DUBAI METRO PROJECT DUBAI RAPID LINK CONSORTIUM DUBAI METRO PROJECT OFFICE Dubal Rapid Link Contract No.: DM001 CDRLNo.: NA Project Title: DUBAI! METRO. CDRL Title: NA Document Title: Method Statement For Installation Of Fan Coil Unit E D A3 | 10Nov 2007 | Checklists Revised N/A Signed below A2 | 23 July 2007 | Checklists & ITP Revised A1 | 08May2007 | FirstIssue mari | DATE DEScRIPTION RAIL ew appRoveD Projed Drecier |S, Shimamura Die | N. Konto 7 ‘Checked By (AGC Manager) | J. Wh Checked By (Safety Manager) F. Dohadwal: hacked By Grestoy (eet arene) | R.Ozalp YC ‘Checked By Checked By (Design Manager) M. Makino, Prepared By Prepared By H. Kayike DATE DATE 40" Nov '07 RAIL SYSTEM CIVIL JV CONTRACTOR'S DOCUMENT No.: | DOCUMENT No.: REVISION DM001-X-AST-GEM-MT-DCC-401181 ASSection No. 01.0 02.0 03.0 04.0 05.0 06.0 07.0 08.0 09.0 10.0 1.0 12.0 13.0 14.0 15.0 16.0 17.0 18.0 19.0 20.0 21.0 22.0 Attachment TABLE OF CONTENTS Title Purpose Scope and Application of Work References Definitions and abbreviations Specification Clauses Resources Mobilization Plan Construction Equipment Personnel Materials Construction Procedure and Construction Methods Responsibility Design and Drawings Statutory Consents Work Program Quality Assurance Health & Safety Environmental Policy Relevant Documentation ‘Sub Contractors Risk & Hazard Assessment Organization Chart Inspection and Testing * Risk assessment form * Check List for Completion of installation of Fan Coil Units. * Test Report Format for Trial Run of Fan Coil Units * Inspection and Test Plan WeINO0 STATEMENT FOR INSTALLATION OF FOU eeument a COL A-AST-CEN-MT-OCe 4841483Men 4.0 Purpose. 2.0 3.0 This document defines the methods to be adopted to ensure that the works conducted at site are in compliance with the approved designs and equipment approvals. That the equipments are installed in accordance with the approved design and using recognized installation practices that are safe and compliant with the Project Safely Plan and associated Safety Procedures. That the inspection and testing of the works are in compliance with the Project Quality Plan, its associated Quality Procedures and an approved Inspection and Test Plan for the works. The method statement describes the procedure for Equipment Delivery Inspection, Storage, Installation, Inspection and Testing of Fan Coil Unit. Scope and Application of Work: This document is concerned with the on site inward inspection, installation and testing methods to be adopted to ensure that all Fan Coil Units ‘supplied, installed, tested and inspected for the works are in accordance with the DUBAI METRO Project requirements. The work methods are summarized as follows: 2.1 PREPARATION WORK, 2.2 RECEIVING FCUs, 2.3 INSTALLATION PROCEDURE, 2.4 PRE-OPERATIONAL INSPECTION, 2.5 OPERATION, References This document has been prepared with reference to the following documents: + Project Safety Plan and associated procedures * Project Environmental Plan and associated procedures + Project Quality Plan and associated procedures * Specifications issued by Dubai Municipality © Part 2 — GENERAL TECHNICAL DOCUMENTS, GENERAL SPECIFICATIONS, DOC. NO. PS007-T-ALLI-PMP-TN-SYS-175001-B2 © Part 4: CIVIL WORKS — UNDERGROUND SECTIONS, SPECIFIC TECHNICAL DOCUMENTS, ELECTROMECHANICAL EQUIPMENT, PARTICULAR SPECIFICATIONS. DOC. NO. PS007-T-ALLI-EME-TN-SYS- 180502-B2. + Relevant design document approvals. * Relevant equipments approvals. * Manufacturer's instructions/ catalogues/ recommendations. In addition, the following Method Statements are provided for reference: * Method statement for Ducting Document Number: DMO01-X-AST- EM-MT-— DCC-401183. * Method statement for Piping Document Number: DM001-X-AST-GEM-MT-— DCC--401184, « Method statement for Cable containments Document Number: DM001-X-AST- GEM-MT-DCC-401177. * Method statement for cables Document Number: DM001-X-AST-GEM-MT— Dec-401175. Memoo STATEMENT FOR NSTALLATION OF FOU ocsmon Ne: MDX AST-SEM-UT-DCE-AUHEA3 eoetateEt 4.0 Definitions and Abbreviations AHU ASHRAE BS DCP DM. DURL DWP EN ENG ETASET FCU Gl HSS HVCA ITP LPs MP. NIA NCR PPE RPM RTA SEM TPS Air Handling Unit ‘American Society for Heating, Reftigeration and Airconditioning Engineers British Standard Design Control Point Dubai Municipality Dubai Rapid Link Consortium Detailed Works Programme Euro Norm ‘The Engineer E&M