Document Type

` DAR
Method Statement

METHOD STATEMENT

ZAID AL-HUSSAIN AND

BROTHERS GROUP OF COMPANIES

P.O. BOX 4756 RIYADH 11412

KING ABDULLAH INTERNATIONAL GARDENS

Contract No.

Method Statement No:

Issued by
Rev. # Date Description Prepared Checked Approved

Page 1
 Document Type

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Method Statement

TABLE OF CONTENTS

1. TITLE

2. SCOPE OF WORK

General description.
Plant and equipment.
Materials.
Site planning & preparation
Work methodology.
Organization, Responsibilities & Supervision.
Work Force.

3. HEALTH & SAFETY

Risk assessments
Protective & Safety Equipment.
Contractual Requirements.
Information to personnel.
Emergency Procedures.
Permit Requirements.

4. ENVIRONMENTAL ISSUES

Environmental Impact assessment.

Contractual Requirements.
Emergency Procedures.

5. QUALITY RESPONSIBILITY

Contractual Requirements.
Critical works.
Inspection & Testing.
Follow up & Evaluation.

6. APPENDICES

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 Document Type

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Method Statement

1. TITLE

Method Statement for Hot Water Heating Boilers

2. SCOPE OF WORK

General Description

 Supply, Positioning, Installation, Testing & Commissioning of Hot Water

Heating Boilers

Plant and Equipment

 List of Tools and Equipment’s:

1. Crane
2. Forklift
3. Basic Mechanic Tools Box
4. Basic Electric Tools Box
5. Scaffolding
6. Painting Tools
7. Lifting Winch

Materials
1. Pipes & Fittings
2. Paint
3. Piping Supports
4. Insulation
5. Cladding
6. Cables, Wires & Wiring Accessories

1.

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 Document Type

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Method Statement

Site Planning and Preparation:

 All equipments and materials to be used will be delivered in the site from
storage area.
 All equipments will be inspected by safety officer on site
 The contractor will provide a route plan and access road prior to starting the
job.
 All necessary safety measures will be provided.
 If necessary, a traffic management will be included in the planning stage.

Work Methodology

Page 4
 Installation

2. Installation The distance from the wall behind the boiler

2.1 Setting up, levelling
No special foundation plate is required for erecting the
boiler (sufficient supporting capacity for the boiler must be
guaranteed) - For operational weight see chapter 3.
In the case of boiler installation in the domestic domain,
vibration dampers are to be mounted under the boiler
plinth rails.
Space requirement
for mounting the thermal insulation and sheet metal clad-
ding:
• is to be at least 40 cm to the left and right hand
sides of the boiler.
• controller side min. 70 cm.
must always be sufficient in order to gain ac-
cess to the cleaning aperture in the flue gas
collector. It must be possible to swing open
the hinged door of the boiler with the burner.
Levelling
Install with the top edge of the boiler water jacket (boiler
longitudinal axis) exactly horizontal or with a slight incline
to the rear, by placing suitable underlays beneath the
plinth rail to ensure effective venting.
Mount the door liner (cladding) before install-
ing the burner (for heating trials, with the boil-
er not yet thermally insulated).

If the distance from walls is less, the boiler must first be

completely thermally insulated and covered before being
introduced to the planned installation location. 2.2 Installation of the regulators
Max-3 plus (420-2700)
The regulators in the combustion chamber must be
installed into the 3rd compartment (Fig. 01).

3rd compartment

Fig. 01

6 4 214 863 / 01
 Installation

Boiler door opens to the left

The boiler door hinges can be changed over to enable
the door to open to the left side. This can be useful where
space is limited.

The hinges are changed over as follows:

1. Tighten the top and bottom locknuts (1, Fig. 02) to-
wards the swing-out flange.
2. Mount flange nuts (2) with hole diagonal on the new
opening side, i.e.,
- change over the bottom left and top right flange nuts
and
- change over the top left and bottom right flange
nuts.
3. Unscrew locknut (3) and turn back approx. 1 cm.
4. Mount the burner plug connector on the other side.

CAUTION
The cable must not contact any hot parts.

WARNING
! Boiler door hinges must be changed over
only by Hoval Service!

2 1 3
2

Figure shows situation as delivered

(boiler door opens to the right)

1
Fig. 02

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 Installation

2.3 Installing the thermal insulation, cladding and boiler controller

2.3.1 Installing the thermal insulation Max-3 (420-750), Max-3 plus (420-750)
Before starting installation, check the dimen- 1. Wrap the insulating mats (1.1/1.2, Fig. 04) around the
sion between the top edge of the boiler base boiler body (joint at the side, black side outwards).
rail and support rail. 2. Fit tension springs (2) to hold the ends of the insulat-
ing mats (1.1/1.2) together.
3. Fasten plastic straps (3) and strap fasteners (4).
- Do not overtighten the straps (reduced insulating
value).
4. Install insulating mat (5.1) and insulating panel (5.2):
- Wrap the insulating mat (5.1) around the flue gas

+3
0
+3
0
collector and fix with tension springs.

Max-3 (620,750), Max-3 plus (420,750) = 1191.5

Max-3 (420,530), Max-3 plus (420,530) = 1072
- Remove cleaning covers from the back of the boil-
er. (The cleaning covers are reattached after fitting
the upper rear cladding wall (18, Fig. 05).)
- Slide insulating plate (5.2, Fig. 04) onto the flue gas
collector.
5. Place insulating mat (6) on the pins welded to the rear
wall of the boiler and secure with the retaining discs
(Fig. 03).

Fig. 03
6. Place insulating mats (7.1/7.2/7.3/7.4) on the pins
moulded to the front wall of the boiler and secure with
the retaining discs (Fig. 03).
7. Wrap insulating mat (8) around the hinged flange and
secure with retaining discs (Fig. 03).

