WORK PROCEDURE FOR TOTAL 32 PAGES

HVAC CONTROL SYSTEM (Including Cover)

● PROJECT CODE : B50532EA Purpose

● PROJECT NAME : MASINLOC POWER PLANT EXPANSION
□ For Information
PROJECT
□ For Review
● DOCUMENT NO.: 0-WD862-CA731-00357
● TITLE : WORK PROCEDURE FOR HVAC CONTROL ■ For Approval
SYSTEM □ For Construction
● OWNER : MASINLOC POWER PARTNERS CO.,LTD.
□ As Built

September Ramil Pack, Nam,

A For Approval J.W Do J.H.Lee H.S.Woo
20, 2017 Cervera Hyeonwoo KiYoon

Rev. PREPARED REVIEWED APPROVED CHECKED REVIEWED APPROVED

DESCRIPTION DATE
No. GTC VPCI
Owner

Contractor
 TABLE OF CONTENTS

1.0 PURPOSE………………………………………………………………….. 3

2.0 SCOPE……………………………………………………………………… 3

3.0 ROLES AND RESPONSIBILITIES……………………………………… 3

4.0 RESOURCES ……………………………………………………………… 4

5.0 PROCEDURE ……………………………………………………………… 5

6.0 ENVIRONMENT, HEALTH AND SAFETY……………………………… 17

7.0 ATTACHMENT …………………………………………………………….. 17

Attachment # 01. Job Environment and Safety Analysis

Attachment # 02. Risk Assessment

1.0 PURPOSE
 This provides the detailed description and method of installation of HVAC Control System used in
building’s for Masinloc Power Plant Expansion Project.

Ensure works and procedure associated to HVAC Control System and Device units be executed in
compliance with the technical specifications of the Masinloc Power Plant Expansion Project.

2.0 SCOPE
This procedure is applicable in accordance with approved for construction drawings and shop
Drawings.

2.1 PROCEDURE
a. Construction Schedule
b. Reference
c. Materials : Power Cable, I&C, HVAC devices (All VPCI Supply)
d. Surveying
e. Execution
3.0 ROLES AND RESPONSIBILITIES
3.1 VPCI Project Manager (Contractor) - shall be the overall responsible for the
implementation of this procedure ensuring that works are completed on schedule,
materials provided in time and in conformity with drawings and specifications.

3.2 VPCI Project EHS Manager (Contractor) shall ensure safe implementation of this procedure
promoting an Incident and Injury Free environment.

3.3 VPCI & GTC Global Inc. QA/QC (Contractor & SubCon) Engineer shall be responsible
for the implementation of construction specification and standards and see to it that this
written method statement of the work shall be carried out.

3.4 VPCI & GTC Global Inc./BMC ACE Material Controller (Contractor & Subcon / GTC
Subcon) Inc. shall be responsible on close coordination of material withdrawal on
Laydown area going to site where to be installed.

3.5 GTC Global Inc. Construction Manager/BMC ACE Inc. Project Manager– shall have
the overall responsibility for the direction, monitoring, coordination and control of all the
construction activities attached and related to Automatic Control works and the overall
Health and Safety procedure.

3.6 GTC Global Inc. HSE Supervisor/BMC ACE Inc. Safety Officer along with the Safety
Officer shall ensure implementation of all safety procedures, safety measures related
to the nature of works being carried out and in accordance with the HSE Plan.

3.7 BMC ACE Inc. Site Engineer (GTC Subcon) shall be directly involved in the planning
and execution of the activities. He shall be responsible for the preparation of work plan,
safety action plan and safety. Responsible for the cable tray installation, cable laying,
roughing-ins, HVAC Control device, electrical & instruments wiring & interconnection
and close coordination with DMGNSP E, I&C contractor.

3.8 BMC ACE Inc. Workers shall be adhered to the rules and guidelines in this instruction
during the Automatic Control System Erection Works, shall comply with the site rules
directed without any kind of failure. (BMC Ace Inc. Supply of Labor only)

4.0 RESOURCES
4.1 Manpower (ALL BMC Staff & Workers)

Site Manager 1
QA/QC Engineer 1
Site Engineer 2
 4.2 Equipment & Tools

Pipe Bender 1
Hole Saw 1
Battery Pack (Electric Drill) 1
Wire Stripper 1
Electrician Pliers 1
Philip & Flat Screw Driver 2
Crimper 1
Threading Machine 1
Electric Drill with Concrete 1
Bit
Multi-Tester 1
Continuity Tester 1
File (Round, Half Round) 2
Open End Wrench 2
Level bar 2

