PROJECT

CGK 063

METHOD STATEMENT OF MECHANICAL WORK FOR

DOCUMENT
REFRIGERANT (COPPER TUBE) & CONDENSATE
TITLE
PIPE INSTALLATION
Contents

1.0 PURPOSE.......................................................................................................................................................
2.0 SCOPE OF WORK...........................................................................................................................................
3.0 DEFINATIONS................................................................................................................................................
4.0 REFERENCE....................................................................................................................................................
5.0 RESPONSIBILITIES.........................................................................................................................................
6.0 PROCEDURE..................................................................................................................................................
6.1 General Description...............................................................................................................................
6.2 Material..................................................................................................................................................
6.3 Plants, Machinery & Equipment............................................................................................................
6.4 Manpower..............................................................................................................................................
7.0 PROCEDURES REFRIGERANT & CONDENSATE PIPE INSTALLATION...........................................................
7.1 Introduction...........................................................................................................................................
7.1.1 Pre - Planing Stage.......................................................................................................................
7.2 Receiving Material at Site......................................................................................................................
7.3 Refrigerant Pipe Installation..................................................................................................................
7.3.1 Refrigerant Fabrication................................................................................................................
7.3.2 Flushing Pipe.................................................................................................................................
7.3.3 Pipe Leakage & Pressure Test.......................................................................................................
7.3.4 Vacuum.........................................................................................................................................
7.3.5 Charging........................................................................................................................................
8.0 APPENDICES..................................................................................................................................................
8.1 Drawing..................................................................................................................................................
As Attached Drawing.............................................................................................................................
8.2 RISK ASSESSMENT (RA)..........................................................................................................................
8.3 INSPECTION TEST PLAN (ITP).................................................................................................................
8.3.1 CGK063-ITP-RFSI-Request for Site Inspection.................................................................................
8.3.2 CGK063-ITP-M.03 - Site General Report..........................................................................................
8.3.3 CGK063-ITP-M.04 - Site Defect Inspection Report..........................................................................
8.3.4 CGK063-ITP-M.13 - Piping Installation Checklist.............................................................................
8.3.5 CGK063-ITP-M.14 - Condensate Drain Pipe Water Leakage Test...................................................
8.3.6 CGK063-ITP-M.15(1) - Condensate Flow Test Before Insulation.....................................................
8.3.7 CGK063-ITP-M.15(2) - Condensate Flow Test After Insulation.......................................................
8.3.8 CGK063-ITP-M.16 - Piping Pressure Test & Leakage Function Test................................................
8.3.9 CGK063-ITP-M.17- Pipe Flushing Test.............................................................................................
1.0 PURPOSE
The purpose of this statement is to document the correct procedure and installation of
refrigerant & condensate pipe for CGK 063 project, and to ensure that all concerned
are familiar with the sequence of activities, utilization of resources and execution of the
works in compliance with applicable safety, quality procedures and project documents
and specification.

2.0 SCOPE OF WORK

This method statement is the necessary measures to ensure that all installation
activities to be identified and established and approved by the Employer’s
representative. All activities will be carried out in accordance with the contract details
and in full compliance to the contract specifications will be done in compliance with
requirements issued by authorities. The scope of this plan is to provide a guideline for
the implementation of quality assurance on installation work of refrigerant &
condensate pipe.

3.0 DEFINATIONS
Terms Definition
Project CGK 063
JO PT Jaya Obayashi
MOS Method of Statement
MSA Material Submission Approval

Table 1: Definitions

4.0 REFERENCE
The following Standards of Practice shall be applicable to the works:
 ASTM C921 : Standard Practice for Determining the Properties of Jacketing
Materials for Thermal Insulation.
 NFPA : National Fire Protection Association
5.0 RESPONSIBILITIES
No Designation Qty Responsibility
.
Responsible for overall commercial, contractual
& technical performances associated with
1 Project Manager 1
specific project. Reporting to the Project
Director.
2 M&E Engineer 4 Planning and supervising installation activities.
Inspect, verify, and prepare work statement for a
quality installation works. Material storage, fit
3 QA / QC Engineer 2
for use tools and equipment, and installation
works
To provide toolbox and guidance to work and to
4 Safety Officer 1
ensure that work is carried out in a safe manner.
Obtain permit to work, control the sequence
according to MOS, approved shop drawings, and
MSA, ensure mechanical aspects of the work are
according to the specifications, ensure safe
practices are followed and ensure quality of
workmanships during execution. Ensure material
5 Supervisor 3-5
temporary storage and protection meet vendor
and standards requirement

. Ensure tools being used for installation are

calibrated and meet vendor and standards
requirement
To carry out all the mechanical aspects of the
6 General Workers 10-15
refrigerant & condensate pipe installation.

