ELECTRICAL & INSTRUMENTATION INSTALLATION WORKS FOR HVAC SYSTEM

SCOPE OF WORKS
PURPOSE
RESPONSIBILITIES
REFERENCES
PROCEDURES
1. General Requirements
2. Material Handling & Preservation
3. Material Receiving
4. Installation
5. Pre-Commissioning
TOOLS AND EQUIPMENTS
INSPECTION AND TEST
QUALITY CONTROL
SAFETY
DOCUMENTATION
JOB HAZARD ANALYSIS.

1.0 SCOPE OF WORK

1.1 This Procedure or Method statement describes in detail the procedure and requirements in installing HVAC Control and Monitor Panel using commercially available equipment and techniques to provide Automatic Temperature Controls (ATC), and when required, humidity, pressure and air quality as well as safe operation of the entire HVAC System in conformance to the approved designs, specifications and as specified.

2.0 PURPOSE

2.1 The method statement shall address the procedure of physical operations applicable in order to attain and maintain the desired indoor temperature and environmental condition for efficient equipment operation.

2.2 This document shall address safe work process applicable from preparing HVAC System requirements from construction to Commissioning; including commitment to utilize the most suitable Control System with incorporation of measures into relevant set points and parameters of work procedure to achieve the requirements of Specification.

3.0 REPONSIBILITIES

3.1 Construction Manager

3. I. I Assigned particular responsibilities and authorities to construction personnel.
3 .1.2 Executes the construction according to the construction plan and the work procedure.
3 .1.3 Co-ordinate with the Owner Representative, Construction Engineer, HSE Manager and QA/QC Manager for the safe and proper execution of the work.
3 .1.4 Give specific attention to all safety measure and quality control in co-ordination with HSE Manager, QA/QC Manager and in line with Approved HSE Plan and Approved Quality Plan.
3.1.5 Reviews the construction plan and work procedures referring to this work instruction, which shall include the following items:
(i) Owner’s requirements in the Specification
(ii) Work procedures, Inspection and Test Standards, ITP and checklists.
(iii) Input plan for materials, equipment and workers.

3.2 Q4/QC Manager

3.2.1 Ensure that all works are carried out as per work procedures/MS and other quality procedure.
3.2.2 Maintain inspection and records complete for future references.
3.2.3 Reviews the construction plan and the work procedure related with this work.
3 .2.4 Checks whether the construction plan and the procedure are well observed in the actual construction.
3.2.5 Controls the Inspections and Tests related with this work.
3.2.6 He shall coordinate all inspection with Company including submitting advance notification for inspection.
3.2.7 He shall be responsible for the final AS-BUILT and QC dossiers for submission to company.

3.3 Safety Officer

3.3.1 Check the possible hazards of the activities to be done and co-ordinate to the site supervisors to rectify if there is any to ensure the safety of the workers at job site.

3 .4 Supervisors

3 .4.1 Ensure the supervisor will be responsible only for their specified discipline.
3 .4.2 Responsible for the daily work progress to meet the work schedule.

3.4.3 Responsible for confirming the Installation locations from the approved drawings.
3.4.4 Responsible for preparation of Materials and Installation according to approved procedures IFC drawings as per the specific discipline.
3 .4.5 Organize tools and equipments required at work site and sequence of activities to be carried out for the work as per document.
3.4.6 Ensure required work permit and copy of job safety analysis at site.
3.4.7 Conduct daily tool box meeting prior to start of work.

3.4 Foreman

3 .4.1 Responsible for installation activities on site after receiving of work permit and achieve the targets as given by supervisor.
3 .4.2 Responsible to conduct daily tool box meetings to aware about safety hazards and specified job locations.
3.4.3 Responsible for the daily reporting of Site progress to Supervisor and attendance of Site Manpower.

