(A2) MS For Testing and Commissioning of Secondary Chilled Water System

Dubai Metro Red Line Project
Secondary chilled water

Commissioning
Method Statement
Project: Dubai Metro Red Line Project Date: 25 Feb 2009

Document: T&C-Sec.CHW-MS-007 (A2) Author: G.Gillard
Revision: A2
Page 1 of 10
Project: Dubai Metro Red Line Project
Secondary CHW Commissioning- Method Statement
Document Control:
PROJECT: DUBAI METRO RED LINE PROJECT
CLIENT: ETASET
DOCUMENT: METHOD STATEMENT
TITLE: SECONDARY CHILLED WATER COMMISSIONING
AUTHOR: G.GILLARD Comm Mng.
APROVE BY:
REVISION: A2
DATE ISSUED: 12 FEBRUARY 2009

Document: T&C-Sec.CHW-MS-007 (A2) Author: G.Gilllard
Revision: A2
Page 2 of 10
Index
Section Page No.

1.0 Introduction 4
2.0 Pre-requisites 5
3.0 Health & Safety. 5
4.0 Risk Assessment & Hazard Analysis 5
5.0 Equipment Required 5
6.0 Reference Standards 6
7.0 Commissioning & Testing Procedures 6-7
8.0 Witnessing 8
9.0 Compliance Sign off sheet 9
10.0 Appendix 10
10.1 Chilled water circuit Pre-Commissioning Test Sheet

10.2 Pump Pre-Commissioning Test Sheet
10.3 Pump Performance Test Sheet
10.4 Water balance record Test Sheet
10.5 Risk Assessment Form

Revision: A2
Page 3 of 10
1.0 Introduction.
1.1 The following method statement has been prepared as a guideline. For the
Commissioning of the Secondary Chilled Water Circuit on the Dubai Metro Red Line
project. This is to be reviewed and agreed by the Design Consultants, M&E Contractor
and the Testing and Commissioning Company that will be performing the procedure.

Revision: A2
Page 4 of 10
2.0 Pre-requisites.
2.1 The following pre-requisites must be in place before work can start.
• Static completion of the system and relevant documentation signed off.

• Flushing completed and signed off.
• Suitable access to all Valves, Commissioning sets, Strainers and Control
valves etc.
• Provide scaffolding and Mobil Lifting Platforms where necessary.
• Start up and emergency shutdown procedures issued.
• Power supply available and constant.
• Chilled water provided if possible.
3.0 Health & Safety.

The execution of works will strictly follow the project safety manual.
4.0 Risk Assessment & Hazard Analysis.
Risk assessment form is enclosed.
5.0 Equipment Required.
5.1 Any instrument that requires calibration must have a valid calibration certificate.
And be logged on the Instrument Log Sheet with a copy of the calibration
certificate.
The following test instrumentation & tools will be required to undertake the tests
detailed within this procedure:
• Pressure Gauges*
• Mercury and fluorocarbon Manometer/ Digital Flow Meter
• Relevant valve charts
• Clamp-on Ammeter *
• Tachometer *
• Hand Tools (Mirror, torch, screwdrivers etc)
(* Instruments requiring a calibration certificate)

Revision: A2
Page 5 of 10
6.0 Reference Standards.
6.1 The following standards have been referenced when preparing these test
procedures:
• CIBSE Commissioning Code W – 1994 – Water Distribution Systems.
• BSRIA Commissioning of Water Systems in Buildings – AG2/89.
These standards should be adhered to throughout the testing and commissioning

process.
7.0 Commissioning & Testing Procedures.

CHW Circuit Pre-commissioning.
7.1 Confirm CHW system has been pressure tested as per project specifications and
There is no evidence of leakage at joints or valves.
7.2 Pressure gauges and thermometer are installed at correct location.
7.3 Confirm CHW system has been flushed and cleaned.
7.4 All the strainers are cleaned.
7.5 Confirm CHW circuit has been vented of all air.
7.6 All insulation and vapour sealing should be completed.
7.7 Confirm all the AHUS & FCUS cooling coils should be in cooing mode, all the
supply & return valves should be fully open all the by pass valves should be in
closed position.
CHW Pump Pre-commissioning.
7.8 Confirm pumps are installed as per manufacturer recommendations and project
specifications.
7.9 Pump impeller is free to rotate.
7.10 Motor terminal wiring is checked.
7.11 Local electrical isolator provided in case of emergency shutdown.
7.12 Direction of volitions correct & checked.
7.13 No excessive vibration and abnormal noise.
7.14 Follow the pre-commissioning check list attached in appendix.
Initial Volume Check

