray.

b)    Install cable tray ensuring that it is properly fixed to its supports. Where necessary to cut the cable trays, the cutting line of the cable trays shall be through continuous metal parts and not through the perforation. Burrs and sharp ends shall be removed prior to the installation of tray section or accessories.

c)    Cable tray shall be connected to adjacent lengths, tees, bends and fittings with approved couplers and securely fastened by mushroom head steel roofing bolts and nuts. Connection shall be mechanically strong, so that there is no relative movement between joints.

d)    Place the next straight section across the next support, and attach it to the previous section with a pair of splice plates and hardware. Splice plates shall be placed on the outside of the Cable tray, unless otherwise specified by the manufacturer, with the bolt heads on the inside of the Cable Tray.

e)    Holes for splice plates must be drilled in field-cut Cable tray. A common method of locating the hole positions is to use a splice plate as a template.

f)     Clearances shall be maintained / observed during installation between Cable trays / Supports and from any services. Identify cable tray separation of voltage and service as per Construction drawing and Specification.

g)    For floor and roof installation, cable tray shall not be laid directly on the floor or roof. It shall be mounted far enough off the floor or roof to allow the cables to exit through the bottom of the cable tray. If Unistrut is used for this purpose, mount the strut directly to the floor or roof and attach the cable tray to the Unistrut using hold-down clamps and/or guide clamps.

h)    Cable trays that have a hot dip galvanized coating applied after fabrication need to be retouched after cutting, drilling, or deburring or if the coating gets damaged.

i)      After completion of the work, inspection shall be carried out prior to cable pulling. Examine cable paths to ensure all areas are free from debris that may interfere with the cable installation.

j)      Cable tray covers shall be provided and installed as a mechanical protection in outdoor area prone to direct sunlight. Flange type covers shall be secured with banding, one band per meter of cover length with a minimum of 3 bands per cover. If the cable trays are installed indoor locations, the tray cover shall be installed on the top layer only.

k)    Provide identification / labels on cable tray and node marked. Identification made up a stencil and spray paint.

l)      Mark-up / As Built drawings for any changes of routing of cable tray.

m)  Clean the cable tray including the area where cable tray system is installed.

6.4       Installation Procedure (Grounding and Bonding Installation)

a)    Grounding works for the cable tray system shall be in accordance with Issued for Construction (IFC) drawings (Erection details / Grounding system layout drawings), SAES-J-902 and SAES-P-111 or as supplemented by this guideline.

b)    Metal cable trays must be grounded and electrical continuous systems.

c)    If the cable tray is to be used as an Equipment Ground Conductor (EGC), bonding jumpers must be installed on both side rails at the locations illustrated below:

Figure A EXPANSION SPLICE PLATES	Figure B HORIZONTAL ADJUSTABLE SPLICE PLATES
Figure C DISCONTINUOUS SEGMENTS	Figure D CABLE TRAY SECTIONS VERTICAL ADJUSTABLE SPLICE PLATES

d)    Typical installation of grounding bonding for cable tray is to drill holes inside rail 50 mm from each end of the splice plate so the jumper will span the discontinuity. Do not use splice plate bolt locations to connect jumper to cable tray.

e)    Place screw head on inside of cable tray, put a jumper on outside of cable tray, add flat washer,Locknut and tighten.

f)     Bare cooper shall not be used as a bonding conductor at cable tray.

g)    When a separate EGC cable is installed in or on cable tray, it may be bonded to the cable tray with a grounding clamp. Ground clamp style includes bolted lug type that requires drilling the cable tray side rail and clamp-on styles that work like a beam clamp.

h)    Bonding jumper is not required if the separate EGC is properly bonded to all cable tray.

i)      Minimum size of grounding conductor can be referred to NEC standard and/or as per Construction drawing.

