MD-402-1060-CN-HV-PRO-00001 Method Statement For HVAC Duct Refrigerant ...

Ma’aden Alumina Refinery Project
MD-402-1060-CN-HV-PRO-00001
MA’ADEN Bauxite Alumina Method Statement for HVAC Duct &
Company (MBAC) Refrigerant Line (Copper tube) Installation Rev. E 1 Of 15
Method Statement for HVAC Duct & Refrigerant Line

(Copper tube) Installation
MD-402-1060-CN-HV-PRO-00001
MD-402-1060-CN-HV-PRO-00001
MD-402-1060-CN-HV-PRO-00001
REV DATE DESCRIPTION PREPARED CHECKED APPROVED
E 2013-08-07 Issued for Approval M.S.Kim Y.S.Kang S.B.Park

D 2013-07-16 Issued for Approval M.S.Kim Y.S.Kang S.B.Park
C 2013-02-09 Issued for Approval M.S.Kim Y.S.Kang S.B.Park
B 2013-01-11 Issued for Approval M.S.Kim Y.S.Kang S.B.Park
A 2012-12-17 Issued for Approval M.S.Kim Y.S.Kang S.B.Park
PROPRIETARY INFORMATION
MD-402-1060-CN-HV-PRO-00001
THIS DOCUMENT CONTAINS INFORMATION BELONGING TO MAADEN. NEITHER THE DOCUMENT,

NOR ANY OF ITS CONSTITUENT PARTS, MAY BE REPRODUCED OR DISCLOSED WITHOUT THE PRIOR
WRITTEN AUTHORIZATION OF MAADEN.
MD-402-1060-CN-HV-PRO-00001
INDEX
1. PURPOSE
MD-402-1060-CN-HV-PRO-00001
2. SCOPE OF WORK
3. REFERENCES
4. RESPONSIBLE PERSONNEL
MD-402-1060-CN-HV-PRO-00001
5. METHOD – PRE-INSTALLATION
6. METHOD OF INSTALLATION
MD-402-1060-CN-HV-PRO-00001
7. REFRIGERANT PIPE INSTALLATION WORK
8. QA/QC
MD-402-1060-CN-HV-PRO-00001
9. SAFETY AND ENVIRONMENTAL CONSIDERATION
10. ATTACHMENT
MD-402-1060-CN-HV-PRO-00001
1. PURPOSE
This method statement cover onsite installation of pre-fabricated duct-work systems

manufactured from hot dipped galvanized steel sheet as per S.M.A.C.N.A and details the
method of performing the various activities involved in the course of work for field
installation work of HVAC including HVAC Control system.
MD-402-1060-CN-HV-PRO-00001
2. SCOPE OF WORK
This method statement is to define the method to be used to ensure that prefabricated ducting,
bracketing, and in line equipment installation and final connections and workmanship are
correct and acceptable, and conforming to the contract documents and General Specifications,
Materials to be submitted for review by the Client- see latest Revision of the Material
Procurement Schedule.
3. REFERENCES
MD-402-1060-CN-HV-PRO-00001
BPS - Brazing Procedure Specification QB-200.1 Section IX ASME Boiler and

Pressure vessel code (Attached)
SMACNA – Sheet Metal and Air Conditioning Contractor’s National Association Inc.
ASHRAE – American Society of Heating, Refrigerating and Air Conditioning Engineers
UMC – Uniform Mechanical code
Project Specification - MD-402-1000-EG-HV-SPC-50001