4.2.1 Special Equipment

Clamp Ammeter with Ohmmeter 1

Megger tester 1

.0 PROCEDURE
5.1 CONSTRUCTION SCHEDULE
No Description Months
5 6 7 8 9 10 11 12
.
1 Steam Turbine Building
2 Central Control Building
3 Water Treatment Building

5.2 REFERENCES
 1) NFPA 70 National Electric Code

2) Standards published by the International Standards Organization(ISO)

3) National Electrical Manufacturer’s Association (NEMA)

4) Drawing Number (3-WD960-EE177-00001 Rev. 0)

5.3 MATERIALS (all Materials are VPCI Supplied)

1) Galvanized Cable Trays & Connectors with accessories

2) RS Conduits & Connectors with accessories

3) Flexible Conduit & Connectors with accessories

4) Unistrut Channel, Spring Locks, with accessories

5) Control Cable Wire (36Core, 28Core, 6Core, 2P, 3P etc.)

6) Cable Tray Hangers & Supports

7) Duct & Humidity Sensor, Pressure Differential Switch, Air Flow Switch, HVAC Control
Panel, Damper Actuator, etc.

Cable Tray Rigid Steel Conduit & Connectors

Flexible Conduit Cable Tray Support Unistrut Channel

Unistrut Spring Locks with accessories Cable Drum (Reel) HVAC Devices

5.4 SURVEYING
5.4.1 Start - end Cable Tray elevation or Bottom of Cable tray (B.O.C.) shall be indicated in the
approved for construction drawings or other documents, unless otherwise stated. All reference
elevations shall be for construction drawings or approved shop drawings.

5.4.2 Surveyor (GTC) will set coordinates reference location from either center of column and offset
One (1) meter from the finish floor line as indicated in approved for construction drawing or other
documents, unless otherwise stated.

5.5 EXECUTION

5.5.1 Shop Drawing/IFC Drawings

5.5.1.1 The BMC Ace Inc. (GTC Subcon) shall submit shop drawings as necessary to the
Engineer for his approval prior to the commencement of the HVAC Control Works.
Also responsible for the execution procedure and breakdown of activities.

5.5.1.2 The BMC Ace Inc. (GTC Subcon) shall review IFC Drawings, Shop drawings and
other trade services to incorporate any clash and discrepancy on the issued
approved plans.

5.5.1.3 The BMC Ace Inc. (GTC Subcon) shall proposed detailed support on interior
installation and Roof or exposed installation, size, spacing and configuration before
commencement of the HVAC Control works.

5.5.2 Reception of Materials/Preparation

5.5.2.1 Prepare issue slip for the release of materials to be used from laydown area to site area.
Upon secure the signatories for release of required material on lay down area. Provide
transport to transfer to Installation site area. During Pull out of Materials inform VPCI
Material Inspector to witness the opening of Material package for Defects and Damages
to properly report if need rectification or replacement of the materials.
5.5.2.2 Designate a proper staging area for site installation. Material handling shall be carried out
in a manner to minimize potential damage, and/or rust which may be caused by water,
dust, shock, pressure, etc. Stored away from the high traffic areas. Cable tray should be
stacked by width and type.

5.5.2.3 When HVAC Control materials laid down on site provide wood planks and cover with
blue sack for proper materials handling and storage. Ensure proper storing and handling
of the Cable trays without damaging the surface. To prevent damage to cable tray, never
pull cable tray from truck trailer by chaining to bottom rung and dragging out of the trailer.
(See picture above for correct hauling of materials).

5.5.2.4 The material shall be segregated drawing wise quantity and quality check upon reception.
Inspect all reels (Cable drum) upon receipt. Do not allow the reels drop from the delivery
truck during unloading process. When forklift is used, the fork must support both reel
flanges. Reels can be hoisted by lifting on a metal shaft of sufficient size and strength
placed through the center hole of the reel. Handling equipment must not come in contact
with the cable. Reels may be marked with a directional arrow and phrase “Roll This Way”
to indicate proper direction to roll the reel, rolling the reel in wrong direction can cause the
cable to loosen on the reel and may de-reeling. Use care when storing the cable, reels
should never be stored or stacked on their sides. Store on their flanges, properly to
prevent rolling. And be sure have enough room between reels to allow access to the reels
for removal.