6.5        Cable Pulling Procedure

a)    Field supervisor shall organize the cable-pulling plan, lifting method to be used (by boom truck, crane or forklift), number of required persons and location of cable drum.

b)    Cable drum will generally be placed on drum jacks with an axle of sufficient size and strength to allow the drum to turn freely with a minimum of friction.

c)    Communications shall be established between the pulling end of the run and the drum end of the run.

d)    Be sure to have adequate personnel available at the drum end to aid in feeding the cable, watching to prevent cables from being crossed and for drum braking if necessary.

e)    Cables may be pulled by hand with operatives placed at frequent intervals to support the cables and avoid excessive tension. Where cables are not supported at frequent intervals by operatives, then they must be supported by cable rollers and placed at suitable intervals to avoid contact of cable sheath with abrasive surfaces.

f)     The cable shall be pulled by hand at a constant speed during the pull.

g)    Cable pulling lubricant (pulling compound) shall be applied during cable pulling inside conduits. Induct banks care shall be taken to protect the cables already pulled by means of temporarily inserted half cut PVC pipes or by means of rubber sheets placed above cables already pulled.

h)    Ensure that the cables are installed at the correct level of ladder rack in accordance with the cable pull-sheet.

i)      The cable shall not be pulled bends excessively; Care shall be taken to avoid any scratches on the cable sheath while pulling cables.

j)      Do not allow the cables to drop in the cable tray as this may damage the cable and/or the cable tray.

k)    Extra care shall be taken when pulling cables to avoid loops. If a loop shall occur under no circumstances, attempt be made to remove the loop by tensioning the cable, the loop shall be removed by carefully coiling to the nearest end.

l)      Unwind the cable from the drum to secure the required extra length to reach the panel and coil it on the tarpaulin.

m)  When the cable reaches end of the trench at the equipment location, allow two (2) meters of extra length of cable fro dressing and termination requirements.

n)    Cutting cables must be done with appropriate tools such as hydraulic shears, hand shears, cable cutter or hacksaw (measure the required length before cutting).

o)    Immediately after a cable has been laid and cut temporary protection cover shall be made on the ends to avoid moisture absorption to the cable strands and temporary identification label shall be made at each end, the identification shall be as on the cable pull schedule. Final label or identification will have to be installed after termination is completed.

p)    Each cable shall be dressed to provide for the right installation along its entire length. Once, all cables have been laid on a route level; dress the cables, removing all temporary tie wraps and securing with permanent tie wraps/clamps on all vertical cable risers.

q)    Mark-up / as-Built drawings for any changes made. Clean the area after completing cable pulling, cable tagging were installed.

6.6           Field mounted instruments / Devices

a)      Prior to Instruments / Device installation check the elevation is as per the standard and approved construction drawings.

b)      If installed with supports make sure that the supports are strong enough and bolts are fastened.

c)      Where possible the instrument shall be installed in 1.4m from grade level.

d)     All indicating instruments should be installed at visible height.

e)      Where required, the instruments / Devices shall be provided with sunshade as per the approved construction drawings.

6.7         Control Panel Installation

a)    Control panel installation shall be done based on project specification, plan drawings, and related vendor document of the control system.

b)    Prior to panel installation it shall be ensured that inside the access floor are clean and free from debris that may interfere with the panel installation.

c)    Rubber plate (PAD) will be placed between support and panel base.

d)    The panel shall be correct mounted horizontally, vertically using the specified liners.

e)    Upper and front side of the panel shall be correctly mounted in place.

f)     Once the panel is aligned properly Stud bolt & Nut will be tightened properly.

g)    After completion of the work, the panels shall be cleaned and covered with suitable protective materials.

h)    Any energization / preservation if required, shall be carried out on vendor / client presence and recommendation.

i)      Other consoles & accessories shall be installed as per the approved layout

drawing.

6.8         Cable Gland Installation

a)    Cable gland installation shall be in accordance with the recommendations of cable gland manufacturer or as per following typical installation guideline.

b)    Fit rubber shroud over the cable outer sheath, if applicable.

c)    Prepare the cable by stripping back the outer sheath and armor to suit the equipment geometry. Expose the armor by stripping back the outer shear further using the Detachable cone or Reversible armor cone length as a cable-strip equivalent length. If applicable, remove any tapes or wrappings to expose the cable inner sheath.

d)    Secure the entry component into the equipment.

e)    Locate the detachable armor cone into the recess of the entry component.

f)     Pass cable through entry component evenly spacing the armor around the cone.

g)    Whilst continuing to push the cable forward to maintain the armor in contact with the cone tighten the body of sub-assembly onto the entry component.

h)    Ensure the two components make “metal to metal” contact. Tighten the outer seal nut until either:

i)      The outer seal nut makes metal to metal contact with the gland body,

ii)     The outer seal nut has clearly engaged the cable and cannot be further tightened without the use of excessive force by the installer.

i)      This completes the procedure for cable gland installation.