Sub contractor Fan Coil Unit Galvanized Iron Health and Safety Standard Heating and ventilating Contractors Association Inspection and Test Plan Lighting Power Station Management Procedure Not Applicable Non Confirmity Report Personal Protective Equipment Revolution Per Minute Dubai Roads and Transport Authority Structural E&M requirements Traction Power Station 5.0 Specification Clauses The specification requirements for FCU are as contained in the following specifications and clauses: Specification: * Part 4: CIVIL WORKS — UNDERGROUND SECTIONS, SPECIFIC TECHNICAL DOCUMENTS, — ELECTROMECHNICAL EQUIPMENT, PARTICULAR SPECIFICATIONS. DOG. NO. PS007-T-ALLI-EME-TN-SYS-180502-B2 The specific clauses are reproduced below 3.16.7 Performance Requirements for Fan Coil Units Fan coil units shall be provided for all staff rooms and technical rooms not provided with specific AHU. Fan coil units shall comply with the following requirements: * FCU shall be of standardised type and their cooling capacity certified by EUROVENT or equivalent + FCU shall be manufactured with material which will not produce toxic vapour in case of fire + FCU shall be connected to the chilled water pipes by two shutoff valves and bya 3 ways regulating valve + FCU shall be equipped with air filters easily removable. Filters efficiency shall be 90% down to 10 microns particle size + FCU shall be provided with heating resistance with safety thermostat + Motor shall be capable to deliver 3 different fan speeds of operation (low/ medium high) + FCU shall be selected to meet the temperature design criteria in the concerned room while operating at medium fan speed (MEMO0 STATEMENT FOR MSTALLATION OF FU (osu Ne: DNOI-A-AST-GEM-AT-DCO~Y401A9~MeN 6.0 The control temperature system shall be installed either in the fan coil units (case of one or two fan coils units in the same room), or centralised for several fans coils, in the same room (in this case one or several ambiance probe(s) shall control the fans coils units concerned). In addition to the requirements of the specification referred above, the FCU installations shall be installed as per the detailed shop drawings prepared by ETASET based on approved design to be provided by the DURL, as approved by the ENG and the installation instructions of the damper manufacturer In addition, the following Method Statements are provided for reference: + Method statement for the cable containment; Document Number: D001 ~ X — AST = GEM ~ MT - DCC ~ 401177. + Method statement for the Installation of LV cables and wires; Document Number: DM001 ~ X - AST ~ GEM - MT — DCC — 401175. Resources Mobilization Plan According to the works programme, and planned site access availabilty at the respective work sites, appropriate staff, labour, equipment and materials will be mobilized to the site to install the FCU in accordance with the approved design. ‘The actual mobilization of staff, labour and equipment and the materials delivery schedule will be dependent on site access. Actual site access dates will need to be notified by DURL at least four weeks ahead of targeted handing over of the site and confirmation of site access date one week before the access date. Notification and confirmation of site access dates shall be provided by DURL to ETASET as required. It is understood that DURL will be responsible for the provision of appropriate types and quantities of cranes, cradles, working platforms and scaffoldings. Temporary construction water supply, ventilation, power supplies and lighting systems will be provided to all works locations by DURL. Aspects of the ETASET mobilization of the various resources are described in detail in the following sections of this method statement. 7.0Construction Equipment It_is envisaged that no major plant or equipment will be required to be provided by ETASET for the activities involved in the supply and installation of the FCU systems. The typical construction equipment requirements is as listed below, and will be used for erection activities at site. 7.1 PPE for all staff and labour 7.2 Measuring tapes and setting out markers 7.3 Spanner set /Other Hand Tools 7.4 Certified chain blocks, Nylon straps /shackles/ Spreader bar 7.5 Mobile Crane/Tower Crane 7.8 Scaffolding 7.7 Other special tools for FCU assembly 7.8 Spirit Level 7.9 Vacuum cleaner, Coil fin comber. 