Methodology

Project Name: Date Approved: Page No. : 1

Methodology
For
Chilled Water Piping System &
Ducting Works

ABDEL CONSTRUCTION CORP.

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TABLE OF CONTENTS

 CONTRACT SCOPE OF WORKS

 SCHEDULE
 ORGANIZATIONAL DETAILS
 TOOLS & EQUIPMENT
 WORK BREAKDOWN METHOD & SEQUENCE
 SAFETY MEASURES
 ENVIRONMENTAL CONTROL
 QA/QC
 REFERENCES
 OTHERS

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1. CONTRACT SCOPE OF WORKS :

Mechanical Works (Child Water Installation and Ducting Works)
2. SCHEDULE (Input awarded schedule and manpower loading)

3. ORGANIZATIONAL DETAILS (Provide Table of Organization and their respective responsibilities)

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4. TOOLS & EQUIPMENT (List down all tools and equipment’s which will be used in the activity)

 Pallet truck  Grooving Machine

 Ladder  Levelling Equipment
 Mobile Scaffoldings  Pressure Gauge
 Angle Grinder  Wrenches
 Welding Machines  Drills
 Cutting Outfit  Cut off Machine
 Chain Block  Measuring Tools
5. WORK BREAKDOWN METHOD & SEQUENCE
CHILED WATER WORKS
This method statement covers on-site installation of pre-fabricated and site fabricated mild steel
pipework including supports, expansion and anchor points for chilled water system.

This procedure is to define the method used to ensure that the Chilled Water Pipework System
installation is as per project requirements.

System comprises all pipes, tubes, valves, fittings, reducers, expanders, nipples, vents, bleed off,
expansion and contraction devices, hangers, brackets, anchors, supports, sleeves, plates and all
accessories.

By following this method statement you shall ensure that components connected thereto as an
integrated pipework system, installation final connections and workmanship is correct and
acceptable. Also you shall make sure that all the work conforms to the contract documents and
General Specifications. Materials required to submit and reviewed the Client.

In addition to piping works, this procedure will ensure that the pipe insulation to all supply and
return mains, headers, branches, risers, drips, run-outs, pump suction and discharge, pipework,
fittings, flanges, valves, expansion and movement devices and flexible connections etc.

Pre Requirements before installation

 All materials and documentation relevant to a particular section of works will be checked by
the Construction Department prior to the commencement of work ensuring that these are
of the correct type as reviewed by the Client.
 Before commencement of any construction works, pre-inspections will be carried out on all
materials prior to them leaving the storage area. Invite the client or consultant to attend the
material receiving inspections asper their discretion.

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 Prior to the commencement of any construction works, areas and access will be inspected
to confirm that they are in a suitable condition for safe construction works to commence.

Chilled Water Piping System Installation Method

Mechanical Supervisor will instruct tradesmen regarding the execution of the works and will
distribute all necessary approved construction status drawings of the latest revision.

The supervisor will also check that tools and equipment available are in compliance with the
contract requirements.

 Verify sleeves to be fixed at the required locations and are of the same material.

 By means of string and chalk lines the actual pipe layout will be identified, so as to allow
for the installation of pipe supports, anchors, and guides.
 Pipes will be free from burrs, rust, scale and other defects and will be thoroughly
cleaned and painted with 2 primer coats before erection and closing up
 Supports for chilled water piping will be fixed in place by an approved construction
method to suit the elevation of piping as indicated on the approved construction
drawings.
 Hanger rod sizes will be in accordance with the requirements of the specification. The
spacing of supports for steel pipework will be in accordance with Contract Specifications.
 Supports will be arranged as near as possible to pipe joints and any change in direction.
Additional supports will be added within 300mm of any branch lines. Heavy in-line
equipment will be supported independently.
 Vertical rising pipework will be supported at the base or as indicated on the approved
construction drawing.
 Pipework will be installed so as to allow sufficient space for expansion or contraction
and thermal insulation. During installation open ends of pipes will be protected by
plastic caps, which will only be removed when the adjoining section is installed.

Coordinated chilled water piping installations will generally run parallel to the alignment of the
adjacent building surface’s, and as close to the construction as possible, or in certain cases, slope
towards a drain point. All high points within pressure pipes will be vented by means of automatic
air vents.

Drain outlets will be provided at all low points of the system, and means of air venting at all high
points of the system.

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Chilled water piping over service passages for plant operators, will be installed to a minimum height
of 2meters from finished floor.

Pipework will rest freely on supports and carefully aligned prior to final connection to each other,
or any other pertaining equipment as listed in the scope of works.

Where possible all pipes of straight runs will be lined up with facilities for pipes to be rotated for
welding joints –bottom welding will be excluded as far as is possible.