MD-402-1060-CN-HV-PRO-00001
Project ITP - MD-402-1030-QD-QC-PLN-00015
4. RESPONSIBLE PERSONNEL
 Construction Manager
 Mechanical Superintendent
MD-402-1060-CN-HV-PRO-00001
 Warehouse Controller
 Q.C. Engineer/Inspector
MD-402-1060-CN-HV-PRO-00001
5. METHOD – PRE-INSTALLATION
 All materials drawings and other documentation relevant to a particular section of works
will be checked by the Construction Department prior to the commence of work ensuring
that these are of the correct type as reviewed by the Client.
MD-402-1060-CN-HV-PRO-00001
 Before commencing any construction works, pre-inspections will be carried out on all
materials prior to them leaving the storage area.
 Prior to the commencement of any construction works, areas and access will be inspected
by the Construction Team to ensure that they are in a suitable condition for construction
works to commence. The Client will be invited to attend this inspection at his discretion.
 A close co-ordination with other trades will be carried out on site prior to commence
work.
MD-402-1060-CN-HV-PRO-00001
 A safe and protective storage area will be allocated on site, in close co-ordination with
the employer.
6. METHOD OF INSTALLATION
 Supervisor will instruct tradesmen regarding the execution of the works and will
distribute all necessary approved construction drawings of the latest revision.
MD-402-1060-CN-HV-PRO-00001
 The supervisor will also check that tools and equipment available are in compliance with
the contract requirements.
 Ensure horizontal ductwork is adequately supported at equal distances in accordance with

Construction Drawings with all brackets fixed to the vertical face of ribbed beams of the
structure.
MD-402-1060-CN-HV-PRO-00001
 Care will be taken during setting out, that ductwork runs between ceiling module lines so
as to maintain maximum flexibility for any future relocation of lighting fixtures or other
services.
 Ductwork supports unless otherwise indicated will be installed to provide a minimum

space of 15mm between finished covering and adjacent work, and 100mm clearance from
suspended ceiling.
MD-402-1060-CN-HV-PRO-00001
 Screwed drop rods will have thread adjustment in either direction for leveling of
ductwork and associated plenum boxes.
 As indicated on relevant approved construction drawings where more than one duct can
be supported on one hanger – the size of the hanger will be assessed on the sum of the
maximum widths.
MD-402-1060-CN-HV-PRO-00001
 Ductwork passing through non fire rated walls and floors will be adequately supported on
either side.
 All locknuts are tightened correctly. At all open end’s check for debris, install covers of
suitable material to prevent any ingress of debris vermin, or moisture.
MD-402-1060-CN-HV-PRO-00001
 Supervisor to ensure that there are no dents, distortion or buckling of ducting during
installation being aware that damaged sheet metal work will be rejected.
 Supports are to be fixed at correct levels checking the bracket material is compatible with
the installation and the correct method used for thermal insulation.
 Ducting to be installed allowing sufficient space for expansion/contraction and thermal

insulation.
MD-402-1060-CN-HV-PRO-00001
 Fixing of flanges to ductwork will be by the approved details and in compliance with the
specification requirements: a) Clean both flange faces to be joined. b) Add gasket
jointing material to flanges to be mated. c) Using only undamaged rust free bolts nuts
and washers join mating flanges together and tighten bolts. d) Clean any excess jointing
material from flanges.
MD-402-1060-CN-HV-PRO-00001
 Continuously check horizontal and vertical alignment of ductwork and compliance with
contractor’s drawings and specification requirements by using spirit level plumb or other
suitable instrument.
 In line equipment is to be independently supported from main structure and not block
work walls or sub-structure.
MD-402-1060-CN-HV-PRO-00001
 Sound attenuator, fire dampers, balancing dampers & other plant items will be installed
as per contractor’s drawings, and will be supported adequately.
 Supervisor to check before end of work day’s by recording in his diary (as necessary)
that: a) The correct type supports installed, b) Supports are adequately supporting the
ductwork and associated plant equipment.
 Test holes to be provided and plugged ready for commissioning and control equipment.
MD-402-1060-CN-HV-PRO-00001
 Ensure terminal equipment is installed as specified.
 Supervisor to ensure that all completed installations look neat and tidy, that there is
adequate spacing between ductwork and in line equipment to allow access for operation
and ease of maintenance and installed to approved drawings and manufacture’s
recommendations.
MD-402-1060-CN-HV-PRO-00001
 Check for correct material for duct fixtures installation i.e. square diffusers, grilles,
registers etc.
 All join shall be sealed with approved mastic and taped externally to make an air-tight
joint.
DIFFUSER, GRILL & REGISTER INSTALLATION