7.10 Measuring instruments Note: All powered hand tools shall be suitable for use with a 110 volt power supply. (METHOD STATEMENT FORMSTALLATION GF FCU ——_Decumee e DMEL-1-AST-SEN-T-OCC-O118-838.0 9.0 10.0 i Personnel Installation of the FCU will be organized from a central location by the project management team. It is envisaged that the installation of FCU on site wiil be conducted by one or more FCU installation teams. Each FCU installation team will comprise of a supervisor, up to 2 skilled workers/riggers and up to 4 helpers. The FCU installation teams will report to the site construction management organization, in general, and the Station Engineer (Mechanical) in particular. The personnel on site will be fully competent to carry out the installation of FCU and all related works associated with it The site personnel will have attended the required contractors safety induction and/or competency training and will abide by the health & safety plans, policy and procedures as well as Environmental Plan. Personnel will be deployed to the various sites on the basis of programme requirement and site access availability. It is intended that the works teams will be organised by geographical areas. Materials The FCUs will be procured from approved vendors. Units will be ordered as per approved equipment submittal. All units delivered to the site will first be inspected to check that they are in accordance with delivery documents, and that they are free from any damage caused during transportation to site. Delivery documentation shall be checked for completeness. Defective or damaged equipment shall be notified to the supplier and stored on site at a suitable quarantine location. The defective equipment will be either replaced or repaired at the option of the supplier. The inward inspection of materials will be carried out in accordance with the relevant QA/QC procedure (Document Number DM001 —X — AST — GEM — PR -DCC-409603). No materials will be permitted to be used without being inspected on arrival to the site. Construction Procedure and Construction Methods The construction procedures and methods described here are based upon the scope and application of the method statement summarized in section 2 of this method statement and the work methods are structured accordingly. 10.1 PREPARATION WORK. Before commencement of installation, following are required to be carried out. * Check the drawing of the FCU layout is approved, and that the drawings for the FCU installation are issued with “Approved for Construction” status, in accordance with document control procedures. * Check that the design of the Builders Work and SEM requirements, as applicable, is approved, and that the Builders Work and SEM requirements drawings, as applicable, are issued with “Approved for Construction” status, in accordance with document control procedures, + Check that site access to the work area for installation is available, that the works area is clean and safe and that the temporary services provisions are available, Check that the applicable builder's works and SEM requirements works are completed. If these provisions are available and adequate a joint taking over inspection between DURL and ETASET shall be conducted and recorded. + Check the installation room layout in the approved drawing for the size, quantity and arrangement of Fan Coil Units. ETA00 STATEMENT FOR INSTALLATION OF FO ‘Document Ne: DMSI-ROAST-GESIN-DCO~110-89 Powesateet * Unloading platform and equipment access hatch must be provided prior to the equipment delivery. * Check that ail the allocated equipment position and dimensions are correct and the means of access toward the FCU plant room is iree from blockage. If any of the above is not found Ok work will not start and a NCR will be issued. 