Pipework connections to final equipment will be made by the designated flexible connection where
required.

All branch connections will be factory fabricated, if site fabrication is necessary it will be of the
same standard. Sample of material will be submitted for approval prior to any production work
starts.
All tees will be of the same size as the pipes connected to them, bushed outlets will only be used if
the required outlet size is not of standard manufacture.
Reductions will be made by means of straight through reducing sockets, reductions on bends by
bushes will not be used.

Valves and other in line equipment will be installed where indicated on the approved construction
drawings, installation will be in accordance with the manufacturer’s recommendations and will be
consistent with the flow direction of fluids.

Flexible connection, anchors, guides expansion joints and loops will be installed where indicated on
approved construction drawings.

When installing universal and swing type expansion joints the axial movement of the building
structure shall be taken into consideration at the time of installation.

All chilled water piping system will be provided with adequate removable sections to assist cleaning
and for ease of maintenance operations, just the equipment connections.

Chilled Water Piping Jointing Requirements

 Screwed pipe work and joints up to and including 50mm mild steel pipe
 Pipe ends will be threaded by the use of an appropriate threading machine.
 The machine die head will be suitable to cut tapered type threads.
 Threads will be cut to the correct thread length.

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 After the suitable thread has been cut, burrs, surplus oil and swarf will be removed prior to
the selected fitting being screwed in place.
 Threads will be applied with threaded joint compound of the approved type. By means of an
appropriate pipe wrench, the selected fitting will be screwed onto the pipe thread to the
correct tightness required without causing any damage to the pipe/fitting.

Flanged Jointing Procedure

Fixing of flanges to pipe ends will be either screwed or welded type.

The type selected for a specific application will be as per approved details and in compliance with
the specification requirements.

Gaskets will conform to ANSIB 16.21 and ASTMD200.

Follow below steps:

1. Clean both flange faces to be joined.

2. Hold gasket in correct position on clean flange face until flanges meet.
3. Using only undamaged rust free bolts, nuts and washers, lubricate bolt threads and all
mating surfaces using an automotive grade of oil or grease.
4. Tighten bolts in the sequence as recommended by the manufacturer until full torque is
achieved.
5. Prior to any pressure testing taking place check, and if necessary re-tighten bolts.

Procedure of Mechanical Joints

 The mechanical joint consists of a split coupling housing and an insert-able rubber gasket.
 To accept the mechanical joint the pipe ends must be grooved. Grooves will be achieved
with the use of an appropriate grooving machine.
 Pipe grooving and joint will be installed in accordance with the manufacturer’s
recommendations.
 Prior to any prefabricated pipework being released from the pipe fabrication shop for
installation on site, the shop manager or his representative will complete the “material
release note for prefabricated pipework” so as to ensure compliance with the specification
requirements.

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DUCTING WORKS

Ductwork supports shall be installed based on the approved shop drawings, and 250mm clearance
from suspended ceiling. Leveled supports or hangers will be placed within 300mm of any 45 - 90
bend.

Threaded rod hangers will have thread adjustment in either direction available after leveling of
ductwork and associated plenum boxes. Ductwork passing through non fire rated walls and floors will
be adequately supported on either side. 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

Fabrication, Assembly, and Installation of Duct

Prior to lay-outing and fabrication of duct, all duct material shall comply to section VE- Ventilation
System on the Technical Specification on mechanical works. Fabrication of ducts will not be at project
site.

 Fabrication-All ducts will be fabricated and assemble outside the project site, and then it will be
brought to site ready for installation.
 Preparations-Scaffoldings shall be assembled firmly prior to usage of the duct man or installer for
safety. And all tools must be ready for use.
 Jointing-All duct jointing shall be done in a good workmanlike manner, ensuring that it would be
smooth and straight.
 Sealants- Duct sealants on joints shall be properly done to assure no leakage.
 Alignment-Continuously check horizontal and vertical alignment of ductwork and compliance with
approved drawings and specification requirements by using spirit level plumb or other suitable
instrument.
 Duct Testing-Once duct has been satisfactorily install, light testing will follow in the presence of the
site managers or project managers.
 Equipment installation- Once the fans and blowers like In line fan arrived, it should be
independently supported from main structure and not block work walls or sub-structure.
 Air Terminal Device Installation- The most important point on grill installation activities is, the grill
shall not be directly bolted to narrow sectioned ducts. If the installation is executed directly by
bolting to the narrow sectioned ducts, the air flow will be reduced and not requested sounds will
occur. In such cases the grill shall be installed to a tee piece so that the damper can be adjusted.
In the area where the ceiling is suspended, to prevent the vibration the diffusers may be fixed to
the plenum box, and the plenum box may be fixed to the upper level floor slab.