MD-402-1060-CN-HV-PRO-00001
 Final connections to diffusers shall be carried out using flexible ductwork as per drawing.
 Wall or ceiling opening for air outlets or diffuser, refer to Architectural plans for details of
Construction.
7. REFRIGERANT PIPEINSTALLATION AND BRAZING WORK

MD-402-1060-CN-HV-PRO-00001
7.1 Braze welder qualification procedure.
. Brazing procedure specification and Braze welder qualification record shall be keep as per
Attached document.
7.2 Work Equipment.
 Work equipment used in the process of brazing copper pipework for refrigeration
System shall consist of the following items:-
MD-402-1060-CN-HV-PRO-00001
 Manual flame torch designed to burn mixtures of natural gas, propane, and butane,
acetylene, with air or oxygen.
 Regulators and gauges. (single or two stage)
 Hoses and connections suitable for gas welding and related processes.
MD-402-1060-CN-HV-PRO-00001
 Supply of appropriate gases for fuel, oxidizing and purging purposes.
 Operator’s personal protective equipment and any other safety equipment appropriate to
the requirements of the process.
 Sundry items for cleaning and preparation of joints prior to and after the jointing Process.
MD-402-1060-CN-HV-PRO-00001
7.3 Methods of Heating – General
 Heating for brazing depends on the capillary attraction for penetration of the fill alloy
into the joint in order to achieve an effective joint.
 Heating for brazing must be uniform over the whole joint area, so that when the Brazing
temperature is reached, the filler alloy melts and spreads to bond with the Parent metal
surfaces within the joint. Care must be taken to avoid local overheating.
MD-402-1060-CN-HV-PRO-00001
 The burner is adjusted to achieve optimum flame conditions (neutral flame) and the torch
manipulated to concentrate the heat at the optimum working distance from the component
of greater mass. Filler rod is then applied intermittently to the entrance to the joint until
the melting temperature of the rod is reached. The rod is then normally allowed to dwell
on the joint until fusion of the filler material occurs.
 The process may be used with copper phosphorus rods or pre-fluxed silver solder rods or
non-fluxed silver solder rods with externally applied flux. Preplaced flux paste can be
MD-402-1060-CN-HV-PRO-00001
applied on the internal surfaces of a joint; this method applies particularly to joints of
dissimilar parent metals.
7.4 Joint Preparation
 The component parts of a joint should be clean and properly fitting. When required,
oxide, grease or oil should be removed by chemical and mechanical methods, this may
involve degreasing, scratch brushing and other similar processes.
MD-402-1060-CN-HV-PRO-00001
 Correct joint alignment must be maintained by the use of jigs or supports as necessary.
 For a brazed joint to be effective the filler alloy must penetrate the overlap between the
surfaces being jointed to the prescribed depth. To achieve this requires an accurate
assembly of components, the use of a suitable brazing alloy and a satisfactory heat
Pattern. The making of joints on site requires care and can
MD-402-1060-CN-HV-PRO-00001
 Frequently necessitate the use of forming tools (swaged joints). It should be emphasized
that the presence of a fillet around the joint does not necessarily constitute a joint of
satisfactory quality.
7.5 Brazing Method
 Accurately measure the length of each tube segment (Figure 1).

