chiller installation method statement.pdf

9/7/2014 Chiller installation method statement

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Method Statements Chiller installat ion method statement

Chiller installation method statement

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Below is a standard operating procedure which can

be used a a method statement for installation of

chillers on its foundation after it is delivered on the

sites. Before starting the activity of chiller installation

following tools/equipment shall be arranged:

Tool Box.

Lifting Equipment (Cranes)

Basic Electrical Tools

Measuring Tape.

Hack Saw Blade

Spirit Level

Electric Drill Machine

Ladders

Threading Machine

Welding/ Brazing Machine (if required)

Torque Wrench

Pipe Cutting Machine

Grinding Machine

Pressure Gauge

Hammer

Water Level Marker

Mobile Scaffolds

Staging Platforms

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General Requirements

All the materials received at site shall be as per the approved technical material submittal for

Chillers to be inspected upon receipt & approved by the engineer prior in proceeding with the

installation. Any discrepancies, damages etc., should be reported to the supplier for rectification

or replacement& to be removed from site immediately.

All construction preliminary inspection/testing works shall be carried out in accordance with the

specifications & to be done by qualified Mechanical Engineers and shall be checked and

approved by MEP Subcontractor Construction Manager along with QA/QC Engineer.

Material Transport/ Delivery

Chillers are normally shipped & dispatched from factory as a hermetically assembled package,

factory piped, wired and tested. All openings except for the water box vent & drain holes are

covered or plugged to prevent contamination during shipment & handling.

Special care must be taken to ensure that units are offloaded from containers. Rough handling

can result in damage to the unit.

Use appropriate type of vehicles in transporting the units and that they are protected against

mechanical & weather damage.

As soon as the units arrived at site, raise immediate inspection to the consultant & inspect

thoroughly for damage. Hence, in case of transit damage, supplier/ manufacturer must be

informed immediately.

Ensure that the units have been inspected & accepted by the consultant as per the approved

material submittal prior to offloading & site storage.

Storage on Site Store

Ensure that the storage location of the units has solid foundation, vibration free, dry, &

temperature range shall be -40F to 158F.

It is much recommended not to remove the plastic coverings or packaging materials during the

delivery to avoid any corrosion & deterioration.

Avoid any mechanical shocks and strokes during handling operations.

All packages for the equipment reaching the site shall be identified as per package list.

Sequence of Installation for Chillers

The entire assembly of the Water Cooled Centrifugal Chillers will be rigged from store to place of

installation i.e. roof etc. Refer to Manufacturers Instruction Manual for rigging instructions for the

Chiller.

All site safety rules & regulations shall be complied.

Supervisors will deliver tool box talks, relevant to these activities to all operatives involved in the

installation and shall be recorded.

All operatives will be equipped with minimum personnel protective equipment; hard hat,

coveralls, safety boots, safety glasses.

The persons using cleaning fluid, solvent cement& any other forms of chemicals have to wear

hand gloves.

Ensure only qualified personnel shall install, test & commissioned the equipment.

During installation, display warning sign boards to be provided and barricade the area

whenever necessary. Close monitoring by the site engineers during installation is much highly

recommended.

Only competent, experienced & trained personnel shall perform all the required activities stated

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Preliminary Checks Before Chiller Installation

Before commencement of Installation activity, the supervisor/ engineer must ensure that:

All Installations & Pressure Testing of Pipe/ Duct works have been completed & approved by the

consultant.

Determine whether the units occur damages during the storage & shifting of location.

Permission to start or Civil Clearances prior to installation has been given by the main

contractor.

All relevant Approved Shop drawings for the installation of the equipment shall be available &

approved by the consultant.

Installation activities shall only commence when all associated works by the Civil has been

completed.

Safe access shall be provided by the Main Contractor thru Work Permit in coordination with the

Safety in charge at site.

General Installation Procedures for Chillers

Prior to moving the chillers at site, ensure that the foundation requirements have been done.

Foundation details & requirements for the chillers shall be as per approved shop drawings or as

recommended by the manufacturer as follows:

1. Rigid non-warping mounting pads or a concrete foundation is available prior to shifting chillers

at site.

2. Ensure that the foundation will be able to support the chiller at its full operating weight.

3. For proper unit operation, the chiller must be level within 1.6mm over its length & width when set

into place on the mounting surface.