The following insulating mats are not at-

tached until the cladding is installed (see
chapter 2.3.2).
- Insulating mats to prevent vertical air circu-
lation
- Insulating mats between the door and door
cladding

8 4 214 863 / 01
 Installation

5.1
1.2 5.2

1.1

7.3

7.1

3
2 4

7.2 7.4
Fig. 04

4 214 863 / 01 9
 Installation
2.3.2 Installing the cladding and boiler control Max-3 (420-750), Max-3 plus (420-750)
1. Hook the right side walls (9.1/9.2, Fig. 05) on the top
longitudinal strutting and at the bottom in the pins at-
tached to boiler rail (see detail A).
2. Hook the left side walls (10.1/10.2) on the top longitu-
dinal strutting and at the bottom in the pins attached to
the boiler base rail (see detail A).
3. Attach the bottom rear wall (11) to the special screws
in the rear side walls.
4. Route the burner cable (12) with the burner connec-
tion plug (12a) through the prepared bore hole in the
side wall, then attach the cable route with the rosette
(12b) to the side wall.
- The burner must be connected to the boiler with the
standard plug connection.
- The burner cable must be installed so that the plug
connection has to be disconnected in order to swing
out the burner.
5. Mount the boiler controller (13) and wire up the im-
mersion sensor (14) and burner cable (12), see chap-
ter “2.3.7 Installation of boiler controller”, page 20.
WARNING
! Capillaries must not be folded or kinked
10
6. Insert 2 insulating mats (15.1/15.2) (to prevent ver-
tical circulation of air) longitudinally on the left and
right.
7. Attach C-clips (16) to the top of the side walls (9.1/9.2/
10.1/10.2).
8. Mount all cladding covers (17.1/17.2/17.3).
9. Attach the top rear wall (18) to the bottom rear wall
(11) and attach the cladding covers (17.2/17.3) to the
special screws on the top rear wall (18).
10. Fasten all cladding covers (17.1/17.2/17.3) at the
sides with self-tapping screws.
11. Mount cleaning cover back onto rear of boiler (attach
to the rear wall (18)).
12. Fix lead-through (19).
13. Installing door cladding:
- Fasten 4 threaded bolts (20) with nut and two wash-
ers to the boiler door (see detail B).
- Push insulating mat (21) onto the boiler door.
- Install door cladding (22).
14. Attach shield plate (23) to the front of the boiler (see
detail C).
15. Affix labels and, where applicable, mount manual
holder on the side.
4 214 863 / 01
 Installation

17.2

17.3
19

17.1

10.1 18
15.2
14a 10.2

11
15.1

14
21
B
13 9.1
22

12 16
9.2

A,C
12a 12b

A B 20 C
9.2

23

20 22 21
Fig. 05

4 214 863 / 01 11
 Installation

2.3.3 Installing the thermal insulation Max-3 (1000,1250), Max-3 plus (1000,1250)
Before starting installation, check the dimen- 1. Wrap the insulating mats (1.1/1.2, Fig. 07) around the
sion between the top edge of the boiler base boiler body (joint at the side, black side outwards).
rail and support rail. 2. Fit tension springs (2) to hold the ends of the insulat-
ing mats (1.1/1.2) together.
3. Fasten plastic straps (3) and strap fasteners (4).
- Do not overtighten the straps (reduced insulating
value).
4. Install insulating mat (5.1) and insulating panels
(5.2/5.3):

+3
0
- Wrap the insulating mat (5.1) around the flue gas

Max-3 (1000,1250), Max-3 plus (1000,1250) = 1391.5

collector and fix with tension springs.
- Remove cleaning covers from the back of the boil-
er. (The cleaning covers are reattached after fitting
the upper rear cladding wall (18, Fig. 08).)
- Slide insulating plates (5.2/5.3, Fig. 07) onto the
flue gas collector.
5. Place insulating mat (6) on the pins welded to the rear
wall of the boiler and secure with the retaining discs
(Fig. 06).

Fig. 06
6. Place insulating mats (7.1/7.2/7.3/7.4) on the pins
moulded to the front wall of the boiler and secure with
the retaining discs (Fig. 06).
7. Wrap insulating mat (8) around the hinged flange and
secure with retaining discs (Fig. 06).

The following insulating mats are not at-

tached until the cladding is installed (see
chapter 2.3.4).
- Insulating mats to prevent vertical air circu-
lation
- Insulating mats between the door and door
cladding