MD-402-1060-CN-HV-PRO-00001
 Cut the pipe to the measured lengths. The pipe can be cut with a disc-type tube cutter
(Figure 2).
MD-402-1060-CN-HV-PRO-00001
(Figure 1) Measuring (Figure 2) Cutting
 Heat the pipe first (Figure 3), beginning about one inch from the edge of the fitting,
sweeping the flame around the pipe in short strokes at right angles to the axis of the pipe.
MD-402-1060-CN-HV-PRO-00001
 Switch the flame to the fitting at the base of the cup. Heat uniformly, sweeping the flame
from the fitting to the pipe until the flux on the fitting becomes quiet.
 When the flux appears liquid and transparent, start sweeping the flame back and forth
along the axis of the joint to maintain heat on the parts to be jointed, especially toward
the base of the cup of the fitting (Figure 4).
MD-402-1060-CN-HV-PRO-00001
 The flame must be kept moving to avoid melting the pipe and fitting.
 Apply the brazing filler metal at a point where the pipe enters the socket of the fitting.
When the proper temperature is reached, the filler metal will flow readily into
 The space between the tube and fitting socket, drawn in by the natural force of capillary
MD-402-1060-CN-HV-PRO-00001
action.
 Keep the flame away from the filler metal itself as it is fed into the joint. The temperature
of the pipe and fittings at the joint should be high enough to melt the filler metal.
 Keep both the fitting and tube heated by moving the flame back and forth from one to the
other as the filler Metal is drawn into the joint.
MD-402-1060-CN-HV-PRO-00001
 When the joint is properly made, filler metal will be drawn into the fitting socket by
capillary action, and a continuous fillet of filler metal will be visible completely around
the joint. To aid in the development of this fillet during brazing, the flame should be kept
slightly ahead of filler metal application.
 Brazing Filler Metals used for joining copper tube & fittings shall comply with AWS
A5.8: B Cup (Brazing-Copper-Phosphorus).
MD-402-1060-CN-HV-PRO-00001
 When the brazing horizontal joints, it is preferable to first apply the filler metal slightly
off-center at the bottom of the joint, proceeding across the bottom of the joint and
continuing up the side to the top of the joint. Then, return to the beginning point, over
lapping slightly.
 On vertical joint it is immaterial where the start is made. If the opening of the socket is
pointing down, Care should be taken to avoid overheating the tube, as this may cause the
MD-402-1060-CN-HV-PRO-00001
brazing filler metal to run down the Outside of the pipe.

MD-402-1060-CN-HV-PRO-00001
MD-402-1060-CN-HV-PRO-00001
(Figure 3) Heating Pipe (Figure 4) Brazing
7.6 Inert Gases
 When heat is applied to copper pipe in the presence of air, oxides form on the inner and
outer surfaces of the tube, this is not generally harmful but scale on the inside of the
refrigeration pipework can cause blockage & damage once refrigerant and oil begin to
circulate throughout the system. To overcome the formation of scale on the inside of the
pipework a suitable inert gas such as oxygen free nitrogen (OFN) is passed through the
MD-402-1060-CN-HV-PRO-00001
pipework during the brazing process. A typical method to achieve this is outlined below:-
 Pipework and components prepared for brazing with one end of pipework sealed (tube
cap fitted and taped to pipe with an 8mm hole in the tube cap). If there are more than two
ends of the pipework configuration then other ends need to be sealed in similar manner
leaving just one “open” end for the introduction of the OFN.
MD-402-1060-CN-HV-PRO-00001
 Connect a suitable length of braided hose to an OFN cylinder through an appropriate low
pressure regulator and flow meter; insert the other end of the tube into the open end of the
pipe work on which the brazing process is to be carried out.
 Open the nitrogen cylinder and set the flow meter to the following suggested level stop
introduce nitrogen to the pipework system at the rate of 5 to 10 l/min for diameters<1
1/8” and 10 to 15 l/min above. Ensure that pipework is not over pressurized. High flow
rates of OFN can cause vortexes which trap oxygen within the system and can also over
MD-402-1060-CN-HV-PRO-00001
cool the joint being brazed, preventing full joint penetration. The entry point of the OFN
must be sealed around the entry pipe to prevent the induction of air.
Note: Ensure the regulator outlet pressure does not exceed the flow meter’s maximum
inlet pressure, typically 2 bar.
7.7 Finishing of Joints

MD-402-1060-CN-HV-PRO-00001
 Flux residues should be removed by an environmentally acceptable method, as per

manufacturer’s recommendations. The degree of difficulty with which they can be
removed will depend largely on the amount of flux left over from the brazing process; it
will also depend on the avoidance of overheating and a minimum heating time.
 As most fluxes are chemically active complete removal is essential if undesirable

corrosion of parent metals is to be avoided. Removal of flux can be achieved by washing
the outside of the joint(s) with a cloth saturated with cold water, after the assembly has
MD-402-1060-CN-HV-PRO-00001
cooled to normal ambient temperature (care must be exercised to avoid the introduction
of moisture into the pipework). If flux still remains at this stage it must be removed by
abrasive techniques. Finally the joint(s) should be finished by polishing with a non-
metallic pipe abrasive.
Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

MA’ADEN Bauxite Alumina
Company (MBAC) Refrigerant Line (Copper tube) Installation 53 Of 15
Rev. E
7.8 Finishing of Joints
 Flux residues should be removed by an environmentally acceptable method, as per

manufacturer’s recommendations. The degree of difficulty with which they can be
removed will depend largely on the amount of flux left over from the brazing process;
it will also depend on the avoidance of overheating and a minimum heating time.