Revision: A2
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7.15 After the pre-commissioning checks have been carried out successfully, start the
required number of pumps as per the design specification.
7.16 Measure the main commissioning set and set it to 110% of the design volume.
Either by adjusting the VFD or if no VFD is installed, by regulate the main DRV
to achieve the correct flow.
Note: If the circuit has a stand by pump the volume must also be checked with the
standby pump running and one of the primary pumps isolated. Repeat this for each
standby pump.
Circuit Balancing
7.17 The following procedure will be followed to balance the Secondary Chilled Water
Circuit after the pre-commissioning has been successful.
• Perform an initial scan at each commissioning set.

• Find the index commissioning set and keep fully open.
• Balance the other commissioning sets proportionally to the same
percentage of flow set in the branch commissioning set. (ideally an overall
reading of within 10% between commissioning sets should be obtainable ±
5% of design)
• Repeat this procedure for all branches on the circuit.
• When all branches have been balanced separately use the branch
commissioning sets to bring each index in to balance.
• Perform a final scan at eat each commissioning set and record on the
appropriate test sheet.
• Lock off and record every commissioning set position.
Pump Performance / Commissioning Test
7.18 Verify all the balancing valves of the CHW circuit are balanced according to
above mentioned circuit balancing procedures.
7.19 Measuring the discharge pressure and the suction pressure. Determine the pump
head by subtracting the suction pressure from discharge pressure.
7.20 Plot the head on the pump curve using the determined shut off head curve and
establish flow. Include the pump curve in report.
7.21 Record the motor Amps, voltage and speed of the motor by tachometer.
7.22 Fill the data in the attached pump commissioning report.

Revision: A2
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8.0 Witnessing
8.1 After the circuit have been commissioned, and all the relevant paper work
completed. It must be offered to the Commissioning Manager. He/she will organise
a time and date with all relevant parties to witness the system. After the system has
been witnessed the witnessing team or individual will decide to sign off the system
or not depending on the success of the witness.
Note: It is up to the witnessing team’s discretion as to what percentage of the system is

to be witnessed.
9.0 Compliance Sign off Sheet:

Revision: A2
Page 8 of 10
9.1 We confirm that we have read and understood the attached method statement, for
the commissioning of Secondary Chilled Water Systems. We accept and agree to
follow the procedure laid out in this method statement.
NAME COMPANY DATE SIGN
10.0 Appendix:
10.1 Chilled water circuit Pre-Commissioning Test Sheet
10.2 Pump Pre-Commissioning Test Sheet

Revision: A2
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10.3 Pump Performance Test Sheet
10.4 Water balance record Test Sheet
10.5 Risk Assessment Form

Revision: A2
Page 10 of 10
Risk Assessment Analysis (Safety & Health) : Testing & Commissioning of Secondary CHW system
Initial Risk Final Risk Residual Risk
POTENTIAL ACCIDENT Rating Risk CONTROL MEASURES / Rating Risk Acceptable
BASIC JOB STEP / ACTIVITY
OR HAZARD Probability x Factor MITIGATION ACTIONS Probability Factor
Severity x Severity
1 Checking electrical motor Hazard of shock, 1. Work area should be demarcated restricting
Connections of the access.
equipments. And electrical faults, 2. Ensure properly trained personnel checking
measuring voltage & the connection.
Amps in starter panel etc causing 3. All safety precautions to be followed.
damage to 2 3 6 2 1 2 Low
materials and/or
manpower.
2 Fall from height during May cause death 1. Use of PPE and safety belts
measuring the flow of 2. Tool talks and trainings to workers
water at the balancing or permanent
valves. 2 3 6 1 2 2 Low
disability
RISK FACTOR MATRIX