3 .5 Subcontractor

3.5.1 The subcontractor shall be responsible for the direct implementation of this method statement.
3.5.2 Subcontractor shall prepare documents for notification of inspection and of the construction record (Inspection and Test Report) in accordance with related
procedure.
3.5.3 Subcontractor shall utilize and maintain the revised documents and drawings up-to-date for the construction work.
3.5.4 Subcontractor shall use Company approved documents and numbering system in accordance with project’s specification.
3.5.5 Inspection Test Report(s) shall be submitted to Contractor or Owner/Engineer Representative.
3.5 .6 Inspection Test Report(s) shall be approved and reviewed for its completion by relevant Contractor/Company.

4.0 REFERENCES (APPLICABLE CODES & STANDARDS)

Particular reference shall be made to the latest edition of the following international and national industry codes, standards and Specifications which apply for the construction work involved in this HVAC Controls and Monitor Panel Installation Works which include but are not be limited to the following:

SAES – Saudi Aramco Engineering Standards.
AMSS -Saudi Aramco Material system specifications.
SAEP -Saudi Aramco Engineering procedure.
SATIP -Saudi Aramco typical inspection plan.
SAIC -Saudi Aramco inspection check list.
SATR – Saudi Aramco test report.
NFPA 70 National Electrical Code, NEMA VE1 & NEMA VE2.
SHRATESTB- 62 – Ventilation for acceptable indoor Air.
UMC-1997 -Uniform Mechanical codes.
27-CAID-01 -HVAC system inspection requirements.
ASHRAE 15 -Safety Code for Mechanical Refrigeration
ASHRAE37 -Methods of Testing for Rating Unitary Air Conditioning and Heat Pump Equipment.
ASHRAE 90.1 -Energy Conservation in New Buildings Design Except Low-Rise residential Buildings.
AMCA210 -Laboratory Methods for Testing Fans for Rating Purposes
ARI 430 -Central Station Air – Handling Units
ARI 520 -Positive Displacement Refrigerant Compressors, Compressor Units and Condensing Units
ARI 850 -Commercial and Industrial Air Filter Equipment
EC 529 -Classification of Degree of Protection Provided
L465 -Central Cooling Air Conditioners
L900 -Test Performance of Air Filter Units
Construction Safety Manual Volume.
Manufacturer’s Recommended Installation Manual.
Schedule “Q” Att. IV Quality Requirements for the Construction Phase.
Schedule “G” Materials, Tools and Equipment.

4.1 SAES -Saudi Aramco Engineering Standards.

SAES-P-104 -Wiring Methods and Materials.
SAES-P-111 – Grounding.
SAES-P-119 -Onshore Substation.
► SAES-K-100
SAES-J -Saudi Aramco Instrumentation code.
SAES-K-001 – Saudi HVAC code.

4.2 SAMSS -Saudi Aramco Material system specifications.

► 27-SAMSS-011 -Fire Dampers.
► 34-SAMSS-820

4.3 SAEP -Saudi Aramco Engineering procedure.

► SAEP-K-003 -Air conditioning system for commissioning.
► SAEP-103 -Metric Unit of weight & measure.

4.4 SATIP -Saudi Aramco typical inspection plan.

► SATIP-P-111 -Grounding.
► SAES-P-104 -Wiring Methods and Materials.
► SAMSS-820.

5.0 ELECTRICAL & INSTRUMENTATION INSTALLATION WORKS PROCEDURE FOR HVAC SYSTEM

5.1 General Requirements

5 .1.1 All HV AC units and systems shall be provided with local control panels for local manual/automatic control. Local control panels shall be provided for the HVAC Equipment to allow for local operation. Data gathering panel (DGP) shall be provided as required (typically one per Plant room/area) to interface controls and status indicators/alarms to a Building Management System (EMS) for remote control. EMS status/ alarm information shall be provided to the CCR operator, hard wired via the DCS. All system status, alarms, set point indication etc shall be available at the remote station as well as at the local control point.
5.1.2 Complete controls shall have Direct Digital Control (DDC) that can also be used as stand-alone unit and interlock devices. A Data Historian shall be implemented for the plant, capable of recording SOE ‘s for five (5) years. Numeric display i.e, Temperature and hours shall have one decimal point. A maintenance tool set (lap top computer) shall be provided including the software program copy for future use.

