Commissioning and Functional Test for HVAC Control Panel | Method of Statement

1. SCOPE
2. PURPOSE
3. RESPONSIBILITIES
4. REFERENCES
5. PROCEDCJRES
   1. PRE-COMMISSIONING AND START UP
   2. COMMISSIONING
   3. PERFORMANCE ACCEPTANCE.
6. ORGANIZATION CHART
7. ATTACHMENT
8. JOB SAFETY ANALYSIS: .

1. SCOPE:

This section describes the method to be applied for pre-commissioning, commissioning and functional test of HVAC Control Panel (HCP) and associated equipment being controlled and installed in Project. Separate Loop Test is not applicable to HVAC system.

2. PURPOSE

A work method statement, sometimes called a “safe system of work”, is a document that details the way a work task or process is to be completed. The method statement should outline the hazards involved and include a step by step guide on how to do the job safely.

3. RESPONSIBILITIES:

3.1. Construction Manager

– Coordinate with the Owner Representative, Commissioning Engineer, HSE Manager and QA/QC Manager for the safe and proper execution of the work.
– Assigned particular responsibilities and authorities to construction personnel.
– Give specific attention to all safety measure and quality control in coordination with HSE Manager, QA/QC Manager and in line with Approved HSE Plan and Approved Quality Plan.

3.2. Commissioning Engineer

– Assigned for the task shall be fully responsible in applying this method and make sure that it is followed with. Ensure that the system is functional according to the approved drawings and design specifications. And ensure proper coordination with other services.

3.3. Site Supervisor

4. REFERENCES:

– SAES-J-902 – Electrical System for Instrumentation
– SAES-P-111 -Grounding
– SAES-P-104 – Wiring Methods and Materials
– NFPA 70 – National Electrical Code
– Schedule “Q” Att. IV Quality Requirements for the Construction Phase
– SATIP-P-104-08 – HVAC Equipment
– SATIP-J-902-01 – Metallic Instrumentation and Control Cable
-SAIC-J-6606 – Instrument Cable – Installation, Termination, Identification and Pre-Commissioning
-SATR-J-6602 – Instrument Cable – Continuity, Insulation Resistance(lnstalled) and Termination Torque Testing.
-SATR-P-3402 – HVAC System – Energized Functional Testing & Motor Four Hour Run Test.

5. PROCEDURES:

5.1 PRE-COMMISSIONING AND START UP

In order to achieve the purpose of pre-commissioning of the above mentioned subject title, this section describes what operations will be carried out and how it will occur. Accomplish pre­ commissioning checklist form for the forms listed below that are associated to present method statement and required to obtain PMCC issuance.

Pre-Commissioning Form – “ZCC 03 10” (Please see sample attached paragraph 5)

Plans & Shop Drawings                    Drawing Ref. No.                            Remarks

Wiring diagram
Flow diagram
Manufacturers installation datasheets
Panel layout, included internal component (e.g. DOC controller, relays, terminal blocks, breakers and etc.)
Points list

Panel Verification

Installation Checks
Panel mounting
Accessibility

Visual Checks

1. Panel color, dimension and fabrication, locking device.
2. Check name plates is provided
3. Check HMI (Touch Screen), if provided
4. Check installation of power switches, transformer, breakers and etc.
5. Check signal / power cable dressing, crimping and termination.
6. Check all components prior to energization (breakers, switches, fuses, terminal blocks and etc.)
7. Check all DDC panel internal lightings are properly installed.
8. Check all DDC panel service outlets are properly installed
9. Check all DOC panel ventilation fans and its corresponding thermostats are properly installed
   Check all heaters for DOC panel enclosures and its corresponding humidistat are properly installed.
10. Check all Ethernet switches and Fiber Optic patch panels are securely fixed and installed
11. Check address pins are installed to all /O module, applicable for modular type.
12. Check I/O module are fully engage in din rail and carrier
13. Check for loose terminal blocks if properly engaged.

Electrical and Grounding

1. Check grounding wire/cable is terminated in its corresponding
   1. Grounding bus bar
   2. Check power redundancy UPS, if applicable

Cable Verification

Perform end to end signal/control cable integrity test from DOC panel to field instruments/device/equipment as performed by sub-contractor per RFI.

Interfaced to Related Equipments.

AHU’s Air Handling Units

Instruments installation checklist for Equipment and duct mounted devices

1. Location of field sensors and installation quality, indicated in item 1.0.
2. Instrument tags as per tagging system.
3. Check lagging’s and termination of wires/cables from both ends simultaneous! to avoid errors.
4. Provision of required lugs and wire nuts.
5. Check installation of wire glands, flexible conduit and plastic hoses connections.
6. Verify damper actuator installation and right position.
7. Verify damper actuator is working properly.

Instruments installation checklist for CHW PIPES

1. Location of field sensors and installation quality, indicated in item 1.0.
2. Instrument tags as per tagging system.
3. Check lagging’s and termination of wires/cables from both ends simultaneous! to avoid errors.
4. Provision of required lugs, wire nuts and auxiliary switches.
5. Check installation of wire glands, flexible conduit connections.
6. Verify valve actuator installation and right position.
7. Verify valve actuator is working properly.

FAN’s SF, EF, RF, BF and etc.

Instruments installation checklist for Equipment and duct mounted devices

1. Location of field devices and installation quality, indicated in item 1.0.
2. Instrument tags as per tag system.
3. Check lagging’s and termination of wires/cables from both ends simultaneously to avoid errors.
4. Provision of required lugs and wire nuts.
5. Check installation of wire glands, flexible conduit and plastic hoses connections.
6. Check proper installation of sensors and actuators.

Air Cooled Condensing Unit

1. Instruments Installation checklist for ACCU
2. Location of field sensors and installation quality, indicated in item 1.0
3. Instrument tags as per tagging system.
4. Check tagging’s and termination of wires/cables from both ends simultaneously to avoid errors.
5. Provision of required lugs, wire nuts and auxiliary switches.
6. Check installation of wire glands, flexible conduit connections.
7. Verify PDSV working properly.
8. Verify LPS working properly.
9. Verify HPS working properly.
10. Verify Liquid Line Pressure Gauges working Properly.
11. Verify Suction Line Pressure Gauges working Properly.
12. Verify Compressor Oil up to required level.

DAMPERS MFD, MSFD MVD and etc.

Device installation checklist for Equipment and duct mounted devices

1. Location of field device and installation quality, indicated in item 1.0.
2. Device tags as per tagging system.
3. Check tagging and termination of wires/cables from both ends simultaneously to avoid errors.
4. Provisions of required lugs and wire nuts.
5. Verify damper actuator installation and right position.
6. Double actuator Dampers to be operated with one command.
7. Verify damper actuator is working properly.

Interfaces to Related Equipment Panels (MCC, LCP, VFD, EDH etc. )

1. Location of field wirings/cablings and termination quality, indicated in it 1.0.
2. Wire/Cable tags as per tagging system.
3. Check tagging and termination of wires/cables from both ends simultaneously to avoid errors.
4. Provision of required terminal lugs.

DDC BASED HVAC CONTROL PANEL SEQUENCE OF OPERATION (Substation Building)

JOB SAFETY ANALYSIS OF HVAC COMMISSIONING AND FUNCTIONAL TEST