Probability Methodology
4 -Probable-Likely to occur immediately or shortly 1. Identify Hazards
3 -Reasonably probable-Probably will occur in time. 2. List Hazard Event
2 -Rem ote- May occur in time 3. Calculate risk factor with initial risk rating i.e., probability x
1 -Extremely remote–Unlikely to occur Probability RISK PRIORITY severity
4. Detail controls
5. Calculate residual risk factor with final risk rating
Severity
6. Enter risk priority
4 – Catastrophic – Imminent danger exists, hazard capable of causing
7. Evaluate acceptability of risk
death and illness on a wide scale
s 4 3 2 1 8-16 High Risk
3 – Critical – Hazard can results in serious illness, severe injury,
e
property and equipment dam age 4 16 12 8 4 6 Medium Risk
v
2 – Marginal - Hazard can cause illness, injury or equipment damage, 3 12 9 6 3 1-4 Low Risk
e
but ht results would not b expected to be serious
r 2 8 6 4 2
1 – Negligible – Hazard will not result in serious injury or illness, remote
i
possibility of damage beyond minor first aid case.
t 1 4 3 2 1
y
PERFORMANCE TEST RECORD - WATER BALANCE REPORT
CLIENT : ROADS AND TRANSPORT AUTHORITY
PROJECT :DUBAI METRO-
MAIN CONTRACTOR :JTMJV
MEP CONTRACTOR :ETA - SET
MEP CONSULTANT :SYSTRA AND PARSONS
SYSTEM :
LOCATION / AREA : DATE:
Design Intial Pr. Final Reading

Valve Size Design
Sl.no Terminal Ref. Location pr.drop at Drop at Pr.drop % of Turns
in (mm) Flow (L/s) Flow (L/s) Kv Value
F/O Kpa F/O kpa Kpa Design Open
10
11
12
13
14
15
INSTRUMENT DETAILS:- NAME: MODEL:
Remarks :
DETAILS PERFORMED BY PRIME TECHNOLOGIES WITNESED BY MEP CONT'R. APPROVED BY CONSULTANT
SIGN :
NAME :
DATE :
F : 208 : 13 0508
PERFORMANCE TEST RECORDS - PUMPS
CLIENT :ROADS AND TRANSPORT AUTHORITY

MEP CONSULTANT :SYSTRA & PARSONS
SYSTEM :
LOCATION / AREA : Date :
PUMP
MANUFACTURER : MODEL: Sl.NO.:
TYPE : IMPELLER SIZE: STAGES:
TYPE OF SEAL :
MOTOR
MANUFACTURER : OUT PUT (KW) : VOLT/ FLC (A) :
SL.NO : H.P : PHASE / Hz :

FRAME NO : O.L.R - RANGE : O:L.R - SET :
SL.NO PARAMETERS DESIGN TEST
Suction Pressure (kpa / psi )

1 Operating Pressure
Discharge Pressure (kpa / psi )
2 Operating Head (M)
3 Water Flow L/S
SUCTION (kpa)
SHUT-OFF PRESSURE
4 DISCHARGE (kpa)
5 SHUT-OFF HEAD(M)
R
6 Amperage Y
R-Y
7 Voltage Y-B
B-R
8 Motor Speed RPM
REMARKS :
DETAILS PERFORMED BY PRIME TECHNOLOGIES WITNESSED BY MEP CONTRACTOR APPROVED BY CONSULTANT
SIGN.
NAME
DATE
F : 208 : 11 0508
PRE COMMISSIONING CHECKS - CHILLED WATER CIRCUIT
CLIENT :ROADS AND TRANPORT AUTHORITY
SYSTEM :

SL.NO CHECK THAT COMMENTS FOLLOW UP
Confirm CHW system has been pressure tested and there is
1
no evidence of leakage at joints and valves
Pressure gauges and thermometer are installed at correct
2 location.
3 Confirm CHW system has been flushed and cleaned.
4 All the strainers are cleaned.
5 Confirm CHW circit has been vented of all air.
6 All CHW pipe insulation works should be completed.
Confirm all the AHUS & FCUS cooling coils should be in
cooling mode, all supply,return & control valves should be
7
fully open all the by pass valve should be in closed
position.
REMARKS :
PERFORMED BY PRIME
DETAILS WITNESSED BY MEP CONTRACTOR APPROVED BY CONSULTANT
TECHNOLOGIES
SIGN.
NAME
DATE
F : 208 : 10 0508
PRE COMMISSIONING CHECKS - PUMPS
CLIENT :ROADS AND TRANPORT AUTHORITY
SYSTEM :

SL.NO CHECK THAT
COMMENTS FOLLOW UP
Mechanical Checks
1 Alignment of Pump and motor Coupling is Checked
2 Pump Fixed on Isolated Floating Base