After ensuring that the foundations for the chillers are satisfactory, shift the chillers by means of

cranes to its exact location.

Ensure that the lifting cables are capable of supporting the entire weight of the chiller. Failure to

properly lift the unit could result to serious injuries & damage of the unit.

System evacuation, dehydration and charging with refrigerant shall be carried out by skilled &

experienced personnel only.

Ensure isolator pads or spring isolators are available in the chiller feet/ legs prior to lowering the

unit to its foundation.

Ensure that all piping connected to the chiller must be properly isolated & supported so that it

does not place any stress on the unit.

It is much recommended to avoid piping from 3 feet minimum to the equipment to allow

proper fit-up upon arrival of the unit at job site.

Pipe the evaporator into the chilled water circuit.

Pipe the condenser into the cooling tower water circuit.

Locate pressure gauge taps in a straight length of pipe. Place tap a minimum of one pipe

diameter downstream of any elbow, orifice, etc.

Install air vents & drain valves on the water boxes. Each water box is provided with 3/4 NPTF

(National Pipe Thread Female) vent & drain connection. Plastic plugs are factory installed in

both openings. Remove & discard the same before installing the water box vents & drain valves.

Install pressure relief valves in the condenser & evaporator water circuits to avoid water box

damage due to hydro-static expansion.

Whenever are applicable, install pressure relief valves at the drain connections on the

evaporator and condenser water boxes.

Install a strainer in the entering side of each piping circuit to avoid possible tube plugging in the

Working At Height

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chiller with debris.

Install flow sensing device. Use either flow switches or differential pressure switches in conjunction

with the pump interlocks to verify evaporator and condenser water flows.

Install by pass valve system to avoid circulating water through the auxiliary shell when the unit is

shut down.

Pipe the evaporator & condenser as per the approved shop drawings. Ensure that the correct

pipe sizes are to be connected to the evaporator & condenser circuit.

Ensure that the evaporator water piping is clear; check if the chilled water pump is operated

but before initial chiller start-up. If any partial blockages exists removed the same to prevent for

possible tube damage resulting from evaporator freeze-up or erosion.

For condenser & large evaporator connections, arrange the water piping so that the water

supply enters the shell at the lower connection, and exists from the top connection.

Units shall use grooved- pipe connections and flanged connections for 300 psi water boxes, use

welded flanges.

Piping joined using grooved type couplings, like all types of piping systems; require proper

support system to carry out the weight of the pipes & equipment.

Ensure that system refrigerant differential pressure must be maintained above 21 kpa at all times.

Failure to do so could result in operating problems.

Ensure that the discharge piping that allows pressure relief devices to safely vent refrigerant to

the atmosphere if over pressure occurs.

Make sure that the minimum pipe size for the vent must be equals the size of the discharge

connections on the pressure relief device.

When connecting the vent line to the chiller do not apply threading torque to the outside pipe.

If the unit is not factory insulated, install insulation around the evaporator bulb wells and ensure

that the bulb wells and connections for the water box drains and vents are still accessible after

insulation is applied. Ensure that the sensor modules and interconnecting four wire cables must

be raised up above the field installed insulation. Do not insulate over the wiring or sensor

device. Insulation shall be as per approved material submittal.

Install the controller hardware/ equipment which are used to interface with the internal chiller

data & functions provide by the controls. Note that there are four connections on the controller

that support the communication interface.

Install the control panel & ensure low voltage & high voltage areas are in proper route & field

wiring.

Install the display. The display is boxed and shrink-wrapped behind the control panel during the

shipment. Follow the procedure for installation of display as follows

Unwrap control panel & display arm.

Plug the power cable and the Ethernet cable into the bottom of the display.

Adjust the display support arm so the base plate that attaches to the display is horizontal.

Position the display with the LCD screen facing up, on top of the display support arm base plate.

Align the four holes in the display support arm base plate.

Attach the display to the display support arm base plate.

Ensure all Electrical requirements have been wired & connected as follows:

Power supply wiring to the starter

Starter to motor wiring

Starter to control panel wiring

System Control Circuit wiring

Water pump interlock circuits & flow switches & other devices.

Temperature Sensor circuits

Other unit control options present

Any field supplied control devices

Ensure that all wires & cables are of the correct sizes as voltage/ampere requirements of the

units.

After installation of the chillers, raise inspection to the consultant for acceptance prior to

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