12 4 214 863 / 01
 Installation

5.1 5.2 5.3

1.2

1.1

7.3
7.1

3 4
2
7.2 7.4
Fig. 07

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 Installation
2.3.4 Installing the cladding and boiler control Max-3 (1000,1250), Max-3 plus (1000,1250)
1. Hook the right side walls (9.1/9.2/9.3, Fig. 08) on the
top longitudinal strutting and at the bottom in the pins
attached to boiler rail (see detail A).
2. Hook the left side walls (10.1/10.2/10.3) on the top
longitudinal strutting and at the bottom in the pins at-
tached to the boiler base rail (see detail A).
3. Attach the bottom rear wall (11) to the special screws
in the rear side walls.
4. Route the burner cable (12) with the burner connec-
tion plug (12a) through the prepared bore hole in the
side wall, then attach the cable route with the rosette
(12b) to the side wall.
- The burner must be connected to the boiler with the
standard plug connection.
- The burner cable must be installed so that the plug
connection has to be disconnected in order to swing
out the burner.
5. Mount the boiler controller (13) and wire up the im-
mersion sensor (14) and burner cable (12), see chap-
ter “2.3.7 Installation of boiler controller”, page 20.
WARNING
! Capillaries must not be folded or kinked
14
6. Insert 4 insulating mats (15.1/15.2/15.3/15.4) (to pre-
vent vertical circulation of air) longitudinally on the left
and right.
7. Attach C-clips (16) to the top of the side walls (9.1/9.3/
10.1/10.3).
8. Mount cladding covers (17).
9. Attach the top rear wall (18) to the bottom rear wall
(11) and attach the cladding cover (17) to the special
screws on the top rear wall (18).
10. Mount cladding covers (19.1/19.2/19.3).
11. Fasten all cladding covers (17/19.1/19.2/19.3) at the
sides with self-tapping screws.
12. Mount cleaning cover back onto rear of boiler (attach
to the rear wall (18)).
13. Fix lead-through (20).
14. Installing door cladding:
- Fasten 4 threaded bolts (21) with nut and two wash-
ers to the boiler door (see detail B).
- Push insulating mats (22.1/22.2) onto the boiler
door.
- Install door cladding (23).
15. Attach shield plate (24) to the front of the boiler (see
detail C).
16. Affix labels and, where applicable, mount manual
holder on the side.
4 214 863 / 01
 Installation

17
20
19.2
18
19.3
19.1
14a 15.3 10.2
15.2
11
10.1
10.3 15.1

22.2 14

22.1
B 9.2
13
23
9.3
12 16
9.1

A,C
12a 12b

A B 21 C
9.1

24

21 23 22.1
Fig. 08

4 214 863 / 01 15
 Installation

2.3.5 Installing the thermal insulation Max-3 (1500-2700), Max-3 plus (1500-2700)
1. Wrap the insulating mats (1.1/1.2, Fig. 10) around the
boiler body (joint at the side, black side outwards).
2. Fit tension springs (2) to hold the ends of the insulat-
ing mats (1.1/1.2) together.
3. Fasten plastic straps (3) and strap fasteners (4).
- Do not overtighten the straps (reduced insulating
value).
4. Install insulating mat (5.1) and insulating panels
(5.2/5.3):
- Wrap the insulating mat (5.1) around the flue gas
collector and fix with tension springs.
- Remove cleaning covers from the back of the boil-
er. (The cleaning covers are reattached after fitting
the upper rear cladding walls (11.2/11.3, Fig. 11).)
- Slide insulating plates (5.2/5.3, Fig. 10) onto the
flue gas collector.
5. Place insulating mat (6) on the pins welded to the rear
wall of the boiler and secure with the retaining discs
(Fig. 09).

Fig. 09
6. Place insulating mats (7.1/7.2/7.3/7.4) on the pins
moulded to the front wall of the boiler and secure with
the retaining discs (Fig. 09).
7. Wrap insulating mat (8) around the hinged flange and
secure with retaining discs (Fig. 09).

The insulating mats between the door and

door cladding are only attached after the
cladding is installed (see chapter 2.3.6).

16 4 214 863 / 01
 Installation

5.1 5.2 5.3

1.2

1.1

7.3
7.1

3 4
2
7.2 7.4
Fig. 10

4 214 863 / 01 17
 Installation
2.3.6 Installing the cladding and boiler control Max-3 (1500-2700), Max-3 plus (1500-2700)
1. Hook the right side walls (9.1/9.2/9.3, Fig. 11) on the
top longitudinal strutting and at the bottom in the pins
attached to boiler rail (see detail A).
2. Hook the left side walls (10.1/10.2/10.3) on the top
longitudinal strutting and at the bottom in the pins at-
tached to boiler rail (see detail A).
3. Attach the rear walls (11.1/11.2/11.3) to the side walls
and screw them in.
4. Mount cleaning cover back onto rear of boiler (attach
to the rear walls (11.2/11.3)).
5. Route the burner cable (12) with the burner connec-
tion plug (12a) through the prepared bore hole in the
side wall, then attach the cable route with the rosette
(12b) to the side wall.
- The burner must be connected to the boiler with the
standard plug connection.
- The burner cable must be installed so that the plug
connection has to be disconnected in order to swing
out the burner.
6. Mount the boiler controller (13) and wire up the im-
mersion sensor (14) and burner cable (12), see chap-
ter “2.3.7 Installation of boiler controller”, page 20.
WARNING
! Capillaries must not be folded or kinked
18
7. Attach C-clips (16) to the top of the front side walls
(9.1/10.1).
8. Position all cladding covers (17.1/17.2/17.3/17.4/17.5)
and fasten (17.1) according to detail B.
9. Installing door cladding:
- Fasten 8 threaded bolts (18) with nut and two wash-
ers to the boiler door (see detail C).
- Push insulating mats (19.1/19.2) onto the boiler
door.
- Cut a recess for the burner flange out of the insulat-
ing mat (19.3).
To achieve continuous thermal insulation be-
tween the boiler front and burner, the recess
in the insulating mat (19.3) must have the size
and shape of the burner flange.
- Push the insulating mat (19.3) into the recess be-
tween the insulating mats (19.1/19.2).
- Install door cladding (20.1/20.2).
10. Affix labels and, where applicable, mount manual
holder (21) on the side.
4 214 863 / 01
 Installation

B
17.4 17.2
17.5

17.3

17.1 11.3

11.2
10.3
16
10.2 11.1

14a 10.1

14

19.1
C
19.2 9.3
13
20.2
20.1 9.2
19.3 12 21
9.1

A
12b 12a

A 9.1 C 18

9.1

18 20.2 19.2
Fig. 11

4 214 863 / 01 19
 Installation

2.3.7 Installation of boiler controller 2.3.7.2 Boiler controller T0.2 / T2.2

2.3.7.1 Boiler controller TopTronic® E
13a
13a 13c

13b 13
13 13b
13c
13c
Fig. 15

WARNING
! Capillaries must not be folded or kinked

1. Mount the special screws with nuts (13a, Fig. 15) on

Fig. 12 the side wall.