3 Vibration Isolated Spring fixed
4 Mechanical Checks Completed
5 Direction of the rotation correct and checked
6 Pumps and motors are Lubricated
7 No excessive vibration & abnormal noise.
Electrical Checks
1 Panel board installation correct
2 Panel and Switch gears are Cleaned
3 All Connections are frim and Tight on Busbar
4 Starter Over laod are Correct Set /range is Ok
5 Motor terminal Wiring is Checked

6 Local isolator is provided in case of emergency shutdown
7 All power and Control Wiring is Completed as per the Drawing
8 All Fuse rating are Correct
9 No Loose Components and Wiring is Checked
10 Design Voltage is available in all phases
REMARKS :
PERFORMED BY PRIME
DETAILS WITNESSED BY MEP CONTRACTOR APPROVED BY CONSULTANT
TECHNOLOGIES
SIGN.
NAME
DATE
F : 208 : 10 0508
PERFORMANCE TEST RECORD - WATER FLUSHING VELOCITY REPORT
CLIENT :ROADS AND TRANSPORT AUTHORITY
SYSTEM :
LOCATION / AREA : Date :
Final Reading
Design pr. Drop
Sl.no Terminal Ref. Location Valve size in (mm) Design velocity m/s
kpa
Pr.drop Kpa Velocity m/s Turns Open Kv Value
Remarks:
DETAILS PERFORMED BY PRIME TECHNOLOGIES WITNESSED BY MEP CONTRACTOR APPROVED BY CONSULTANT
SIGN :
NAME :
DATE :
F : 208 : 12 0508
SYSTRA/PARSONS (The Engineer)
The Engineer’s Office, Union Square, P.O. Box 111081, Dubai, UAE
Tel.: +971 (0) 4 234 0202, Fax: +971 (0) 4 234 0203
DUBAI METRO PROJECT

DESIGN REVIEW COMMENTS 11/1/2009
ELECTROMECHANICAL EQUIPMENT
Document title Method Statement for Testing and Commissioning of Secondary Chilled Water System
Design Stage
Discipline Electromechanical equipment
Reviewer
Document Project DM001-X-AST-GEM-MT-DCC-1285165
Number
Revision n°/Date A1 of 16 December 2008
Transmittal ID TRANSMIT-025071
comments for Method Statement for Testing and Commissioning Page 1

of 5
The Engineer’s comments are given to ensure the reviewed submission conforms to the Contract provisions and shall not be construed as limiting the Contractor’s
liability in any way or constituting an instruction, direction or notice to change or vary the Works.
Tel.: +971 (0) 4 234 0202, Fax: +971 (0) 4 234 0203
Reference Of The Clearance

N Engineer Comments Contractor Answers
Document / Section Date
Commissioning plan to be submitted include the

following :
- General plan and scope of Subcontractors in
relation with T&C of all equipment in the project. These issues are covered in the
1
- ITP with check lists with agreed Witness and T&C Plan.
Hold points for all parties
- QA Processes during T & C.
Acceptance criteria should be clearly defined in MS/T&C Refer 7.17 +/- 5% WITH 10%
2
documents SPEARD
This issue is covered in the T&C

VTA plan for “the system” will be implemented by Plan and VTA Plan. VTA is a process
3
DURL before starting T&C implemented before, during and
after T&C.
DURL will deploy standard format
cover sheets including Work
Package specific data and
DURL to develop a Standard Format check list (for
4 signatures boxes. Specialist
Engineer’s approval) applicable to all Subcontractors.
manufacturer’s/supplier’s/subcontra
ctor’s certifying sheets will have to
be maintained.
comments for Method Statement for Testing and Commissioning Page 2 of 5

Tel.: +971 (0) 4 234 0202, Fax: +971 (0) 4 234 0203

The test procedure should be submitted in detail before Site Specific test sheets will be
the tests, containing : prepared in the Work Packages.
5 Document details, reference, test record sheet showing the These will be submitted attached to
parameters to be measured/checked, theoretical values the ITR’s. (Covered in the T&C
and acceptable tolerance Plan)
For each equipment A Data sheet to be attached contain :
Type of equipment
Location
Manufacturer
Model No.
6 Refer APPENDIX 10.3
Serial No.
Power (kW)
Power Factor (%)
Starting method
etc
All specialized tools, test equipment and instruments
required to execute Start-up, checkout, and testing of
7 equipment to be provided with sufficient quality and Refer 5.0 EQUIPMENT REQUIRED
accuracy to test and/or measure system performance
within specified tolerances