6.9     Cable Termination Procedure

a)    Typical termination works shall be in accordance with the recommendations of cable manufacturer’s instructions or as per following typical termination guideline.

b)    The cable has to be properly dressed inside the junction box, cabinets, marshalling panel, instruments etc.

c)    The lugs/ferrules used shall be of proper size and type. Ring type lugs shall be used in the places where 100% break free termination is required, such as Solenoid valves, Instrument installed in vibrating area, etc. In another place depending on the type of terminal -bootless or pin type lugs shall be used.

d)    The lugs shall be insulated type only, not be used for compensating cable and single stranded cables.

e)    Crimping shall be done with the proper crimping tool. Use of cutting pliers shall be avoided. Ensure the terminal lugs are properly crimped with the right crimping tool.

f)     Individual conductors shall be terminated on terminal strips and identified with a tubular wire marker installed on a terminal, cabinets marshalling panel, and junction boxes. When heat shrinkable tubes are used, they shall be heat shrink and shall be loose enough to replace easily, if necessary.

g)    Terminate the core corresponding terminal blocks properly and check the tightness.

h)    Shielded cable shall be grounded at one point only, typically at the marshalling cabinet of the control room or process interface building (PIB).

i)      Ensure that the wire loops are kept neatly bed with ties.

j)      Ensure that all cables are clamped inside the Trunking and tie wrapped on instrument tray with approval fixing material.

k)    Fix the cable identification on a tag on the cable near to the gland using approved straps.

l)      Ensure that the cover of the equipments fixed after termination.

m)     This completes the procedure for cable termination works.

6.10     Cable  Test Procedure..

  

6.11.1    Cable continuity test :-

a)       Connect the free Megger test probes to any two conductors required to be tested.

b)         With all the appliance connected or the two ends of the conductors shorted and all Switches switched ON the reading shown on the Megger should be zero. If the reading shows infinity then there is an open circuit. The fault should be traced and rectified.

 For cables, the extreme ends of any two phases are shorted and when the test is conducted the reading should be zero if the meter reads infinity or some value of mega ohms then there is a fault in the cable and it should be rectified. The same procedure shall be repeated for another 3 conductors of the cable.

6.11.2     Cable Insulation Resistant Test.

a)     For wires the circuit is tested, Megger range should be 500V.

b)    Between phase and neutral.

c)     Between phase to earth

d)     Between neutral to earth

e)    With the other ends of the circuit conductor open the value should be infinity for all the tests. If the value is zero, there is a short circuit or the insulation of the wire is damaged and the wire is changed accordingly.

6.12    Pre-Commissioning & Commissioning,Start-Up of HVAC Control Systems.

a)    Close all punch list before pre-commissioning

b)    Prior to pre commissioning check for  all Installation inspections as per ITP.

c)    Prior to  commissioning check for  all Testing  inspections  as per ITP.

d)    The Vendor only can do the pre-commissioning ,commissioning and Start Up activities.

e)    Down load the Software  program for  DDC Control Devices.

f)     Manually check the UPS Power, Relays, Damper Actuator, Air Flow devices,Pressure Transmitters through Panel.

g)    After confirmation, check the whole system operate by manual mode.

h)    After  observation  change over  from Manual mode to auto mode.

i)      The site acceptance test (SAT) Shall be conducted by Vedor  with the Contractor and Clint  representative Approval.

j)      The Vendor shall give the operator training to Contractor and client representatives.

k)    Operation and Maintenance shall be Monitored by HVAC Engineer until handover to client.

l)       Record all Data and submit to the client with Handover Documents.

7.    Attachment

            JSA (Job Safety Analysis)

            SATIP-P-104-08  (HVAC Equipment)

             SATIP-J-902-01  (metallic Instrumentation and control cables.)

            SATIP-P-104-03  (cable Tray)

            SATIP-P-104-05  (A/G Conduit)

            SATIP-P-104-07  (B/G Conduit))

            SATIP-P-111-01  (Grounding & Bonding as applicable.)

            SATR-P-3203 (cable continuity and Insulation test.)

            SATR-P-3205 (Power cable termination Torque test)

            SATR-P-3406 (cable continuity and Insulation test.)