WARNING
! Capillaries must not be folded or kinked
1. Mount the special screws with nuts (13a, Fig. 12) on
the side wall.
Fig. 13
2. Hook the boiler controller (13) into the side wall with
the recesses for the special screws.
3. Fasten boiler controller with 4 self-tapping screws
Ø 3.5x 6.5 and serrated lock washers (13b).
4. Pull the capillaries with the immersion sensors (14,
Fig. 14) through the opening in the side wall, insert
them into the immersion sleeve (14a) as far as the
stop and fix in position with retaining spring (14b).
16a
Fig. 16
2. Hook the boiler controller (13) to the special screws.
3. Fasten boiler controller with the self-tapping screws
Ø 3.5 x 6.5 and serrated lock washers (13b).
4. Pull the capillaries with the immersion sensors (14,
Fig. 17) through the opening in the side wall, insert
them into the immersion sleeve (14a) as far as the
stop and fix in position with retaining spring (14b).
16a
16c
16
Fig. 17
5. Plug in the burner plug.
6. Attach cover plate to the boiler controller (13c, Fig.
15) with self-tapping screws ø 3.5 x 6.5 and serrated
lock washers.

16c Continue fitting the cladding.

16
Fig. 14
5. Plug in the burner plug.
6. Close the boiler controller and screw on (13c, Fig.
12).

Continue fitting the cladding.

20 4 214 863 / 01
 Technical information

3. Technical information
3.1 Description of the boiler
The Max-3 or Max-3 plus boiler is constructed in 3-compartment form. The flue gases flow from the cylindrical combus-
tion chamber into the water cooled reversing elbows and through the 2nd compartment into the front reversing cham-
ber. The 3rd compartment comprises a specially formed beading pipe through which the flue gases are conducted to
the flue gas collector.

Figure: Max-3 (420-1250) type

4 214 863 / 01 21
 Installation

4. Installation ref. a)
Flue gas systems according to EN 13384, part 2, execu-
4.1 Boiler installation room requirements tion types I and II are appropriate for modern firing sys-
The valid building supervisory regulations for the instal-
tems (advice from the specialist is necessary). Pay at-
lation location are applicable for the construction require-
tention to the flue gas temperature at rated output; see
ments for boiler rooms and their aeration and ventilation.
chapter 4.6, page 38.
In Germany the firing regulations for the individual Bun-
desländer are to be complied with.
ref. b)
The boiler should be connected to the flue gas system with
Make sure there is an adequate supply of fresh air to
a short flue gas pipe at an ascending gradient of 30-45°.
the boiler room,
Carefully seal the flue gas pipe against the flue gas system.
to ensure that the combustion air supply necessary for
The introduction of the flue gas pipe into the vertical part
all the firing systems operated there can flow in without
of the flue gas system (a) must be executed so that no
hindrance and that no oxygen deficiency occurs for the
con­densate water can flow from the chimney into the flue
operating personnel.
gas pipe and the boiler. (Fig. 18)
The binding values for the size of intake air apertures
are not usually stated in the relevant regulations, it is laid
down only that the partial vacuum in the boiler room must
not exceed 3 N/m2. To comply with this requirement, an 30-45°
30-45°
air supply cross section of 500 cm2 is to be provided up
to a rated heat output of 1000 kW. With rectangular aper- a
tures the side ratio is not to exceed 1.5 : 1 and an appro-
priate supplement is to be made with grilles to ensure that
the free cross section reaches the above values.

In Austria ÖNORM H 5171 additionally stipulates a flue

air aperture. This must have a minimum cross section of Fig. 18
180 cm2 up to a rated heat output of 100 kW. The cross
section is to be increased by 1 cm2 for each additional kW.

4.2 Flue gas connection and dimensioning NOTICE

To guarantee economic and fault-free operation, boiler For Max-3 plus, a condensate trap must im-
and flue gas system must be mutually adapted to create peratively be mounted on the flue gas outlet.
a functional unit.

NOTICE
If the flue gas temperature is under 160 °C,
the chimney must be watertight and acid re-
sistant.

Renovation, respectively flue gas pipe cross-section ad-

justment can be necessary with existing flue gas systems,
according to the instructions of a specialist.

The function of the flue gas system, i.e. the production of

the necessary delivery pressure is basically dependent on:
a. the type (nature) of the flue gas system (thermal insu-
lation, interior surface roughness, sealing etc.)
b. the connection of the boiler to the flue gas system ac-
cording to specification
c. the correct dimensioning of the flue gas system

30 4 214 863 / 01
 Installation

Basic data:
NOTICE Flue gas pipeline 5 m long, 2 90° elbows and 1 45° elbow,
Normally only one heat producer may be outside air 15 °C, height above sea level max. 800 m, flue
con­nec­ted to the flue gas system! gas pipeline same ø as flue gas connector on boiler.

Flue gas pipes longer than 1 m are to be insulated. You are recommended however to use the services of the
Where a transition element is necessary from the boiler specialist right from the planning stage!
flue gas pipe to the chimney inlet, this should be executed
as a slender cone. Chimneys are to be fitted with a water drain system to
per­mit the draining of any condensate.
The installation of a noise damper in the flue gas pipe is
from
vom
to
zumgas recommended to dampen flue gas noise.
flue
boiler
Kessel Schornstein In the case of boiler installation locations in the domestic
system
sphere, the flue gas pipe is to be flexibly connected with
Fig. 19 compensators.

ref. c)
Dimensioning the flue gas pipe cross-section. The cross
sec­tions are to be calculated for boilers without delivery
pres­sure requirement according to EN 13384. (Please
note also DIN 18160, part 1 “House chimneys”). Take in­to
account the local, special situation (position of the house
on a slope, position of the flue gas pipe, roof pitch, flue
gas exit shape etc.)!
In Switzerland, take note of SIA Recommendation 384/4!
In Austria the calculation is carried out according to
ÖNORM M 7515.