Tel.: +971 (0) 4 234 0202, Fax: +971 (0) 4 234 0203

Contractor must calibrate test equipment and instruments Calibration certificates will be
according to manufacturer’s recommended intervals. submitted attached to the ITR’s
8
Calibration tags must be affixed to the test equipment or within Work Packages. (Covered in
certificates readily available the T&C Plan)
In case of no permanent PS test will be done with

temp. power supply sours and will be repeated
9 T & C PLAN
again randomly for some equipment with the
permanent source
10 - Temperature and humidity measurement is not included. To be covered in ECS MS
11 - Physical check for condensation to be checked . To be covered in ECS MS

Earthing continuity to be checked
12 INSTALLATION CHECK
functional checks and interface for remote function
13 to be added ECS
item 1.2 to be revised ,we do not have chillers

14 REVISED
item ,5.6 the 10% tolerance in water flow is not accepted, Refer 6.1 REFRANCE &
15 moreover, this item is matching with air balancing STANDARDS

Tel.: +971 (0) 4 234 0202, Fax: +971 (0) 4 234 0203

not water
One half of controller tests shall be on the emergency

16 ECS
power source
Loss of primary source shall be simulated and transfer
17 ECS
shall occur while the pump is operating at peak load.


(A2) MS For Testing and Commissioning of Secondary Chilled Water System

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Dubai Metro Red Line Project

Secondary chilled water

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

PROJECT: DUBAI METRO RED LINE PROJECT

DOCUMENT: METHOD STATEMENT

TITLE: SECONDARY CHILLED WATER COMMISSIONING

AUTHOR: G.GILLARD Comm Mng.

DATE ISSUED: 12 FEBRUARY 2009

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

Section Page No.

3.0 Health & Safety. 5

4.0 Risk Assessment & Hazard Analysis 5

5.0 Equipment Required 5

6.0 Reference Standards 6

7.0 Commissioning & Testing Procedures 6-7

9.0 Compliance Sign off sheet 9

10.1 Chilled water circuit Pre-Commissioning Test Sheet

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

• Static completion of the system and relevant documentation signed off.

3.0 Health & Safety.

4.0 Risk Assessment & Hazard Analysis.

Risk assessment form is enclosed.

5.0 Equipment Required.

(* Instruments requiring a calibration certificate)

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

• CIBSE Commissioning Code W – 1994 – Water Distribution Systems.

• BSRIA Commissioning of Water Systems in Buildings – AG2/89.

These standards should be adhered to throughout the testing and commissioning

7.0 Commissioning & Testing Procedures.

CHW Pump Pre-commissioning.

Initial Volume Check

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

• Perform an initial scan at each commissioning set.

Pump Performance / Commissioning Test

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

Note: It is up to the witnessing team’s discretion as to what percentage of the system is

9.0 Compliance Sign off Sheet:

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

NAME COMPANY DATE SIGN

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

Project: Dubai Metro Red Line Project Date: 25 Feb 2009

RISK FACTOR MATRIX

CLIENT : ROADS AND TRANSPORT AUTHORITY

PROJECT :DUBAI METRO-

MAIN CONTRACTOR :JTMJV

MEP CONTRACTOR :ETA - SET

MEP CONSULTANT :SYSTRA AND PARSONS

LOCATION / AREA : DATE:

Design Intial Pr. Final Reading

INSTRUMENT DETAILS:- NAME: MODEL:

DETAILS PERFORMED BY PRIME TECHNOLOGIES WITNESED BY MEP CONT'R. APPROVED BY CONSULTANT

CLIENT :ROADS AND TRANSPORT AUTHORITY

TYPE : IMPELLER SIZE: STAGES:

MANUFACTURER : OUT PUT (KW) : VOLT/ FLC (A) :

SL.NO : H.P : PHASE / Hz :

Suction Pressure (kpa / psi )

2 Operating Head (M)

3 Water Flow L/S

DETAILS PERFORMED BY PRIME TECHNOLOGIES WITNESSED BY MEP CONTRACTOR APPROVED BY CONSULTANT

CLIENT :ROADS AND TRANPORT AUTHORITY

PROJECT :DUBAI METRO-