5.5.2.5 Prior to start of activity, area and access will be inspected to ensure that the area is ready
for the work to start.

5.5.2.6 Prepare a layout of HVAC control cable tray run and HVAC control device and hangers
and supports location from source point to the end point as per construction drawings
elevation indicated. (See on REFERENCES 4.2 No.4 Drawing Number).

5.5.3 HVAC Control Devices Checking

5.5.3.1 Shall verify the HVAC Control devices tagging, brands, according to approved for
construction drawing or shop drawing, and project specification.

5.5.3.2 Check all HVAC Controls Location as per approved for construction drawing or shop
drawings and project specifications.

5.5.3.3 During Pull out of Materials inform VPCI Material Inspector to witness the opening of
Material package for Defects and Damages to properly report if need rectification or
replacement of the materials.

5.5.4 Control Cables, Cable Trays, Support accessories

5.5.4.1 Shall verify the HVAC Control materials, sizes, quantity, check for damages,
If defective materials found report to VPCI material controller regarding the issues.
During Pull out of Materials inform VPCI Material Inspector to witness the opening of
Material package for Defects and Damages to properly report if need rectification or
replacement of the materials.

5.5.5 Cable Tray Supports Installation

5.5.5.1 Lines and Grades, elevation are laid out based on the approved construction drawings
and shop drawings. Ensure the center of the cable tray layout is always center based on
approved for construction drawings. Locate the elevation from the floor to the bottom of
the cable tray and establish a level line with nylon string.

5.5.5.2 Install trapeze type hangers by installing thread nuts onto threaded rod approximately 2
in. (50mm) above desired location for bottom of cable tray.

5.5.5.3 Slide on washers followed by cross member and second set of washers insert the second
set of nuts onto threaded rod same installation on other side of threaded rod.
5.5.5.4 Move cross member so the top surface is located where the bottom of cable tray run will
be located.

5.5.5.5 Laid out Cable tray connectors with proper routing in which indicated on the approved for
construction drawings or shop drawings.
a. Prepare cutting list of cable tray from point of origin to the distribution branch
 cable tray going into each HVAC Devices. In order to lay out the cable tray
splice joints fall between the support and the quarter point. See Figure 4.10A

b. Place a straight section across two supports so that the ends of the section
are not directly on the support (See Figure 4.10B).

c. If the support span is equal to the length of the straight sections, bolt two
pieces together for this step (Figure 4.10C). the support should not be greater
than the straight section length or as recommended by the manufacturer, to
ensure no more than one splice is located between supports. As a general
practice, avoid placing splice plates over supports or at mid-span.

d. Place the next straight section across the next support, and attach it to the
previous section with a pair of splice plates. Splice plates should be placed on
the outside of the cable tray, unless otherwise specified by the manufacturer,
with the bolt heads on the inside of the cable tray (Figure 4.11 & 4.12).

e. For dead end closure indicating termination of cable tray run use end plates.
(See Figure 4.20)
 f. Drill hole in side rail 2” (50mm) from each end of the splice plate so the jumper
will span the discontinuity. Do not use splice plate bolt locations to connect
jumper to cable tray. Place screw head on inside of cable tray, put jumper on
outside of cable tray. Add flat washer and locknut and tighten.

g. Fabricate and install the cable tray which was laid out based on the elevation
indicated on the approved for construction drawing.
If clashes happen, proposed a FCR for the existing for construction drawing to
issue a revised approved drawings.

5.5.6 Cable Pulling Activity

5.5.6.1 Prior to installing cable in the cable tray, examine cable paths to ensure all areas
are free of debris that may interfere with the cable installation. The cable tray
should never be used as a walkway.

5.5.6.2 Prepare a Reeling jacks with an axle of sufficient size and strength to allow the
reel to turn freely with a minimum of friction in which the Cable drum will roll while
cable is pulled during control cable is laid out into the cable tray going to specific
HVAC Devices.

5.5.6.3 Before cable pulling; mark the end of control cable wires with paint marker and
wrap it with clear tape which will be laid out for specific device (ex. Damper
Actuator) and the other end also with mark with paint marker going to DDC panel
with 500mm to 1 meter offset for allowance prior cable wire termination.
5.5.6.4 Arrange and Fix the control cable wire in place with cable tie wire.

5.5.6.5 Temporary protection for the cables and cable tray can be constructed and care
must be taken to protect the exposed cables from falling objects or debris that
could cause damage to the cable.
5.5.6.6 Prior to termination control cable wire; cable inspection and function test
(continuity test) is to be done.