Rev. E
 As most fluxes are chemically active complete removal is essential if undesirable

corrosion of parent metals is to be avoided. Removal of flux can be achieved by
washing the outside of the joint(s) with a cloth saturated with cold water, after the
assembly has cooled to normal ambient temperature (care must be exercised to avoid
the introduction of moisture into the pipework). If flux still remains at this stage it
must be removed by abrasive techniques. Finally the joint(s) should be finished by
polishing with a non-metallic pipe abrasive.
8.0 QA / QC

Rev. E
8.1 Reference Standards
 SMACNA - HVAC Duct Construction Standards – Metal & Flexible
 ASHRAE Handbook - HVAC System &Equipment’s
8.2 Responsibilities
 QA / QC Inspector shall make sure that all activities related to ductworks are carried
out in accordance with the project specification and approved drawings. He shall

Rev. E
arrange Inspection & Testing required with WPF, MA’ADEN in accordance with the
QA/QC Plan. He shall maintain and keep records for all QC Documents.
 Site Engineer, Supervisor and Foreman shall assist the QA/QC Inspector whatever he
required in relation to the quality of works, procedures or documents.
8.3 Inspection
 Request for Inspection shall be issued WPF, MA’ADEN. Project Inspection 24 hours
in advance on weekdays and 48 hours in advance for weekends and holidays.

Rev. E
 Inspection Notification shall be issued to Hyundai/ WPF MA’ADEN Project

Inspection 24 hours in advance on weekdays and 48 hours in advance for weekends
and holidays.
 Inspection shall be done in accordance with the Inspection Test Plan (ITP) MD-402-
1030-QD-QC-PLN-00015 and Forms.
9. SAFETY AND ENVIRONMENTAL CONSIDERATION


Rev. E
9.1 Guidelines
 All personnel working with the ductworks shall wear the Personnel Protective
Equipment’s (PPE) at all times on the job site.
 Warning sign boards and barricades shall be provided where necessary to isolate the
working area and prevent unauthorized personnel.
 Scaffolding shall be tagged and approved by safety personnel before using.
 Safety belts shall be used whenever required.


Rev. E
 All electrical equipment’s shall be tagged and checked before using.
 Additional safety requirements shall be provided such as face shields, gloves, mask
and welding apron whenever required.
 Riggers shall be provided whenever heavy material is to be lifted by crane.
9.2 Responsibilities

Rev. E
 Safety Inspector / Officer in conjunction with the site supervisor or foreman shall
physically check and conform that all safety requirements had been provided and
implemented.
 Operators & riggers of lifting equipment’s shall follow and implement proper safe
working procedure at all times.
 HSE Supervisor shall ensure that all work is undertaken in accordance with the
specified work Scope.
 All personnel should be aware of assembly points, escape routes, emergency contact

Rev. E
numbers.
 PPE shall be worn at all times.
 Working platform, scaffolding and ladders shall be adequate for the work.
Scaffoldings shall be Inspected and clearly identified whether it is safe to use or not.
 Good housekeeping shall be observed in work areas. Construction wastes shall be

segregated and Disposed to an approved dump yard.