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6. SAFETY MEASURES

 Before commencing any work, the team shall strictly follow as per the Manufacturer’s/ Client’s /
Consultant’s Health & Safety recommendations for handling and use of the materials and
ensure all involved personnel shall be aware of the same. The general safety guidelines are
given below:
 Ensure the work area is safe & clean.
 All employees shall adopt safe working practices.
 Safety equipment (Safety helmet, safety shoes, coveralls, gloves, goggles, face mask as
applicable) to be worn at all times.
 When working at a high level, the appropriate safety harness shall be used and secured whilst
working-extra care shall be taken whilst using tools at a high level to prevent dropping.
 Ensure sufficient lighting is available during all stages of installation & testing.
 Report all accidents no matter how small to the Safety Officer on duty.
 Ensure any electrical isolation permit is obtained if required, for installation any electrical
equipment, panel, cable, wires and accessories.

7. ENVIRONMENTAL CONTROL

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TASK HAZARD IDENTIFIED RISK RATE OF RISK CONTROL MEASURES

(LOW,MEDIUM,HI
GH)
Delivery of Driver work alone. Fractured on High Assign Helpers, and for
Materials bones, Sprain, those heavy materials
and Unloading of equipment Death and equipment let lifting
Equipment and materials w/ using machines do the job.
to site appropriate tools and
equipment’s for lifting
and hauling.
Working Falling debris, Vertical May fall to the High Conduct survey to
area bar left w/out hazard hole, it can pierce working area first and
signage, slab holes to worker secure or isolate, don’t
work alone, wear proper
PPE’s.
Welding Fumes, Fire, working at Fall, Blindness, High Wear proper welding
works height, Wet working Electrocuted, Gas PPE’s, Secure area from
area, Confined space, Poison/Die, Burn any water, make sure
Uncomfortable on on Skin, scaffolds are secure,
working area, Lack of check all electrical wires
sleep from damages, don’t
work alone, Put Air
Ventilation on Confined
space areas, Rest will
during night. Put Fire
blanket Below the
welding areas, Secure
Hot Work Permit, Fire
Extinguisher is a Must/a
pale of water near
working area. Used
body harness while
working at heights.
Grinding Metal Splinters, Blind, Fall, High Secure Wires, Check
Works Working at heights, Wet Electrocuted, Units before used, Put
working area, Damage Skin/face Cut, Die protective gears on
Wires Head, Used Body
Harness while working
at heights.
Lifting of Lifting equipment Finger may High During lifting call some
Pipes & malfunction. cut/fracture, Body helpers, if materials

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Equipment Lifting with-out using may have a bone having great weight use
lifting equipment. dislocation, lifting machines.
death.

Working at Un-even surface for Fall, Body High Secure area first, used
Heights scaffolds and ladders. damages resulting Body Harness if above
to bone fracture 3ft height, Anchor the
Live wires on the may worst to scaffolding in proper
scaffolding. death. way, don’t work alone if
Electrocuted working at height,
Damage scaffolding Secure live wires on
being used. area before installing
scaffolds.
Grooving Finger may stuck on Finger fracture, Medium Check Units before
on B.I. Grooving Machine, Electrocuted, using, Used lifting
Pipes Wet Working Surface, Feet may crushed machine if great weight
Heavy Pipes to be on pipes.
Groove

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8. QA/QC

TEST SEQUENCE:

The Testing of HVAC systems, equipment and components shall be performed by the Mechanical
Contractor, and all systems, equipment and components shall be certified to be complete per the contract
documents and fully operational prior to calling for the Testing, Adjusting and Balancing (TAB) work by the
independent Testing, Adjusting and Balancing Contractor (TABC)

TESTING EQUIPMENT:

 The Mechanical Contractor shall provide and use the specific equipment required to perform the
work specified herein.

 Apparatus used shall be the standard of the industry.

PIPING PRESSURE TESTS:

 Chilled water and condenser water piping shall be hydrostatically tested to a pressure of 150 psi or
1-1/2 times design pressure, whichever is higher.
 Test shall be performed for a minimum period of 24 hours with no fluctuation in pressure.
 Pressure testing shall be performed prior to installation of thermal insulation and with all joints fully
exposed to inspection.
 Underground and other piping that will be covered by subsequent construction shall not be
covered prior to the approval by MDAD of successful testing.

CLEANING / FLUSHING NEW CHILLED WATER AND CONDENSER WATER PIPING:

 All new chilled water and condenser water piping shall be flushed.
 Temporary by-pass, pumps and strainers shall be used, as required, to circulate the peak design
capacity of the system.
 System shall operate until full flow can be maintained for a 48 hour period without strainer
cleaning, and the water meets the quality test specified below.
 MDAD Engineering shall be notified of the date and hour of proposed flushing not less than seven
(7) working days prior to the system’s being flushed.
 This flushing arrangement shall be temporary until water quality is approved by the Engineer of
Record.
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 After successful flushing, remove unnecessary piping and equipment not required for normal
operation.
 The specific piping arrangement and flow required for this flushing shall be shown on the drawings
and as follows:

 [Add details here as and if required.]