5.5.7 Damper Actuator Installation

5.5.7.1 Rotate the damper to its failsafe position. If the shaft rotates counterclockwise,
mount “CCW” side of the actuator out. If it rotates clockwise, mount the actuator
with the “CW” side out.

5.5.7.2 If the Universal clamp is not on the correct side of the actuator, move it to the
correct side.

5.5.7.3 Slide the actuator onto the shaft and tighten the nuts on the V-bolt with a 10mm
torque wrench.
5.5.7.4 Slide the anti-rotation strap under the actuator so that it engages the slot at the
base of the actuator. Secure the strap to the ductwork with #8 self-tapping screws.

5.5.7.5 See Figure B. Manually move the Damper to the failsafe position (a) usually
closed). If the shaft rotated counterclockwise this is a CCW installation. If
the shaft rotated Clockwise this is a CW Installation. In a Left Hand
installation, the actuator side marked “CW” faces out, while in a CW Installation
the side marked “CCW” faces out. All other steps are identical.

5.5.7.6 The actuator is usually shipped with the universal clamp mounted to the “CW” side
of the actuator. To test for adequate shaft length, slide the actuator over the shaft
with the side marked “CW” (or the “CCW” side if this is the side with the clamp). If
the shaft extends at least 1/8” through the clamp, mount the actuator as follows.
5.4 Lock the clamp to the actuator using the retaining clip.
5.5 Verify that the damperis still in its full fail-safe operation (a).
5.6 Mount the spring return actuator to the shaft. Tighten the universal clamp, finger tight only.
5.7 Mount the anti-rotation strap at the base of the actuator. Do not tighten the screws.
5.8 Remove the screw from one end of the mounting bracket and pivot it away from the actuator.
5.9 Loosen the universal clamp and, making sure not to move the damper shaft, rotate the actuator
approximately 5°C in the direction which would open the damper. Tighten the universal clamp to the
shaft.

5.10 Rotate the actuator to apply pressure to the damper seals. (b) and re-engage the anti-rotation strap
(c).
5.11 Tighten all fasteners.

5.5.8 Duct Temperature/Humidity Sensor Installation

5.5.8.1 Review the Approved for construction drawing or shop drawing for its final location
in which the location satisfies the operating conditions (temperature, humidity,
power, vibration, shock, mounting direction, atmospheric condition, etc.)

5.5.8.2 Make sure that the entire probe is immersed in the process fluid, also make sure
that airflow passes perpendicular to the side of the probe.

5.5.8.3 Leave adequate maintenance clearance in front of the housing cover.

5.5.8.4 Prepare the dedicated mounting bracket. Attach the indicator label for mounting
hole at the probe mounting position on a duct, and open a mounting hole.
5.5.8.5 Mount the mounting bracket onto the duct so that the longer cylindrical part
overhangs from the duct. Fix the mounting bracket with accessory M4 screws.

5.5.8.6 Wrap the duct with an insulating material. (if the duct has been already wrapped
with an insulation material, partially remove the material for mounting the bracket.
Fill the clearance between the bracket and the duct with the insulating material
after mounting the bracket.)

5.5.8.7 Release the stopper of the duct sensor by turning the stopper 45°. Then, insert the
probe into the bracket and engage the tabs of the probe with notches of the
bracket.

5.5.8.8 Completely insert the probe, and lock the stopper of the duct sensor by turning the
stopper 45°.

Duct Temperature and Humidity Sensor

5.5.9 Room Temperature and Humidity Sensor

5.5.9.1 Select the proper mounting location as per approved for construction drawing or
shop drawings. Proper location is inside wall of the room to be air conditioned; not
in recesses, above or close to the heat sources or shelves, the sensor must not be
exposed to direct solar radiation.

5.5.9.2 Follow the Mounting instructions as per manufacturer’s recommendations.

5.5.10 Air Flow Switch Installation

5.5.10.1 Select the proper location. See Mounting.

5.5.10.2 Use the Mounting plate gasket as a template and mark hole positions.

5.5.10.3 Drill or punch screw holes.

5.5.10.4 Cut the center hole large enough for the paddle to pass through.

5.5.10.5 Trim the paddle, if necessary

 The standard paddle fits into ducts of 3 in. x 8 in. (80 mm x 200 mm) minimum.
 The paddle may be trimmed for installing in ducts as small as 3 in. x 6 in. (76mm x
152 mm).
 Mounting on Horizontal position
5.5.10.6 Mounting the switch so that the housing is level horizontally (or plumb
vertically). Use a shim, if necessary.