Table 2: List of Responsibilities

6.0 PROCEDURE
6.1 General Description
The mechanical work for refrigerant (copper tube) & condensate pipe
installation to be carried out at CGK063.

6.2 Material
Materials are as below.

No Description Brand
1 Refrigerant Piping and Fitting KEMBLA ASTM B280
K-Flex
2 Refrigerant Insulation Pipe
Class "0"/ Density: 48 - 70 Kg/m3

Table 3: List of Materials

6.3 Plants, Machinery & Equipment

No Descriptions Purpose

1 PVC Cutter Cutting uPVC Pipe

2 Copper Cutter Cutting Copper Pipe

3 Flaring Tools Making Flare for Copper Connection

4 Standard Tool Kit Standard use
5 Wrench tools For Tighten Copper Nuts at Indoor/Outdoor
6 Scissor Lift Working at heights

Table 4: List of Plants, Machinery and Equipment

6.4 Manpower
The actual manpower of each type of installation may vary according to the site
condition and requirement.

All workers shall wear appropriate PPE (Hard Hat, Protective Boots, Goggles,
High Visibility Vest and Protective Gloves) and safety harness when working
above 2 meter in height.
7.0 PROCEDURE REFRIGERANT & CONDENSATE PIPE INSTALLATION
7.1 Introduction
Refrigerant and condensate pipe installation is applied for VRF system with
water cooled type system, the implementation of work must follow the Shop
Drawing and specifications.

7.1.1 Pre-Planning Stage

 Secure all necessary design information and prepare all the necessary
designed drawings.
 Submission of design drawings for approval.
 Prepare all necessary shop drawings and determine the actual position to
commence installation with the mobilization of required work force, tools
and equipment.
 Prepare all documents required in Specification submittals and all
documents/certification required in Specification.
 Prepare material approval document, complete with confirmation of
conformance between delivered material with approved material
(code/model/type, length, weight, width, materials, quantity, etc).
 Prepare confirmation of conformance between temporary storage and
vendor storage requirement/standard.
 Prepare confirmation of conformance between tools and its calibration
meet vendor requirement/standard.
 Ensure all approval required to perform work are obtained and conform
with approved documents by Consultant Engineers and Architect.

7.2 Receiving Material at Site

 The site supervisor shall receive the pipes upon arrival at site. It is his
responsibility to check the pipes against the delivery order which
accompany the delivery and that the pipes are in good condition.
 The pipes will then be unloaded and placed on the respective floors
where the pipes will be installed.
  Delivery to work site will be closely linked to the installation programme
so as to avoid accumulation of unfixed pipe work and double handling.
Should it become necessary to store pipes at work site, timber or pallets
will be used to ensure that the pipes remain dry and clean.

7.3 Refrigerant (Copper Tube) Pipe Installation.

All refrigerant lines between outdoor and Indoor units shall be of annealed,
refrigeration grade copper tubing, AR Type, meeting ASTM B280 requirements.
Important point when refrigerant pipe fabrication its pipe end protection if
short hours only used pinching and for long hours used taping. Pinching is
temporarily pinch copper tube ends and seal gaps by brazing. Taping method
used seal pipe ends with electrical tape. Bellow its detail for pinching and taping
for refrigerant pipe protection.

PINCHING

TAPING

Picture 1: Pinching & Taping Process

7.3.1 Refrigerant (Copper Tube) Fabrication

1. Cutting
 Use dedicated tube cutter and cut square.
 Slowly fasten cutter onto tube/pipe and rotate it to mark cutting line
while not to deform, and carefully cut.
  DO NOT use metal saw or grinder, which may deform pipe or leave
filing inside.
 Use reamer to remove burrs inside tube/pipe. Do not ream too much,
otherwise burrs will be formed or wall will be thinner than necessary.
 Put pipe open end downward to prevent filings from remaining inside
tube/pipe.

Picture 2: Cutting Pipe

2. Flaring
This point must be check while worker do a flaring works,
 Uniform flare size and shiny inside surface.
 Flared part has uniform wall thickness.
 Flare has appropriate size.
NOTE: Precisely round and uniformly shaped, shiny inside with no
scar/scratch.