Rev. E
9.3 Safety (PPE)
 Safety Helmets (for all personnel present at site)
 Safety Shoe (for all personnel present at site)
 Gloves (to be used by Masons & scaffolder’s as required)
9.4 Personal Protective Equipment for brazing work
When carrying out brazing processes precautions shall be taken to protect exposed

Rev. E
parts of the head, body and clothing against heat and hot metal particles by wearing
adequate protective clothing.
a) Gloves
 These shall be worn to protect against heat and hot particles, and are usually
made from chrome leather.
b) Body Protection
 Flame retardant overalls should be worn wherever practical for all brazing

Rev. E
operations. Additional arm protection may be needed in restricted work areas.
c) Eye Protection
 It is necessary to protect the eyes against heat and glare which may cause eye
strain, but more important from flying hot particles. There are various types of
goggles or safety glasses. Operator preferences and visual activity will
influence the individual’s choice.
d) Head and Foot Protection


Rev. E
 Where there is a risk of injury from falling objects and contact with hot work
pieces etc., both these items of P.P.E. shall be worn.
e) Equipment Safety
 All brazing equipment comprising regulators, flash back arrestors, hoses,

torches, nozzles and cylinders shall be maintained and checked both on a daily
and annual basis, and recording of inspection maintained.

Rev. E
10. ATTACHMENT
10.1 Job Safety Analysis Sheet

10.2 Brazing Procedure Specification and Procedure qualification records

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Ma’aden Alumina Refinery Project

Method Statement for HVAC Duct & Refrigerant Line

REV DATE DESCRIPTION PREPARED CHECKED APPROVED

E 2013-08-07 Issued for Approval M.S.Kim Y.S.Kang S.B.Park

THIS DOCUMENT CONTAINS INFORMATION BELONGING TO MAADEN. NEITHER THE DOCUMENT,

7. REFRIGERANT PIPE INSTALLATION WORK

9. SAFETY AND ENVIRONMENTAL CONSIDERATION

This method statement cover onsite installation of pre-fabricated duct-work systems

BPS - Brazing Procedure Specification QB-200.1 Section IX ASME Boiler and

ASHRAE – American Society of Heating, Refrigerating and Air Conditioning Engineers

UMC – Uniform Mechanical code

Project Specification - MD-402-1000-EG-HV-SPC-50001

Project ITP - MD-402-1030-QD-QC-PLN-00015

 Ensure horizontal ductwork is adequately supported at equal distances in accordance with

 Ductwork supports unless otherwise indicated will be installed to provide a minimum

 Ducting to be installed allowing sufficient space for expansion/contraction and thermal

 Ensure terminal equipment is installed as specified.

DIFFUSER, GRILL & REGISTER INSTALLATION

7. REFRIGERANT PIPEINSTALLATION AND BRAZING WORK

7.1 Braze welder qualification procedure.

7.2 Work Equipment.

 Regulators and gauges. (single or two stage)

 Supply of appropriate gases for fuel, oxidizing and purging purposes.

7.3 Methods of Heating – General

7.4 Joint Preparation

7.5 Brazing Method

 Accurately measure the length of each tube segment (Figure 1).

(Figure 1) Measuring (Figure 2) Cutting

brazing filler metal to run down the Outside of the pipe.

(Figure 3) Heating Pipe (Figure 4) Brazing

7.6 Inert Gases

7.7 Finishing of Joints

 Flux residues should be removed by an environmentally acceptable method, as per

 As most fluxes are chemically active complete removal is essential if undesirable

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

7.8 Finishing of Joints

 Flux residues should be removed by an environmentally acceptable method, as per

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

 As most fluxes are chemically active complete removal is essential if undesirable

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

8.1 Reference Standards

 SMACNA - HVAC Duct Construction Standards – Metal & Flexible

 ASHRAE Handbook - HVAC System &Equipment’s

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

 Inspection Notification shall be issued to Hyundai/ WPF MA’ADEN Project

9. SAFETY AND ENVIRONMENTAL CONSIDERATION

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

 Scaffolding shall be tagged and approved by safety personnel before using.

 Safety belts shall be used whenever required.

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

 All electrical equipment’s shall be tagged and checked before using.

 Riggers shall be provided whenever heavy material is to be lifted by crane.

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

 PPE shall be worn at all times.

 Good housekeeping shall be observed in work areas. Construction wastes shall be

Method Statement for HVAC Duct & MD-402-1060-CN-HV-PRO-00001

9.3 Safety (PPE)

 Safety Helmets (for all personnel present at site)

 Safety Shoe (for all personnel present at site)

 Gloves (to be used by Masons & scaffolder’s as required)