5.2 Material Handling & Preservation

5.2.1 Deliver HVAC (E&I) Panels with factory installed shipping skids and lifting lugs; pack components in factory fabricated protective containers.
5.2.2 Handle HVAC (E&I) equipments carefully to avoid damage to components, enclosures and finish. Do not install damaged components; replace and return damaged components to equipment manufacturer.

5.2.3 Where possible, store equipment inside and protect from the atmosphere and construction worker traffic. When necessary to store outside, take the same precautions and store above grade and enclose with water proof wrapping.
5.2.4 Identification tag or name plate shall be available/attached with all equipment as per Saudi Aramco Material specification.

5.3 Material Receiving

5.3.1 Upon receipt at the site storage and handling area, all HVAC Control Panels (DDC Controls) and other incorporated accessories/field devices shall be recorded and then visually inspected for apparent damage.
5.3.2 Incoming Control Materials and accessories shall be verified against all available documents upon receipt such as; Packing Lists, Purchase Orders, Manufacturer’s/Vendor’s Statements, BOQ/BOM.
5.3.3 Any Excess, Short or Damaged materials/parts shall be recorded.
5.3.4 Control Panel(s) and associated accessories shall be stored with protection from the weather, humidity, temperature variations, dirt and dust, and other contaminants, within the storage condition limits published by the equipment manufacturer.
5.3.5 Any non-conformity with the package shall be in quarantine and been addressed accordingly.

5.4 INSTALLATION

5.4.1 DDC Panel And Field Devices Installation.
5.4.1.1 Prior to installation of HVAC Control System, all submittals for engineering, design, documentation, sytem installer certificates and panel wiring diagram from the supplied company specializing in manufacturing of HVAC Controls must be approved and complied all the requirements from the Company/Owner.
5.4.1.2 Ensure that all devices inside the enclosure are complete and having correct ID labeled as per manufacturer’s arrangement and termination diagram.

5.4.1.3 Check and verify if the location/mounting floor foundation of Control Panel are in accordance with the approved design and lay-out drawings.
5.4.1.4 Follow the Vendor/Manufacturer’s instruction manual the proper minimum clearance to install the panel with its adjacent equipments to ensure suitable space during maintenance and servicing and not to allow obstruction on the door panel when it is fully opened.
5.4.1.5 Install/Mount the Control Panel using the Vendor/Manufacturer’s lifting and rigging procedure manual/ approved drawings.
5.4.1.6 The complete assembly shall be checked to ensure fixing bolts are tightened and the vertical alignment is attained.
5.4.1.7 Field devices must be installed as per the approved Vendor/ Manufacturer’s guidelines/drawings.
5.4.1.8 Control conduits and wirings for power lines and associated field devices shall be installed as per the approved electrical designs, wiring diagrams and drawings.
5.4.1.9 Compatible space thermostat shall be installed and wired to Control Panel as per the approved wiring diagrams/drawings.
5 .4.1.10 The fire alarm shutdown signal shall be interfaced to fit the HVAC Control Panel for alarms and control as per the approved designs for Fire Alarm System wirings diagram/drawings.
5.4.1.11 Smoke detector at duct shall be wired directly to the Control Panel Signaling circuit as per the approved wiring diagrams/drawings.
5.4.1.12 Interconnecting cables and wires of control panel sections/terminal blocks shall be checked against the detailed approved termination wiring diagrams/schedules.
5.4.1.13 Proper crimping procedure shall be done to ensure tightness of all cables and wiring terminal connections.