40.2. RECEIVING FCUs The FCUs are will be generally shipped in assembled condition for site erection. The inspection & receiving procedures at site are detailed below: * All delivered material shall be inspected on arrival at the site. The inspection shall be advised, in advance, as required by the ITP. * The delivered materials shail be inspected in accordance with the appropriate QA and QC procedures. + The delivered materials shall be in accordance with the approved design, approved shop drawings; materials approvals and all applicable documentation and certification shall be available with the delivery. Upon receipt of the FCUs at site, inspect all items for possible shipping damage If the shipment shows any indication of damage or pilferage, it should be noted on the delivery documents and informed to the supplier. Note any hardware or crates that are separate from the FCUs for later reference Sound material handling practices must be used when unloading and handling the FCUs. Care must be taken not to drop, drag, crush or apply excessive twisting, racking or skewing loads on any FCU frame, or any of the accessories. * When unloading, use an appropriate size spreader bar/support rod using lifting holes. or lugs to even out the load Keep all lifting cables or chains away from the body of the FCUs. All materials shall be free from defects or damage. Any material delivered to the site that not conforming to the above shall either be returned to the point of supply or stored on site at a suitable quarantine store. A NCR shall be raised for all such materials, * No materials will be permitted to enter the works locations without being inspected on arrival to the site. 10.3. INSTALLATION PROCEDURE + Fix the supports on the ceiling stroke wall as per approved drawings. * Lift the FCU, and mount and position the FCU properly on the support as per approved drawings. + Make the duct connections as per approved drawings and recommendations of manufacturer. Refer method statement no DM001-X-AST-GEM-MT-DCC-401183 * Make the pipe connections as per approved drawings and recommendations of manufacturer, ‘+ Make the electrical connections as per approved drawings and recommendations of manufacturer. Refer method statement for no, DM001-X-AST-GEM-MT-DCC- 401175 & DM001-D-AST-GEM-MT-DCC-401177 + Install filters as per manufacturer's recommendation. * Ensure all wirings and groundings of electrical installations are in compliance with local electrical rules and regulations. * The unit should be cleaned properly, preferably with compressed air and vacuum cleaner. ETHOO STATENENT FOR NSTALLATION O FU ‘oun Na: MOEA AST-GRILNT-OCC-OHEH-S PuasaEre en 11.0 12.0 METHOD STATEMENT FOR NSTALLATION OF FOU ecient He: DED AST-GEM-NT-OGC-A04-Ad + After completion of installation, cover the unit with polythene to avold damages, * Clean the work location, 10.4 PRE-OPERATIONAL INSPECTION. {Inspect whether the unit installation is completed and all debris has been removed, * Inspect filter and check if the same is in order. Inspect the duct side connections, Check that they are installed correctly, that they afe rigid and are not having any apparent leakage as per approved drawings. * Check whether the water system has been cleaned. Before allowing water to pass through the coil for the first time, open the air vents to remove the locked alr in the oll. Check condensate drain line by craining water poured seperately on the drain pan. * Check the electrical & control connections, Refer relevant method statements. * Check the insulation value of motor and wiring by meggar. If resistance is found below 1 M-ohms the same has to be dry heated to improve insulation value to acceptable value > 1 M-chms The installation is now ready for test run, 10.5 OPERATION. * Check the interlock and safety contro! operations. + Check the operation of vaives. * Check the voltages in all the phase whether they are as per rated voltage, * Give momentary power supply to the motor. Check rotation, vibration, ete. If any abnormality neticed rectify the same by caling authorised service personnel of the Manufacturer before running it continuously. + Run the motor at least ten minutes. * Check and record the following: a. Running current b. Airflow rate ©. Vibration Responsibility tino Project Director isthe overall responsible person for the process implementation of ae tuerks. The Construction Managers will be responsible for all construction nafotien at ihe Site and will directly supervise through erection supervisor / skilled workmen the Work at site. The Construction Manager will also be responsible for arranging and controlling the inspection and testing activities, Notwithstanding the above, it is the responsiblity of each individual employed in the project fo take due care to ensure their own personal safely and that of their wine colleagues, Design & Drawings FCU installation drawings and