Non-binding reference values for the flue gas pipe dimen-

sioning for boiler types Max-3 (420-2700).
Schornsteindimensionierung

3000
DW 600

2800

2600 DW 550
2400
output in (kW)

2200
DW 500
Nennwärmeleistung in (kW)

2000

1800
Rated thermal

1600

1400 DW 400

1200

1000
DW 350
800

600
DW 300

400
DW 250
0 5 10 15 20 25
Effective height
Wirksameof the flue gas
Schornsteinhöhe in (m)pipe in (m)

Fig. 20

4 214 863 / 01 31
 Installation

4.3 Installing the burner Max-3, Max-3 plus

Type (420,530) Type (620-1250) Typ (1500-2700)

15°
60°

45°

15°

screw connection flange screw connection flange screw connection flange

Type (420,530) Type (620,750) Typ (1500-2700)
4 x M12 (45°) 6 x M12 (15°) 6 x M16 (15°)
4 x M12 (15°)
screw connection flange
Type (1000,1250)
6 x M16 (15°)

Firing system dimensions Tilting out of the boiler door

Boiler door opens to the right or left
F (Dimensions in mm)

G H

Dimensions Dimensions

Max-3, Max-3 plus Max-3, Max-3 plus

Type A B C D E F G H M Type a b
(420,530) 290 330 515 250 606 1624 163 30 420 (420) 1060 150
(620,750) 350 400 550 310 684 1899 163 30 500 (530) 1060 150
(1000,1250) 400 450 635 330 782 2182 163 30 550 (620) 1180 150
(750) 1180 150
(1500) 400 450 665 360 880 2417 170 30 600 (1000) 1370 150
(1800) 400 450 735 360 976 2605 170 30 600 (1250) 1370 150
(2200) 400 450 735 360 976 2905 170 30 600 (1500) 1520 175
(2700) 400 450 755 360 976 3233 170 30 600 (1800) 1680 175
(2200) 1680 175
(Dimensions in mm) (2700) 1700 175

32 4 214 863 / 01
 Installation

1. Max-3 (1500-2700), Max-3 plus (1500-2700): Noise damping

Ensure that the insulating mat (19.3, Fig. 11) is cut - Gas pipelines are to be installed so that no vibrations
out and inserted according to the shape of the burner can be transferred to the building.
flange. - The burner can be covered with a noise-damping hood.
2. Mount the burner to the boiler flange with the seal - It is recommended to incorporate a noise damper
and screws. downstream of the boiler in the flue gas pipe.

CAUTION
! Failure to observe the guidelines and stand-
ards for the installation of burners can result
in damage to property and personal injury.
• On installing, comply with the guidelines
and instructions for fitting the burner to the
heat producer.
• Only burners tested according to EN 267 or
EN 676 may be used.
3. Fill the cavity between burner pipe and hinged flange
with the insulating wool provided.
4. For gas and dual-fuel burners:
If the weight of the burner (including attachments)
> 90 kg and the distance of the centre of gravity of the
burner to the door > 60 cm, support the burner hous-
ing weight directly with a strut to the floor.

4.3.1 Heating gas-side resistance Max-3 (420-2700)

12.0

11.0
1000 1800 2200
750 1250 1500
10.0

9.0
620
(mbar)

2700
resistance(mbar)

8.0
530
gas-sideWiderstand

7.0
420

6.0
heizgasseitiger

5.0
Heating

4.0

3.0

2.0

1.0

0.0
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000

Kesselleistung
Boiler (kW)
output (kW)

4 214 863 / 01 33
 Installation

4.3.2 Heating gas-side resistance Max-3 plus (420-2700)

13
2200 2700
1250 1800
12

11
1000 1500
10
750
Heating gas-side resistance (mbar)

9 530

8 620
420
7

0
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000

Boiler output (kW)

kW = Boiler output
mbar = Flue gas resistance λ = 1.11 (Natural gas: CO2 = 10.8 %)
500 above sea level (Tolerance: +/- 20 %)

4.4 Fuel

NOTICE
The boiler is only to be operated with the fuel
stated on the boiler rating plate.

Boilers Max-3 are normally suitable for burning the follow-

ing fuels:
- Heating oil EL according to DIN 51 6093 / SN 181 160/Z
ÖNORM C 1109
- Heating oil L according to ÖNORM C 1108
- all combustible gases according to DVGW Work sheet
G 260

34 4 214 863 / 01
 Installation

4.5 Electrical connection Important!

Electrical connections must be established by
a licensed and qualified electrician.
The connection diagram is located in the ter-
minal box of the heat generator; the circuit dia-
gram is supplied separately.
WARNING
The heat generator can be deprived of only
se­
pa­ rating it from the mains voltage (eg
multi­pole switch).
WARNING
All electric power supply circuits must be
switched off before accessing the terminals.
A main switch must be installed on-site in the supply line
which performs an all-poles cut-out and has a clearance
of at least 3 mm between the open contacts.
For Switzerland:
For the electrical connection, the wiring diagram specific
to the plant must be observed, if one is available!
4.5.1 Electrical connection of burner
- The burner must be connected to the boiler with the
stan­dard plug and socket connection.
- The burner cable must be installed so that the plug and
socket connection has to be disconnected in order to
swing out the burner.