5.4.1.14 End-to-end wire connection shall be re-checked to avoid incidental Misconnection of contacts from panel terminals to field devices terminals.
5.4.1.15 Tagging of wire using ferrule shall be done in a thoroughly manner as per approved wiring termination schedule.
5.4.1.16 Labelled clearly all functions, devices, switches and indicating lights as per SEC requirements. All labels shall be in both English and languages.
5 .4.1.17 Panels/cabinets door keys shall be kept under safe custody of the responsible construction personnel and handed over to the Company after completion of the project.

5.4.3 Cable Tray Installation

5.4.2.1 Cable tray material shall be copper-free aluminum (aluminum with a maximum of 0.4% copper), or fiberglass. For indoor air conditioned areas galvanized carbon steel is allowed. Cable trays shall be of the ladder (two side-rail) type. Cable tray installed outdoors shall have ventilated covers. Flanged type covers shall be secured with stainless steel (grade 316 in sever corrosive areas and 304 in other areas) banding and fasteners, one band per ½ rn of cover length, with a minimum of six bands per cover. Cable trays run vertically in outdoor areas shall have covers on both sides. Cable tray system could be used to support cables or raceways only (Refer to SAES-P-104-05).
5.4.2.2 The working load for cable trays shall consist of the weight of the cables (or tubing, etc.) including future additions (if required), plus a concentrated static load of 90 kg at the center of the span (Refer to SAES-P-104-05).
5.4.2.3 Cable trays installed inside the buildings will be installed at parallel and at right angles to building walls.
5.4.2.4 Sufficient space shall be provided around cable trays to permit adequate access for installation and maintenance of cables.
5.4.2.5 For Substation the minimum elevation of 2.67m will be maintained between the bottom of the cable tray and the building finished floor level.
5.4.2.6 All cable trays shall have a minimum of 300mm clear space above the tray.
5.4.2. 7 All field cuts will be smoothened to remove burrs and then painted to prevent corrosion.

5.4.2.8 All field – cut support shall be painted with approved zinc-rich coating.
5.4.2.9 Straight section and branch connection will be accomplished by using standard fittings and splice plates. Splice plates will be placed on the outside of the cable tray with the bolt head on the inside of the cable tray. Splice plates will be located between supports and quarter points. No splice plate will be placed over the support and at the mid-span of supports. No two splice plates will be installed in between supports.

5.4.2.10 Cable trays will be supported using approved method and materials. Straight run of cable trays will be supported at an interval of 1.5m. Cable Tray Pieces Length is 3 M as per approval brand.
5.4.2.11 Cable trays will be secured on the support using hold-down clamps. Open ends of cable trays will be covered with standard end plate.
5.4.2.12 Using Cable Tray as raceway or Cutting Building Members (i.e. Beams) is prohibited finally as per NEMA VE2.
5.4.2.13 Vertical cable trays should be adequately supported on both the left and right side rails to the wall or support structure with appropriate hold-down clamps as per NEMA VE2
5.4.2.14 Aluminum cable trays do not need to be touched-up as per NEMA VE2.
5.4.2.15 Bonding jumpers will be provided on both side of the cable tray where splice plates is installed to provide electrical continuity. Both ends of the cable tray run will be connected to the nearest grounding points in accordance with SAES- P-111
5.4.2.16 Bonding Jumper will be installed by Screw Head Bolt which located inside Cable tray and Jumper located outside and put flat washer and luck nut and tight as per NEMA VE2.
5.4.2.17 Expansion plates will be installed in accordance with NEMA VE2 Table 4-2.
5.4.2.18 Fastening torques will be applied to carriage bolts in accordance with NEMA VE2 table 3.