Remaining of burrs

Scar/scratch by filings
 Undersized

Oversized

Crack

Picture 3: Defective Flaring

3. Brazing
Procedure for copper tube brazing:
 Adjust torch flame; Make sure torch flame gets neutral before starting
brazing.
 Pre-heating; Evenly heat tube and socket part. DO NOT keep placing
torch flame in a single spot but continue moving it. Proper pre-heat
temperature ranges 1000°F, brazing alloys containing more than 0.05
percent phosphorus are prohibited. Finish heating on socket side,
rather than tube.
 Place torch flame at as right angle as possible with tube surface, and
heat tube and socket part.
 Picture 4: The Pre-heated & Brazing Process

 Nitrogen purging one of method for brazing copper tube, while

brazing pipe must be purge with nitrogen, this purposed for blow out
oxygen in side pipe and change with nitrogen, so when no oxygen
inside pipe, no smut in side pipe causes no oxidations process. Bellow
its detail for purging pipe while brazing copper tube.

Picture 5: The Nitrogen Purging

 Caution in brazing work:

1. Brazing operator shall be have certified and qualified in
accordance with tests prescribed by the National Certified
Welding Bureau (NCWB) or by other approved test procedures
using methodology and procedures covered in the ASME Boiler
and Pressure Vessel Code, Section IX, "Qualification Standard for
Welding and Brazing Procedures, Welders, Brazer’s, and Welding
and Brazing Operators"
2. Either flat or horizontal position. DO NOT braze overhead.
3. To branch liquid or gas line, use designated item by manufacture.
Direction and angle of branch connection must be carefully
confirmed. (To prevent trap of refrigeration oil, turbulent flow).
4. Nitrogen purge inside tube when brazing.
5. When flux is used for brazing, the following must be taken into
account. After brazing, thoroughly remove residual flux. If chlorine
contained in flux remains inside tube, it may deteriorate
refrigeration oil.

Good Bad
Picture 6: Brazing connection results
4. Insulation
All copper tube will insulation with formed nitrite rubber 19mm, but
when installation every joint, and fitting will install insulation after pipe
line finish leakage and pressure test and test was acceptable. Bellow its
detail for insulation copper tube:
 Flare connection; Attach and fill insulation material around flare nut
of liquid and gas lines separately. Press insulation onto equipment
surface and secure it with tape, etc.
 Brazed joint; Ensure brazed part is cooled off until it can be touched
with bare hands. Attach and fill appropriate size of insulation material
and secure it with tape, etc.
 Elbows; Cut slits in insulation material and slide it over piping length
wise. After piping is bent, slide insulation back to bent (elbow) part.
 Refrigerant branch piping; Fill insulation material in the gap between
refrigerant pipe insulation and branch connection insulation.
 Equipment connection; Prevent condensate from infiltrating
refrigerant piping.
 Do not install insulation until system testing has been completed and
all leaks have been eliminated. Pre-insulated pipe is acceptable.
 Install piping free of sags or bends and with ample space between
piping to permit proper insulation applications.
 Install piping tight to slabs, beams, joists, columns, walls, and other
permanent elements of the building. Provide space to permit
insulation applications, with 1 inch clearance outside the insulation.
Allow sufficient space above removable ceiling panels to allow for
panel removal.
Picture 7: Installation of insulation on the connection

Picture 8: The copper pipe with thermal insulation

7.3.2 Flushing Pipe
Purposed to flush oxide film generated within copper tube during
brazing or foreign material inside tube due to inappropriate
protection, and to check connections of piping between inside and
outside units. Here's the procedure:

 Connect nitrogen gas supply hose (from regulation valve of

cylinder) with outside unit.
 Open regulation valve and adjust gas pressure to approx.
0.05MPa.
 Put the palm over tube end to shut off, and release it after
increased pressure is felt.
 Normally, flushing is conducted in a couple of steps, by dividing
piping route (outside unit through inside unit) into some flushing
zones.

7.3.3 Pipe Leakage & Pressure Test

Purposed for ensure no leakage at refrigeration system air
conditioning pipe line, bellow its detail procedure for leakage and
pressure test air conditioning pipe line:

 Check if refrigerant pipe connections of both in/outside are

secure.
 Make sure all valves are shut.
 Open all manual valves and solenoid valves, etc. of system to be
tested.
 Test with pressure 600psig, or 41,5 kg/cm²(PAC Manufacture and
Owner references) then Hold it for 1 hours and check if pressure is
NOT reduced.
 In case there is a risk of leaking nitrogen gas through equipment
valve into outside unit, leak test must be conducted without
connecting piping and equipment. No leakage (no pressure
 change). Detection of leakage, hissing sound of leakage (major
leak), put bare hand on piping to detect leakage (major leak),
apply soap solution and check if bubble is produced (minor leak).