5.5.10.7 The Air flow switch can be mounted on the top, side, or bottom of a duct.

5.5.10.8 Mount the switch in a horizontal duct whenever possible. In a horizontal

duct, the switch housing must be level, and the paddle should be at
approximately a right angle to the air flow. (See figure 3).

Figure 3

Mounting on an angled position

5.5.10.9 When mounting the switch in a horizontal position that is not horizontally true,
check with a level and place a shim under the switch mounting plate. Do not
mount the switch without a shim (See Figure 4).
 Figure 4

Mounting on a vertical position

5.5.10.10 When mounting the switch in a vertical position where the airflow is upward
(See Figure 5), See manufacturers recommendation for the minimum flow
required to actuate the switch.

5.5.10.11 While mounting the switch in a vertical where the airflow is downward (See
figure 5) adjust the switch. Turn the adjusting screw (Figure 6) clockwise until
the switch closes the circuit between the red and blue terminals when there is
no air flow.

5.5.10.12 Turn the adjustment screw one additional turn clockwise.

5.5.10.13 Mount the switch so that the housing is level horizontally (or plumb vertically).
Use a shim, if necessary.

Figure 5

5.5.11 Pressure Differential Indicating Switch Installation

5.5.11.1 Mounting instructions are enclosed with the differential pressure switch as per
manufacturer’s recommendation. Note: as per manufacturer’s recommendation :
Mounting positions other than vertical affect the cut-in pressure.

5.5.11.2 The differential pressure switch is suitable for mounting on air ducts or walls. The
recommended orientation is vertical position.

5.5.11.3 Install the self-drilling screw (3pcs x 4.5 mm) on the indicated hole on this device
 to serve as the mounting bracket to final fix for the final location selection which
comply with manufacturer’s recommendation. (See Figure 6).

5.5.11.4 Cut the pressure connection tubes on any length, but not affect the response
time, response time will increase if they are longer than 6.6 feet (2 meters).

5.5.11.5 The pressure switch should be mounted so that it is above the pressure
connection points. To prevent accumulation of condensation, the tubing must be
routed so that there is a gradual incline from the pressure connections points to
pressure switch (no looping). See Figure 7 Diagram showing the Manufacturer’s
recommended mounting.

Figure 6 : Pressure Differential Switch Dimensions

Figure 7 : Practical Diagram of DPS Connections

6.0 Environment, Health and Safety

6.1 All personnel must wear appropriate PPE at all times. Personnel are empowered to stop
work if safety precautions are not in place.

6.2 The Job Site Supervisor shall ensure that all Safety requirements are put in practice, copy of
MS and JHA (Attached) are available on site for guidance and consultation.

6.3 Contractor Safety Representative shall carry out the safety site inspection to ensure the
safety requirements laid out in the safe work plan are followed during and after the completion of
the works.

6.4 Job Site Supervisor and Safety Representative shall be present at all time while works are in
progress.

6.5 Appropriate PTW and LOTO to be prepared and implemented, modification without OWNER
approval is prohibited.

6.6 Assessed risk as necessary and communicated to concerned parties prior to start of any
work.

6.7 Safety briefing / Tool box talk must be conducted by Supervisors prior to start of work in the
language of workforce.

6.8 Incidents and injuries, damaged to property or near misses should be reported.

6.9 Before wiring, be sure to turn off the power to the HVAC Device. Failure to do so might
cause electric shock.
6.10 After wiring, be sure to reattach the terminal cover. Failure to do so might cause electric
shock. Read manufacturers manual for Electrical Caution and warning recommendation in
handling the HVAC Device.
6.10 Good housekeeping to be maintained during the execution of activity.

6.11 A clear and good communication must be maintained by all personnel involved on the
activity.

6.12 Personnel must be trained/experienced and familiarized with the scope of works to be
undertaken. The location of marshalling point must be identified, emergency evacuation
procedure must be clear to all workers, exercises must be conducted.

6.13 Contractor Safety Manager / Representative shall review Safety Action Plan.

7.0 Attachment

Attachment # 01. Job Environment and Safety Analysis

Attachment # 02. Risk Assessment
Attachment # 01.
 Job Environment and Safety
Analysis

Attachment # 02.
Risk Assessment