5.4.3 Conduit Installation.

5.4.3.l Installation shall be coordinated to other facilities and latest IFC drawing.
5.4.3.2 Conduit installed inside buildings will be installed at right angles and parallel to building walls using approved means of support. Support intervals will be in accordance with NFPA 70 Table 344.30 (B) (2).
5433 Conduits shall he complete between outlets IB before Cable Pulling

5.4.3.4 Rigid Steel conduit shall be extended within 900mm (3ft) for each outlet box, JB, device box, cabinet, conduit body or other conduit termination.
5.4.3.5 Rigid steel conduit shall be supported at interval not exceeding 3 m (10ft).
5.4.3.6 Liquid tight flexible Metallic (LFMC) shall be supported not more than 1.2m (4ft) and shall be fastened 300mm (12in) on each box or other conduit termination.
5.4.3.7 All connections will be accomplished using listed accessories.
5.4.3 .8 Bends in one run shall be not more than four 4 maximum 360 deg. Total between full points.
5.4.3.9 Conduits terminating on cable trays and enclosures will be secured by locknut outside the cable tray/enclosure and grounding type bushing inside to protect the cables from damage when pulling.
5.4.3.10 Conduits will be connected to ground at both ends using grounding type bushings. Where conduits terminate in on cable trays/enclosures, the end at the point of termination will be bonded to the cable
trays/enclosures.
5.4.3.11 Where flexibility is required, liquid-tight flexible metal conduit will be used. Sizes, securing and supporting of LFMC will be in accordance with NFPA 70 section 350.30 (A) and (B).
5.4.3.12 For outdoor installation, conduits will be rigid steel PVC-coated in corrosive environment refer to SAES-P-104.
5.4.3.13 Where above grade extensions of buried PVC conduits are required, a transition shall be made underground, using threaded PVC to rigid metal conduit adapters. PVC stub-ups extending up to a maximum of 150mm above ground and not attached to equipment are permitted.
5.4.3.14 For underground installation of conduits (direct buried), minimum cover, depth of burial and backfilling will be in accordance with Section 10 of SAES-P-104.
5.4.3.15 For conduit penetrating building walls (outside to inside) a seal fitting should be installed to avoid gases and humidity ingress to inside building.

5.4.4 Cable laying, Testing & Termination

5.4.4.1 Cable shall be tested on reel (Cable Drum) after material receiving (Continuity & IR Test) period to bring it to site for installation.

5.4.4.2 Cables will be tested for insulation resistance for I minute before being laid on cable trays or in conduits. For low voltage power cables and control cables rated 0.6/1kV, the test voltage will be 1,000VDC cable voltage for the control cable is 24V. For instrument cables are measured at 500 VDC and Installation should not less than 20 M Ohm.

5.4.4.3 Cables will be laid on Conduit with an allowable cable fill area in accordance with NFPA 70 Table 1. ” Percent of Cross Section of Conduit for Cables “. And Cale will be laid on Cable tray with an allowable cable fill area in according to NFPA Table 392.22 ” Allowance Cable fill Area in Ladder and Tray.”
5.4.4.4 Cable will be laid on cable trays without cable twisting.

5.4.4.5 As per SAES-J-902 sec-5.7 all Cable ties used in the filed shall be nylon coated 316 SS. All cable ties used inside of enclosures and buildings (i.e. filed junctions boxes, marshalling cabinets, control rooms & PIB,s) shall be weather resistant nylon cable ties with SS barb. The cable tie shall have a maximum continuous use temperature rating of 85 ° C Or higher.
5.4.4.6 After cable laying/cable pulling, the cables will be tested again for insulation resistance to make sure that the cables are not damaged during the cable laying process.
5.4.4.7 Continuity test will be performed on each and every cable to make sure that each cable goes to the correct device from the DDC as per the approved cable routing plan and termination diagrams.
5.4.4.8 As per SAER-J-902 sec 15.1 the termination shall be channel mounted, strip-type terminal blocks, with tabular box clamp connector and compression bar or yoke. Insulated ring lugs or locking fork connectors, specially designed to hold the connector on the terminal in the event of loosening of the terminal screw, shall be used on all such connections. Exposed electrical connections shall be completely shrouded by removable, insulating covers. When screw-type terminals are provided on field instruments or other electrical devices, solderless crimp connectors shall be used for connecting standard copper conductors.