FCU shop fabrication drawings will be Prepared based on approved design and will be submitted separately for approval before commencement of works. roti s & 17.0 18.0 19.0 21.0 22.0 Statutory Consents Not Applicable Work Programme Latest coordinated installation program will be strictly followed and fully complied. Quality Assurance All procedures described in the approved quality plan for the Dubai Metro Project contract will be followed. Health & Safety The execution of works will strictly follow the Project Safety Manual. Environmental Policy The Execution of works will sirictly follow the Project Environmental Plan. Relevant documentation A. Approved Design Drawings Approved Shop Drawings (To be submitted later) Relevant codes as in approved design specifications Approved Equipment submissions, ITP Method statement ™moo09 Sub Contractor ETASET has been appointed as E&M subcontractor for the stations and inter station annex buildings of Dubai Metro project phase-. Itis envisaged that the FCU installation works will be undertaken by ETASET's direct workforce; therefore, it is not expected to require any further sub contracting of the works. Risk Assessment & Hazard Analysis Risk assessment form is enclosed. Organization Chart As per Organization Chart of the project Inspection and Testing ‘As per Attached ITP METHOD STATEMENT FOR INSTALLATION OF FEU Dost No: DMOGI-X-AST-GEN-AT-DCC-401184-A2 PontsDUBAI METRO PROJECT Dubai Rapid Link Risk Assessment Analysis (Safety & Health) Ame aa se Stei STOUR Of WREST TOU A Raa — aT Ty] nba Jo inf ssauy ase ues prez — eUyBveHy 2 “obeurop wauidnbo pue Avadotd “nly auonas ‘sau anovos ot ynse! ues nee wont ‘05 app BuO SSOUH DUE Yeap used Jo ageden pure ISH EBLE Lt ~onydagsereD- 5 as + fz]e |e ‘ , 1 z s |e ! oad 5 3 aieans 5 wun [rife | os |e | a ° Suen mas EMER g t soa fearon sims ew seanegieed “F : sun ows foye-sommy sms eee wnuwen [oo |» |e fa | ow : seen snoo ma Awe eer Aeon | “ov tape ere qua oy RSI) be "ung 20 eps se nr ean TERED] aera | Bee =e ‘ie sem Aneel ee oo FOAL AT EUAN outa ievonag aan ones “7 ‘pen og oc somneamie Raye YE onsaueo a) Suew jpovosiad pay Apodeances -z vonedies ope ‘tent Stevan oj sbatrepBueneo se] uownbe ous svopzauca| we z . z n 8 : 2__| ‘snowmen ous mero] eanpare Sanson pe Bonen 01 £ € L sopuuucsery pauesjosen ai “4 2 gmtsoay veees | Rieger snouoy) sores ent sermon | eoneu rent na NOWWOUIN saunsvaNIOULNOD| “Aen arr PR ToTDUBAI METRO PROJECT Dubai Rapid Link Inspection ChecklistsEe |ire DRAWING REF.: MAIN CONTRACTOR : DURL DUBAI METRO PROJECT EMPLOYER: RTA, GOVT. OF DUBAI THE ENGINEER: SYSTRAPARSONS MEP SUBCONTRACTOR : ETA SET L.L.C. CHECK LIST FOR COMPLETION OF INSTALLATION OF FCUs FCU Designation & No: oc. Nor: 5008 PAGE: 1 of 1 JFCU Mod [its No.: DMOO1-X-AST-GEM-MT-DGC—401181 Manufacturer ITP No.: DMO01-X-AST-GEM-IT-DCC—402161 [Location / Area Served: SR. No. ACTIVITIES / ITEMS TO BE INSPECTED STATUS REMARK 4 [Inspection at site documentations are in order 2_| Installation of FCU completed and is as per approved drawings 3 [Ducts connection completed Piping connections completed. Pressure testing of pipes completed before equipment connection 5 [Drain “U" trap is i in order 6 |Condensate Water draining test carried out and results recorg/n\, 7 | Electrical connect tions are secure and In order 8 [Debris are removed 9 [Damper installation is order 410. |Water system has been cleaned properly 11 [Insulation resistance test of motor and wiring | COMMENTS / DISCREPANCIES, IF ANY: ‘WV SITE ENGINEER ‘JVQC INSPECTORFCU Designation & No: MS No.: DM001-X~AST-GEM-MT-DGG—407181 ITP No.: DM001~K-AST-GEM-IT-DCG—402181 no.| NSTRUMENT AME | MooeLno. | wsrmuMEnrseRiALno, | oaLuenaron ome | Se TEST ACTWITIES srarus [rena | 1_|FCU Configuration Safety interlock tests, Electrical safety circuit tests |Operation of fitter motors JOperation of blower motors (Free run) JOperation of dampers ~lolalalealnr Operation od valves Replace filter and check access L\ 9 |FCU total air volume 410 [Motor running current 14 [Vibration TEST RESULT: ACCEPTABLE / UNACCEPTABLE JV SITE ENGINEER JVQC INSPECTOR [SIGNATURE NAME pateDUBAI METRO PROJECT Dubai Rapid Link Inspection & Test Plan ETRE gy iil SP s5sicipetie aan PERIYARizeys5uy sioare0 SENSO SO UNNRO OV CiGORG | Tal beupaRy | TaogIAR TESS iaeAREEP A. 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