 Strainers shall have screens with perforations not larger than 1/8 inch.
 The final flow measurements during flushing shall be performed by the independent TAB Agency
used for the project.
 Flushing shall be witnessed by the A/E Consultant or its representative and by the MDAD
Engineering Representative.
 As an alternate flushing method, a high pressure water jet clearing system may be specified.
 The flushing of each section of pipe, including the proper sealing and any subsequent pipe fitting
work on the open ends of each section flushed, shall be witnessed by the A/E Consultant or its
representative and by the MDAD Engineering Representative.

3.06 WATER QUALITY TEST:

 Chilled water and condenser water systems will not be accepted until a sample of the water has
been taken and analyzed by a reputable, established, local laboratory and a satisfactory report on
the results has been provided to the A/E and the MDAD Engineering Representative for review and
approval.

 Water quality shall not be in excess of the following limits:

1. P & M alkalinity 10 and 40 PPM

2. Chlorides 100 PPM

3. Total dissolved solids 70 PPM

4. Total dissolved solids 400 MMHOS

5. PH 8.2-9.0

6. Soluble/Insoluble oils by 2 PPM

Freon extractable analysis
(72 hour period is required)

 If the oil level is too high, the system shall require a "boilout" using a chemical product composed of
alkalies, soaps, synthetic detergents, embrittlement inhibitors and dispersents.
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 If water is allowed to stand idle in piping system longer than 90 days, this water quality test shall be
repeated before final acceptance.

ACCEPTANCE:

 New chilled water and condenser water systems shall not be connected to existing systems
until the flushing and water quality tests are successfully completed and MDAD’s concurrence
obtained.

 In addition, prior to opening to existing systems, the systems shall be charged.

CHARGING OF SYSTEM:

 For independent new chilled water and/or condenser water systems, the water shall be charged
and maintained with anti-corrosive and anti-scale products after acceptance of the flushing and
water quality tests.

 Refer to Section on WATER TREATMENT OF CONDENSER AND CHILLED WATER SYSTEMS.

 For new chilled water and/or condenser water systems connected to an existing system, use only
anti-corrosive and anti-scale products as follows:

 [Coordinate products with MDAD Engineering and list here during design, as well as construction if
equals or substitutes are proposed.]

 [Calculate the volume of the new chilled water and/or condenser water system and include here.
Refer to Section on WATER TREATMENT OF CONDENSER AND CHILLED WATER SYSTEMS.]

 New chilled water and/or condenser water piping systems shall not be opened to existing systems
until all testing is complete, and MDAD Engineering / MDAD Maintenance Personnel are ready to
add the corrosion and scale inhibitors.

CONDENSER AND CHILLED WATER QUALITY TESTS:

Water quality and corrosion progression tests shall be performed as specified in Section on WATER
TREATMENT OF CONDENSER AND CHILLED WATER SYSTEMS.

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DUCT SYSTEM LEAKAGE TESTS:

A. The following portions the duct system shall undergo leakage tests:
[Identify which portions here]
B. The leakage tests shall be conducted per procedures in the SMACNA HVAC Air Duct Leakage Test
Manual (latest revision).

 The minimum test pressure shall not be less than the fan operational static total pressure.
 The tests shall demonstrate that the leakage is equal to or lower than the allowable duct
leakage as follows:
[Define limits here].
D. If a test indicates excess leakage, sealing and retesting must be conducted.
E. Test report submittal requirements shall include:
[List requirements here.]
F. Refer to Section on TESTING, ADJUSTING AND BALANCING, for additional requirements.

9. REFERENCES
1. Contract specification
2. Approved “FOR CONSTRUCTION” shop drawings
3. Material Submittal
 To control and ensure the construction work is carried out to the required contract specification
and approved shop drawings.
 Notifying QC engineer and issuing the RFI (request for inspection and approval) in timely manner 24
hours in advance. The relevant reports are to be submitted to the Engineer representative.
 Accompanying the Engineer’s representative for ongoing inspection and obtain his approval to
proceed with next activity.

10. OTHERS
Include other matters / attachments necessary to this methodology (if needed)

Prepared by: Recommended by:

(Trade Contractor PM/PIC) (Gen Contractor PM/PIC)
Recommended by: Approved by:
(RLC Construction Engr.) [RLC Construction Manager / Consultant (if
needed)]

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