1.0 SCOPE OF WORK
This procedure covers the technical requirements for the execution of HVAC instrumentation installation works for Building, Plants and Refinery and Terminals Projects.
2.0 PURPOSE
The purpose of this method statement or work procedure is to outline the procedure of the installation of instrumentation systems for Heating, Ventilation and Air Conditioning for Building, Plants and Refinery and Terminals Projects. including the requirements for safety of personnel and Quality Assurance/Quality Control.
3.0 REPONSIBILITIES
3.1 Construction Manager
3.1.1 Assign 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 Coordinate 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 coordination 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 QC E & I Engineer
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
Check the possible hazards of the activities to be done and co-ordinate to the site supervisors to rectify ifthere is any to ensure the safety of the workers at job site.
3.4 Supervisors
3.4.1 Responsible for confirming the installation locations from the approved drawings.
3.4.2 Organize tools and equipments required at work site and sequence of activities to be carried out for the work as per document.
3.4.3 Ensure required work permit and copy of job safety analysis at site.
3.4.4 Conduct daily tool box meeting prior to start of work.
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 method statement which include but are not be limited to the following:
- SAES-P-104 – Wiring Methods and Materials
- SAES-P-111 – Grounding
- SAES-P-119 – Onshore Substation
- SAES-J-902 – Electrical Systems for Instrumentation
- NFPA 70 – National Electrical Code
- NEMAVEI – Metal Cable Trays Systems
- NEMA VE 2 – Cable Tray Installation Guidelines
- IEEE – Institute of Electrical and Electronics Engineers
- NEMA – National Electrical Manufacturer’s Association
- ANSI – American National Standards Institute
- NETA – Inter National Electrical Testing Association
5.0 HVAC INSTRUMENTS INSTALLATION PROCEDURE
5.1 General Requirements
- Equipment, enclosures, boxes, field devices and other installation materials will be as per approved submittals and suitable for the area classification.
- Adequate ventilation will be provided by the construction team to prevent inhalation of fumes, dusts and other particles by the workers as a result of cutting, grinding and other activities.
- Sufficient lighting will be provided to prevent any incidents due to poor sight in the construction area.
- Proper housekeeping will be implemented before and after each working day to minimize hazards.
5.2 Material Receiving
- All materials delivered to site will be inspected jointly by ZP, DEC and SAPID engineers/inspectors in accordance with the approved Inspection & Test Plan.
- Inspection results will be recorded in appropriate approved inspection checklist duly signed by respective QC inspector/engineers.
- Proper storage and preservation of materials will be provided to ensure that materials will be in good condition and to provide protection against deterioration due to effects of environment conditions i.e. direct sunlight, moisture, temperature, humidity, etc.
5.3 Installation
5.3.1 DDC Panel And Field Devices Installation.
- DDC panel will be hauled from storage area to the location of installation by boom truck or other approved means that is sufficient to carry the weight of the panel. Check and verify if the location/mounting floor foundation of Control Panel are in accordance with the approved design and lay-out drawings.
- DDC panel will be transferred in an upright position securely fastened on the truck while moving. Upon unloading from the truck, the panel will be moved to its designated location by means of pallet jack with the anchor bolts
already in place. - DDC panel will then be secured properly by tightening the anchor bolts to hold it to position while checking the level and alignment.
- After installation, check the DDC panel for any items that might become loose during transportation.
- Foreign objects will be removed inside the panel. Cover with plastic to prevent ingress of dirt and other particles from construction.
- Fragile components accessible from outside like the Human-Machine Interface (HM!) and indication lights will be protected from physical damage by suitable means.
- Installation of field devices will be done by qualified technicians in locations shown in the approved drawings.
- As much as possible, devices will be installed only after installation of ducts, pipes and other mechanical services in order to prevent damage to instruments and in line equipment.
- Devices will be installed using the mounting brackets provided by the manufacturer.
- Installation of instruments will be checked for quality like alignment, level, tightness, etc.
- lngress protection (IP) rating of the devices will be checked to make sure that adequate protection is provided against ingress of moisture and solid bodies that may affect the functionality of the device.
- When mechanical protection is required, devices will be installed inside an enclosure with adequate IP rating.
- All devices and enclosures will be thoroughly cleaned of foreign objects like unused screws, dusts, etc.
- After installation, devices will be covered with plastic or other suitable means to protect from physical damage or falling debris that may be present in the construction area.
- Please refer to attached document (JJIK-M98-27-V057-DA, Catalogues and Devices Components) and drawing number VA-539970-006-00 for HVAC Control System Instrument Installation detail and for installation of field instruments and devices as per manufacturer recommendation including grounding requirements.
6.0 TOOLS AND EQUIPMENTS
- Power tools
- Basic electrician hand tools
- Testing instruments with valid calibration certificate
- Cable trays and conduits cutting & fitting tools
- Access ladders I scaffolds
- Personal protective equipment
- Industrial type power cords
- Mobile generators (if power supply is not available at site)
- Adequate ventilation and lighting equipment
7.0 INSPECTION AND TEST
Factory acceptance tests if required in the ITP will be facilitated by the Vendor and witnessed by DEC and SA representatives. Field test reports shall be submitted to SA for review and acceptance.
8.0 QUALITY CONTROL
- Inspection and Test Plan (ITP) pertaining to instrumentation installation work shall detail necessary inspection requirements and shall be submitted to OWNER’S ENGINEER REPRESENTATIVE for review and approval.
- 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.
- Upon completion of inspection, relevant inspection report as specified in ITP shall be signed and accepted.
9.0 SAFETY
- AII the construction personnel involved directly in HVAC instrumentation installation activities shall receive safety orientation/training prior to work at site.
- Warning signboards and barricades shall be provided where necessary to isolate the working area and prevent unauthorized personnel from entering the site.
- All electrical equipments shall be tagged and checked before using.
- In case of extended working hours after daylight, sufficient lighting and welfare facilities shall be made available at site.
- Appropriate work permit system shall be followed during the construction activities werein HSE requirements are fulfilled as specified in Work Permit.
- Housekeeping must be strictly observed at all times during the entire works.
10.0 DOCUMENTATION
- 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.
- Inspection required shall be kept and maintained according to the approved quality plan.
- Correspondence and designed documents such as drawings, design and specifications shall be managed properly.
- Records are corrected after they are reviewed by the originated organization.
JOB SAFETY ANALYSIS FOR HVAC INSTRUMENTATION INSTALLATION