MD-512-5300-CN-HV-MST-2001 A01. MST For Hvac System Installation and Testing

UMM WU’AL PHOSPHATE
PROJECT
SOP PRODUCTION PLANT
GULF ASIA CONTRACTING
COMPANY LLC.
Contract No.: 16-KB-023 Rev. Date :04-MARCH-2017
METHOD STATEMENT FOR
Doc. No.: MD-512-5300-CN-HV- HVAC SYSTEM INSTALLATION
Rev. No.: A01
MST-2001 AND TESTING

HVAC SYSTEM INSTALLATION AND TESTING
MD-512-5300-CN-HV-MST-2001
Rev. Description Prepared Approved By

Rev. Date Checked By Approved By
No. of Revision By (Employer)
J.A.DINESH
N. GOPINATH
A01 04-MARCH-2017 For Approval JIBU K B INNACI
(PM)
(QCM)
METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

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Document Number: MD-512-5300-CN-HV-MST-2001
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Rev. No.: A01
INDEX
1. SCOPE OF WORK
2. PURPOSE
3. RESPONSIBILITES
4. APPLICABLE CODES AND STANDARDS
5. PROCEDURE
5.1. GENERAL REQUIREMENTS
5.2. MATERIAL RECEIVING
5.3. INSTALLATION
5.4. PRE-COMMISIONING
6. INSPECTION AND TEST
7. QUALITY CONTROL
8. SAFETY
9. DOCUMENTS

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1. SCOPE OF WORK
This Method Statement enumerates the activities involved, work sequences, inspection and testing
activities for the completion of HVAC System with temperature control and monitoring using
commercially available equipment and techniques to provide automatic temperature control.
1.1. Fabrication, installation, testing and insulation of ductworks and accessories.
1.2. Installation, brazing, testing and insulation of refrigerant pipes, fitting and accessories.
1.3. Installation and testing of HVAC control cables, field devices and its related accessories.
1.4. Installation and pre-commissioning of HVAC equipment and control panels.
2. PURPOSE
The method statement shall address the procedure of physical operations applicable in order to
attain and maintain the desired indoor temperature and environmental condition for efficient
operation.
This document shall address safe work process applicable from preparing HVAC System
requirements from construction to commissioning.
3. RESPONSIBILITIES
3.1. Construction Manager / Superintendent
Ensure that all personnel including Supervisors, equipment operator, and other craftsmen
associated with the work are properly oriented and the works shall be in compliance to this
document, approved Material Submittal, QA/QC Plan, related ITPs, and other related work
procedures and Owner’s requirement in the project specifications. The CM shall pre plan
the construction activities and material delivery to attain the construction schedule and
ensure that the work is done in a safe manner.

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3.2. Site Supervisor/ Foreman
The site supervisor shall be responsible for confirming the installation location from the
approved drawings in the HVAC works. He shall be responsible for the Job safety analysis
and safe work plan application and securing a work permit prior to the commencement of
any activity.
He shall raise RFI request to the QC department, at appropriate stages of works as detailed
in the ITP. RFI should be raised at least 24 hours in advance to the required time of
inspection.
3.3. QC Manager / QC Engineer / QC Inspector
QC Manager is responsible for all required Quality control activities such as test and
inspection for this desired Works. All inspections will be carried out in accordance with ITP.
The site QC inspector will have the responsibility for making RFI, necessary inspection and
witnessing with Client and preparing necessary documents and he will submit it to QA/QC
Manager. Conduct inspections in accordance with QA/QC Plan, ITP and Method Statement
with proper documentation and to maintain inspection and records complete for future
references.
3.4. Safety Department / Supervisor / Officer
Ensure that the safety requirements have been adequately addressed and work is being
carried out in a safe manner. Conducts safety inspections, monitor and address any unsafe
acts and unsafe conditions.
4. APPLICABLE CODES AND STANDARDS
4.1. Project Specifications
MD-101-SMEM-EG-ME-SPC-0001 HVAC Equipment
MD-101-1000-EG-AR-SPC-00002 Plant Buildings Specifications

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MD-101-SMEM-EG-ME-SPC-0002 Mechanical Equipment Installation Specification
MD-101-SMPM-PM-QA-PEI-0001 Contractor Quality Requirement
MD-101-SMEM-EG-PI-SPC-0005 Piping Installation
MD-101-SMEM-EG-PI-SPC-0007 Pressure Testing of Piping
MD-101-SMEM-EG-ME-SPC-0009 Insulation for Cold Equipment and Piping
MD-101-SMEM-EG-ME-SPC-0006 Insulation of Hot Equipment and Piping
MD-101-SMEM-EG-EL-SPC-0001 Electrical and Instrumentation Installation
And other Ma’aden specification relevant and applicable to HVAC and general works.
4.2. IFC Drawings issued by Client/Contractor.
4.3. Sheet Metal and Air Conditioning Contractors National Association
SMACNA 2005 Duct Construction Standards for Metal and Flexible 3rd Edition
4.4. American Society for Testing and Materials (ASTM)
Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-

ASTM A635 / A653M
Iron Alloy-Coated (Galv annealed) by the Hot-Dipped Process
ASTM A 480 Standard Specification for General Requirements for Flat-Rolled

Stainless and Heat Resisting Steel Plate, Sheet, and Strip
Standard Specification for Seamless Copper Tube for Air Conditioning