7.3.4 Vacuum
Vacuum purposed for remove moisture from system and dry inside
piping. Moisture remaining inside piping may result in lowering of
system performance, i.e. compressor damage. Caution:

 Make sure vacuum pump is capable of vacuuming at -0.1MPa or

lower in advance.
 Run pump for around 1 hour and keep inside piping at -0.1MPa or
lower.
 After pump stops, hold it for around 1 hour. If pressure within the
system is reduced, there is leak or moisture remaining inside.
Detect leak and check dryness.

Picture 9: The vacuum process

 Procedure:
 Manifold settings and operation:
 Low pressure valve (blue) OPEN
 High pressure valve (red) SHUT
 Vacuum valve OPEN
 Connect vacuum pump with backflow preventer.
 Turn on vacuum pump and backflow preventer to start
vacuuming.
 After compound gauge indicates -101KPa (5Torr), continue
vacuuming for about 1 hour. After 1 hour, make sure vacuum
gauge reads -0.1MPa.
 After vacuuming is finished, shut VAC valve and turn off backflow
preventer and pump. Hold it for 1 to 2 minutes and ensure that
there is no variation (pressure increase) in manifold gauge and
vacuum gauge.
(Pressure increase reveals leakage. Conduct leak test to detect
leak and repair it. Vacuum dry the system once again.)

 After vacuuming is finished and no leakage is detected, shut low

pressure valve (blue) of manifold, while slightly opening globe
valve of gas line until compound gage of low pressure side (blue)
of manifold reads 0.1-0.2MPa or over, then immediately pull out
charge hose (blue) (to prevent air from entering refrigerant pipe).
7.3.5 Charging

Normally, PAC system is filled with required amount of refrigerant for

its specified piping lengths. If piping needs to be extended, additional
refrigerant must be charged. Here's the procedure:
 Make sure piping has been vacuum dried.
 Based on size and length of extended piping, calculate recharge
amount of refrigerant.
 Composition of refrigerant blends varies in a gaseous or liquid
state, and refrigerant must be charged in a liquid state. Make sure
cylinder has dip tube before charging. If dip tube is not available,
cylinder must be placed upside down. Connect electric charger,
manifold (for gauge), service valve of outside unit with charging
hose, and set PAC to recharge mode.
 Use electric charger to precisely measure charge amount.
 Make sure specified amount of refrigerant has been charged, and
turn off recharge mode.
 Immediately open stop valves of both liquid and gas lines.

Picture 10: Charge Process

8.0 APPENDICES
8.1 DRAWING
As attached drawing

8.2 RISK ASSESSMENT (RA)

8.3 INSPECTION TEST PLAN (ITP)

8.3.1 CGK063-ITP-RFSI - Request for Site Inspection

8.3.2 CGK063-ITP-M.03 - Site General Report

8.3.3 CGK063-ITP-M.04 - Site Defect Inspection Report

8.3.4 CGK063-ITP-M.013 - Piping Installation Checklist

8.3.5 CGK063-ITP-M.14 - Condensate Drain Pipe Water Leakage Test

8.3.6 CGK063-ITP-M.15(1) - Condensate Drainage Flow Test Before
Insulation
8.3.7 CGK063-ITP-M.15(2) - Condensate Drainage Flow Test After Insulation

8.3.8 CGK063-ITP-M.16 - Piping Pressure Test & Leakage Function Test

8.3.9 CGK063-ITP-M.17 - Pipe Flushing

8.3.10 CGK063-ITP-M.00 - Receipt Inspection Form

 CGK060-ITP-M.00

PROJECT : 063
Category：

MATERIAL ON SITE INSPECTION

We re que st your atte ndance to inspe ct the following Materials

Material/Equipment:

Manufacturer: Model:

MATERIAL AND EQUIPMENT APPROVAL RECORD Ref. No. :

Date of Arrival on Site: Quantity :

Storage Location: Serial No. :

Inspection Report
Date ： Date ：
No. DESCRIPTION Check Check Re marks
(Sub-contractor) (Main Contractor)
1 No Physical Damage ? OK / NG OK / NG
2 Details given above correct ? OK / NG OK / NG
3 Conform with Approved submission ? OK / NG OK / NG
4 Accessories/ Spare Parts included ? OK / NG OK / NG
OK / NG OK / NG

Engineer's Representative's Comments

The above material has been inspected on Site and found at time of inspection to be

Satisfactory / Unsatisfactory

for incorporation in the permanent works.

Comments

Signature
ME MANAGER ENGINEER SUB-CONTRACTOR

Date： Date： Date：

Above inspection shall not relieve Contractor of his responsibilities to incorporate in the Works only such materials that are in
conformity with the Contract.