Folding out the electrical box

(Opening angle 55°):
Remove the screws (left and right)

Open electrical box fully:

Remove wing nut and loosen holding cord

Cable feed-in is at the bottom

Fig. 21

4 214 863 / 01 35
 Installation

4.5.2 Safety measures relating to • Measures must be taken in the building and on electri-
EMC-compliant assembly cal equipment to protect the units against overvoltage
caused by lightning strikes.
• Cables carrying mains voltage must be routed sepa- • The mains connection for the heating system must be
rately from sensor or data bus cables. A minimum dis- designed as an independent electrical circuit. Neither
tance of 2 cm between the cables must be observed. fluorescent lamps nor any other equipment which might
Cable crossovers are permitted. cause interference may be connected, nor may it be
possible to connect such equipment.
Minimum distances for electrical installation
Sicherung
Fuse Heizraumbeleuchtung und
Boiler room lighting
Steckdosen and power
auf getrenntem
Heizraum-
Boiler room sockets must be in a separate
Stromkreis anschliessen
15
≥ 15cm
cm Notschalter
emergency switch circuit

Netz 230
Mains 230V
V

Datenbusleitung 1212VV
Data bus line

2
≥ 2cm
cm

Wärmeerzeuger
Heat generator

• In the case of controller modules with their own mains

supply, it is imperative that cables carrying mains volt-
age are routed separately from sensor or data bus ca-
bles. If cable ducts are used, these must be provided
with separator strips.
• When mounting controller modules or room control
modules, maintain a minimum clearance of 40 cm from
other electrical devices with electromagnetic emis-
sions, such as power contactors, motors, transformers,
dimmers, microwave ovens and TV sets, loudspeakers,
computers, mobile phones, etc.
Minimum distance from other electrical units
• Equipotential bonding must be established between the
individual control components, control panels and the
heating system.
• Shielded cables must be used for the data lines.
Recommended versions:
J-Y(ST)Y 2 x 2 x 0.6 mm
• Shields of data lines, analogue signal cables and power
cables must be connected to earth over a large area
with a highly conductive connection. The cable shields
must be connected to a shield bar directly after the en-
try of the cable into the panel.
• Multiple earthing of a cable is not permitted (ripple pickup).

One-sided earthing of the shielding

≥40
40 cm
cm

Hier Do
nicht erden!
not earth here!

• Avoid unnecessary cable lengths, including in spare cables

• Coils of relays, contactors and other inductors in the pan-
el, and possibly in the vicinity, must be connected. The
connection can be made with RC elements, for example.

Basis-/ReglerModul
Basic/controller mitmodule
module with control BedienModul

36 4 214 863 / 01
 Installation

4.5.3 Recommended cable cross sections

Cable type Cross-section Length

Power supply
of the heat generator
• 230 V min. 2.5 mm2 unlimited m
with 16A fuse
• 400 V min. 1.0 mm2 unlimited m
with 10A fuse
Mains voltage cables
min. 1.0 mm2 unlimited m
of actuators
Low-voltage cables
min. 0.5 mm2 max. 50 m
(sensors)
Data bus lines
2 x 2 x 0.6 mm2 max. 100 m
(shielded cable)

4 214 863 / 01 37
 Installation

4.6 Fuel gas and output diagram

4.6.1 Fuel gas and output diagram Max-3 (420-2700)

420 530 620 750 1000 1250 1500 1800 2200 2700
180.0

170.0

160.0
(°C)

150.0
gas temperature(°C)
FlueAbgastemperatur

140.0

130.0

120.0

110.0

100.0
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000

Kesselleistung
Boiler (kW)
output (kW)

kW = boiler output - operated with heating oil EL, - A reduction of the boiler water temperature of -10 K
°C = Flue gas temperature if surface is cleaned, natural gas effectuates a reduction of the flue gas temperature
boiler flow temperature 80 °C, return tem- λ = 1.22 with max. burner output of approx. 6-8 K.
perature 60 °C (according to DIN 4702). (CO2 heating oil EL = 12.5 %) - A change in the air index λ of ± 1 % effectuates
a change in the flue gas temperature ± 8 K.

38 4 214 863 / 01
 Installation

4.6.2 Flue gas and output diagram Max-3 plus (420-2700)

Flue gas temperature and power ranges For new systems, acid-resistant chimneys must be pro-
In order to achieve a good combustion quality (optimum vided or the flue gas temperature must be set correspond-
flame burnout), the outputs must not be less than the ingly higher (min. 160 °C).
specified minimum values.
The minimum flue gas temperature must be coordinated
with the chimney conditions, otherwise the formation of
sulphuric acid can lead to soot buildup in the chimney.

130
2700
1250 1800 2200
420 620 1000 1500
530 750

120
Flue gas temperature (°C)
Abgastemperatur (°C)

110

100

90

80
100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 2900 3000

Boiler output(kW)
Kesselleistung (kW)

kW = boiler output - operated with heating oil EL, - A reduction of the boiler water temperature of -10 K
°C = Flue gas temperature if surface is cleaned, natural gas effectuates a reduction of the flue gas temperature
boiler flow temperature 80 °C, return tem- λ = 1.22 with max. burner output of approx. 6-8 K.
perature 60 °C (according to DIN 4702). (CO2 heating oil EL = 12.5 %) - A change in the air index λ of ± 1 % effectuates
a change in the flue gas temperature ± 8 K.

4 214 863 / 01 39
 Installation

4.7 Minimum value limiting of STB Flue gas temperature sensor

boiler return temperature
Hydraulic and technical control measures are to be imple-
mented to ensure that the minimum boiler feed and return
temperatures are not fallen below.

4.8 Setting the temperature controller

Boiler temperature controller, selectable TR 65-85 °C.
The basic setting is made by the heating installer. Selec-
tion and setting of the different heating programs accord-
ing to operating instructions.