5.4.4.9 As per SAES-J-902 sec-16.2 all cables shall be tagged, at each end, with a cable tag. The cable tagging philosophy for cables routed from junction boxes to field instruments shall be defined by the proponent representative. As per SAES-J-902 sec-16.1 all wiring shall be tagged at each end. Each wire rag shall have two labels. The first !able( closet to the end of the wire) shall identify the terminal number to which the wire is physically connected. The other label shall be the terminal number of the connection of the opposite end of the wire.

5.4.5 PRE-COMMISSIONING

Consist of various activities/records which are carried out after equipment erection, prior to energization and performance checks including the associated equipments/devices. It is therefore concerned with the verification of the state of readiness, system integrity, quality and compliance with project standards.
5.4.5.1 The following shall be verified after installation and tests had been carried out with the equipment prior to energization.
5.4.5.2 All cable/wire continuity shall be checked to ensure correct termination and identifications.
5.4.5.3 Insulation tests of all cables/wires shall be completed and documented.
5.4.5.4 All cables/wires’ termination and identification is completed and documented.
5.4.5.5 After completion, all wiring termination connection shall be verified as per IFC drawings. 5.4.5.6 Ensure all the instrument control cabinets & panels including all associated devices have the required inspection reports.
5.4.5. 7 Ensure all the required cable/conduit sealing installation shall be completed/inspected with regards to vendor’s instructions after loop functional performance check.

6.0 TOOLS AND EQUIPMENTS

6.1 Personal protective equipments.
6.2 Vacuum cleaner.
6.3 Heat gun.
6.4 Calibrated torque wrench.
6.5 Electric drills .

6.6 Electric grinders.
6.7 Basic electrician hand tools.
6.8 Multi-meter tester.
6.9 Insulation resistance tester.
6.10 Extension cords.
6.11 Temporary lighting.
6.12 Pipe bender.
6.13 Pipe threading machine.
6.14 Speed cutter.

7.0 INSPECTION AND TEST

6.1 Unit performance test, shall be facilitated by the Vendor and witnessed by SA Representatives. Field test reports shall be submitted to SA for review and acceptance.
6.2 Work execution, material approval and test shall be monitored, witnessed and recorded according to the sequence of inspection as per ITP
6.3 Inspection and tests shall be as per ITP procedure.
6.4 Results shall be recorded thru ITP Inspection Report for HVAC Control and Monitor Panel Installation.

8.0 QUALITY CONTROL

7.1 Inspection and Test Plan (ITP) pertaining to HVAC Control and Panel Monitor Installation work shall detail necessary inspection requirements and shall be submitted to OWNER’S ENGINEER REPRESENTATIVE for review and approval.
7.2 Request for inspection (RFI) of works shall be issued to CONTRACTOR and OWNER’S ENGINEER REPRESENTATIVE 24 hours in advance for carrying out inspection in a feasible manner and to avoid delay in the inspection.
7.3 Upon completion of inspection, relevant inspection report as specified in ITP shall be signed and accepted.

9.0 SAFETY

9.1 All the construction personnel involved directly in HVAC CONTROL installation Activities shall receive safety orientation/training prior to work at site.
9.2 Warning signboards and barricades shall be provided where necessary to isolate the working area and prevent unauthorized personnel from entering the site.
9.3 All electrical equipments shall be tagged and checked before using.
9 .4 In case of extended working hours after daylight, sufficient lighting and welfare facilities shall be made available at site.
9.5 Appropriate work permit system shall be followed during the construction activities werein HSE requirements are fulfilled as specified in Work Permit.
9.6 Housekeeping must be strictly observed at all times during the entire works.

10.0 DOCUMENTATION

10.1 This method statement is a controlled document and will be properly be distributed to its responsible department involved in the execution prior to commencement of the works.
10.2 Inspection required shall be kept and maintained according to the approved quality plan.
10.3 Correspondence and designed documents such as drawings, design and specifications shall be managed properly.
10.4 Records are corrected after they are reviewed by the originated organization.