4.9 Safety valves Fig. 22

Heating installations and hot water supply systems are to
be protected against inadmissible overpressure by safety WARNING
valves. The blow-off pressure of the heating system safe-
ty valve must correspond to the maximum rated thermal ! The capillaries must not be kinked!
output of the boiler. The valve is installed in the safety
feed pipe. In Germany, only safety valves with the letter Important note:
“H” in the component test mark may be connected; this to If a remote flue gas thermometer is installed in
be in principle in the boiler safety feed pipe. the electro box, before fitting the cover (Fig. 22),
the capillary of the flue gas thermometer must
be routed on the top, along the boiler insulating
4.10 Filling pump mat, towards the back.
(boiler with separate calorifier)
Speed and output regulation must correspond to the re-
quirements of the separate calorifier. Settings are to be
made by the heating specialist.

4.11 Heating pump

Speed and output regulation must correspond to the re-
quirements of the separate calorifier. Settings are to be
made by the heating specialist.

4.12 Heating connections

In the case of boiler installation in the domestic domain,
heating connections to the boiler are to be made with flex-
ible compensators.

4.13 Installing the flue gas thermometer

A 3/8″ sleeve with a max. length of 25 mm is to be welded
into the flue gas pipe. The thermometer is mounted in the
electrical box; see Fig. 22.
Take off the cover (if already fitted) and introduce the
capillary through the rear wall between the external and
round insulation.
Screw the sensor tube into the sleeve.

40 4 214 863 / 01
 Document Type

` DAR
Method Statement

Responsibility & Supervision

Zaid Al-Hussain Brothers and Group of Companies

RESPONSIBLE
POSITION COMPANY CONTACT NO.
PERSON

Project Manager
Construction Manager

C/S Field Engineer

QA/QC Manager
.
Lead Surveyor

Safety. Manager

DAR
- CONSULTANTS
.

RESPONSIBLE
POSITION COMPANY CONTACT NO.
PERSON

Resident Engineer

Asst. Resident Engineer

Lead Field Engineer

Page 7
 Document Type

` DAR
Method Statement

 Construction Manager - will be the one to plan and coordinate all activity in the
site and he will be responsible for coordinating with other contractor working in the
area.
 Safety Personnel - will be the one to establish all necessary warning signs and
barricades establish the high risk areas in coordination with the Construction
Manager and constantly monitor the activity in terms of safety to all the workers.
Furthermore, he will give advice on current and forecasted safety issues and
concern.
 Field Engineer – will be the one to implement the instruction of the Construction
Manager in the site, he will also directly supervise constantly the manpower and
equipment working in the area and implement all safety regulation and precaution
set by the safety personnel.
 Quality Control Inspector – will be the one to inspect and monitor the area before
recommending to DAR Field Engineer for inspection.
 Foreman – will be the one to supervise and assign the works as per schedule.
 Labourers/Helpers– to assist in the construction.

Work Force

 Listed below is the manual workforce:

1. Field Engineer =1 3. Operators/Drivers =4

2. Foreman =1 4. Labourers/Helpers =10

3. SAFETY AND HEALTH

Risk Assessment (See separate sheets)

Protective & Safety Equipment Contractual Requirements

1. Head Protection – Hard Hat or Helmet

2. The
Eyefollowing are
protection the list Spectacles
– Safety of Personalor
Protective Equipment:
Eye Shields
3. Hand or Arm protection – Rubber Gloves
4. Foot Protection – Safety and rubber Shoes
5. Whole Body Protection – Overalls
6. High visibility vest
7. Hearing Protection- Ear plugs

Page 8
 Document Type

` DAR
Method Statement

Contractual Requirements

 Shall adopt and promote the Zero accident policy for our performance of the
work under this contract.
 Will appoint sufficient ES &H personnel to manage the work.
 Managers and supervisors shall be familiar with an end force site rules,
regulations and all actions taken to ensure compliance with the ZHBG and
DAR ES &H Programme.
 Shall ensure that all our equipment and operator are competent, experienced
and qualified.
 Site management shall attend the weekly toll box meeting.
 Safety Representative shall complete file and make available to the DAR
weekly tool Box Meeting Record.

Information to Personnel

 All the manual workers that will be working in the site will be informed and
reminded by conducting morning tool box meeting in order to continuously
remind them of the existing safety risk and it will be handled by the designated
safety officer and sometimes with the presence of the safety personnel.
 The STARRT card will be used before any work will proceed.
 The third party certificate will be submitted to DAR Consultants for approval.

Emergency Procedures

 The following are the safety procedure that will implemented in case of
accident:

1. In case of traffic accident or person hit by the equipment notify immediately

the police and emergency crew, do not engage in moving the person who are
injured.
2. In case of eye injury the person injured shall immediately stop working and
secured the eye that were injured and avoid scrubbing it and bring him
immediately to the clinic for cleaning and if severe eye injury brings him to the
hospital for proper care.
3. In case chemical contamination in the skin or that may be harmful to the skin ,
immediately clean the affected area by washing it with clean water and soap
do not apply anything on the skin it may cause more serious damage, if
severe injury, cover the injured part with clean cloth and bring the person to
the hospital for proper care.
4. In case of respiratory contamination immediately remove him from the area so
that he can breathe a clean air if it is severe injury bring him immediately to
the hospital for proper care.
5. Emergency contact numbers including Police, Ambulance and Industrial
Security will be prominently posted on bulletin board.
6. First Aid box will be readily available on site.
7. Always inform the DAR Consultants to any incident that may occur in the site.

Page 9
 Document Type

` DAR
Method Statement

Permit Requirements

 The following are the required permit before implementing the activity:

1. Encroachment Permit
2. Work Permit
3. Transport Permit

4. ENVIRONMENTAL ISSUES

 Environmental Impact Assessment:

 Contractual Requirements:

 Shall provide adequate number of skips or containers (bins) clearly identifiable

for each category of waste.
 Shall educate our employee through tool box talk and signage on segregation of
the above waste and the use of waste receptacles.
 General construction waste will dispose at DAR approved land fill site.
 Shall abide by all DAR environmental code and standard for the disposal of
hazardous waste and dispose of through the correct and approved
establishment.
 Maintain housekeeping on the site on daily basis.

 Emergency Procedures:

In an Emergency Site Competent person ensure the following:

 Stop Work.
 Shut down All equipment.
 Evacuate personnel to Assembly Point.
 Account for every men.
 Re-enter work area only with permission from the competent person.

5. QUALITY RESPONSIBILITY

Contractual Requirements
1. Shall implement and maintain an effective quality system in compliance with the
contractual obligations and conforms to the requirements stipulated on the
Project Specifications in construction of boundary wall
2. Will organized a QA/QC group headed by a qualified QA/QC Supervisor, in aid
of equally reliable QA/QC Inspectors.
3. Ensure that the procedures and instructions are issued for the performance of
all activities that bear an effect on quality.
4. Ensure by qualified inspection, that the work is carried out to the required
quality level.
5. Demonstrate by means of documented quality records that the construction
have been carried out and inspected to the required quality level.

Page 10
 Document Type

` DAR
Method Statement

Critical Works

 The possible
Inspection critical work for this activity is the wrong or improper way of using
and Testing
equipments and careless approach towards construction of boundary wall. The
wrong way of construction of boundary wall may cause injuries or fatalities.
Once the preparation is not properly done redoing the job will entail more time,
more labor and material cost.

Inspection and Testing

 ZHBG QA/QC Inspector will determine whether the construction of boundary

wall is conforming to Project specifications.
 DAR Field Engineer will carry out final inspection and testing if needed in
accordance with documented procedures.
 ZHBG QA/QC Inspector together with the DAR Field Engineer will conduct site
inspection where the construction of boundary wall is in progress.
 After the final inspection is already conducted and the approval of DAR Field
Engineer the next sequence of work will proceed.

Page 11
50-CL0014 / 2 / Page 1/1

HT – Final inspection Max-3

Checklist Hoval, s.r.o.

HT - Final inspection Max-3 (350 – 5000) 50-CL0014 3

Issued by: Main process: Status: Valid from: Language:
Sivák Patrik 50-GP02 Approved 26.04.2018 ENG

Final Inspection Month Inspected Qty

Max-3
Type, serial no., date, welding operator

Inspected parameters: Fault description

Combustion chamber
Water shell
QUALITY OF

Front plate
WELDLING

Rear plate
Pipes
Others
Welder identification plate (if
asked)
Flanges, pipes position
Raw material damages
Flue gas box - sealing
Refractory concrete
Seal - rope
DOORS

Door assembly
Door and hinge posi-
tion
Casing frame
Check welding pins for fixation
of insulation and "heavy roll
pins" at boiler base frame
Painting
Labels
Accessories, peep hole parts
Others
Inspected by + date:
Signature:

- OK
X - Fault Date of fault repair if any, operator signature

Printed version will not be considered for change!

 To whom it may concern Vaduz, XX.XX.XXXX

1 Hydrostatic test certificate

Equipment description: Heating boiler

Type: Max-3 (1000)

Order no. (customer/supplier): xxxxxx

Manufacturing no.: xxxxxx

Application range:
Working pressure: bar < 6,0
Test pressure: bar 9,6
.,'
Operating temperature: oc < 120
Design temperature: oc 120

Manufacturing standard: PED/TRD

Quality control system: ISO 9001

Weiding standard: EN 287, EN 288

The product has passed all required quality control checks and pressure test (made
on xx.xx.xxxx) to the expectations of the quality controller.

The undersigned quality controller confirm the above statement.

Quality Control Manager

 Boiler Field Test Report

HO-DHWB-01-1 - Hotel Boiler #2

Customer Name: St. Regis Hotel Date: 28-4-2021

‫اسم الزبون‬: ‫التاريخ‬:

Boiler Model No.: SSK 800 Serial No.: 0800.945.15

‫ رقم املوديل‬: ‫الرقم املتسلسل‬

Burner Model No.: TBG 120 MC Burner Serial No.: BLT000009707672

‫ رقم املوديل‬: ‫الرقم املتسلسل‬

Item Description Check Notes

1 Fuel LPG

2 Burner operation ✓
3 Modulation operation ✓
4 Boiler set point temperature ( oC ) 80

5 Actual water temperature ( oC ) 70

Notes :

Flue Gas Testing.

1 Flue Gas Temperature (˚C) 160 Recommended range 140 - 220 oC

2 Flue Gas CO₂ % 10.1 Recommended range 10 - 11.5 %

3 Flue Gas O₂ % 5.7

4 Flue Gas CO % 26

5 Combustion Efficiency % 93.7

Consultant Engineer Name & Signature: Hoval Representative Name & Signature:
 Document Type

` DAR
Method Statement

Follow-up and Evaluation

 Work evaluation will be based on facts, on the reports/results that has been
conveyed to the DAR, we see to it that it was truly done on the basis of its
requirements and integrity.
 The QA/QC will be always open for suggestions, comments pertaining of their
performance besides, of its obligation to perform on highest quality level.

6. APPENDICES

Appendix A
CONFIRMATION OF INSTRUCTIONS TO OPERATIVES

Those names listed below confirm receipt of the method statement and have had the contents
explained to them/understand it and are aware of the site ES&H requirements.
Name Employer Date Signature

Note to contractor supervisor – Any significant change from this method statement requires it to be
revised and resubmitted to OBI before work can commence.

Page 12