ASTM B 280
and Refrigeration Field Service
4.5. American Society for Heating, Refrigeration and Air Conditioning (ASHRAE)
Hand Book of HVAC Applications

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Hand Book of HVAC Systems and Equipment
Fundamentals Handbook
4.6. American Society of Mechanical Engineers
ASME B31.5 Refrigeration Piping and Heat Transfer Components
4.7. Air Movement and Control Association (AMCA)
4.8. Air-Condition and Refrigeration Institute (ARI)
4.9. National Fire Protection Association
NFPA 90A Standard for Installation of Air-conditioning and Ventilation System
NFPA 70 National Electrical Codes
5. PROCEDURE
5.1. GENERAL REQUIREMENTS TO HVAC WORKS
1. GAC shall ensure that this Method Statement was adhered to the minimum requirements
of the Project Specifications.
2. Equipment installation shall conform to the Manufacturer’s recommendation and govern by

MD-101-SMEM-EG-ME-SPC-0002 –Mechanical Equipment Installation Specification.
3. As Per SMACNA Duct Construction Standards Metal & Flexible 3rd Ed. It is not
recommended that duct systems constructed to 3 in. wg (750 Pa) class or lower be tested
because this is generally not cost effective. However, as per MD-101-SMEM-EG-ME-SPC-
0001 visual examination shall be performed to detect leak, then Light Testing shall be the
method to be used.
4. HVAC works shall be coordinated to all discipline, utilities and other works, involved in this
project.

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5. Defects or leakage exposed during testing shall be rectified immediately otherwise if

irreparable, replaced immediately and shall be re-tested to Client’s satisfaction.
6. HVAC Control works such as control panel installation, cable installation, cable termination,
field testing, installation of cable trays, fitting and accessories shall conform to
MD-101-SMEM-EG-EL-SPC-0001 Electrical and Instrumentation Installation.
7. All HVAC equipment shall be properly grounded requirement of which shall conform to
Ma’aden Specification MD-101-SMEM-EG-EL-SPC-0001 and IFC drawing for Electrical
Grounding Plan. Subsequently, ductwork shall also be grounded by connecting a wire
jumper between the ductwork and machine duct connection opening for both supply and
return line.
8. Any deviation of location and installation procedure of ducts and its accessories, piping
and its accessories, cabling, its accessories and field devices from IFC drawing,
manufacturer
Recommendation and in applicable standards due to actual site condition shall be

submitted for Technical Query and shall secure approval from Contractor/Client.
5.2. MATERIAL RECEIVING
1. All materials and equipment shall be received in manufacturer original, protective packing
and shall be inspected at the time of delivery for damage and compliance with project
specification.
2. Receiving inspections shall be performed for all materials & equipment before accepting
and storing at site. Quality Control Engineer with relevant checklist as per ITP shall carry
out the inspection.
3. All material and equipment received at site shall have the factory test certificate or mill
certificate, whichever applicable.

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4. Installation, Operation and Maintenance manuals are also mandatory for all equipment
with the spare parts list as required.
5. All material and equipment that are damaged or found not to be in accordance with project
specification shall be immediately requested to the vendor or manufacturer to repair or
replace as soon as possible. Report discrepancies to purchasing and customer and to
record the deficiencies and to inspect if it is acceptable.
6. The accepted material and equipment shall be stored to protect it from inclement weather
conditions. Air conditioned storage shall be used for material and equipment which are
climate sensitive.
7. Equipment shall be fully assembled on factory installed base rails or mounting legs. If the
unit is supplied with control panel, it shall be weather resistant if it is meant for outside
installation.
8. Equipment supplied primed or painted shall be scrutinized to examine any physical

damage on the finish surfaces. Compatible primer or paint shall be used to repair the
existing paint on equipment, if required.
9. All materials and equipment shall be handled and stored as per manufacturer’s
recommendation and Ma’aden Specification to prevent damage and deterioration.
10. Materials and equipment shall be loaded appropriately on delivery truck to prevent
damage to materials. Loading and unloading of materials and equipment shall be in
appropriate equipment as per manufacturer recommendation.
5.3. INSTALLATION
5.3.1. EQUIPMENT INSTALLATION
1. Installation, transporting, lifting, hoisting and rigging of HVAC equipment shall conform to
MD-101-SMEM-EG-ME-SPC-0002. Any special requirement mentioned here to shall be
strictly observe and adhere to.

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2. Pre-installation checking/inspection as per ITP shall be done and the following shall be
satisfactory;
2.1 Ensure that foundation have been inspected and accepted by the Client. Counter
check dimensions of foundation and that of the equipment. The equipment should fit
in properly including clearances.
2.2 Clean the equipment of dirt, dust, grease and any other foreign matter and remove
all packing and transporting material.
2.3 Check the equipment for damages. If any, these damages should be assessed by
the Client if these are acceptable or not.
3. Ensure that all personnel involve in transporting, lifting and hoisting are certified on their
own respective fields of expertise, such as operators, riggers, and drivers etc.
4. Ensure that the job site is clean and free from debris and other obstruction. Proper access
should also be observed.
5. Location of HVAC equipment shall be according to IFC drawing. IFC drawing for all
discipline shall have the same location and orientation.
6. Equipment installation shall be in accordance to manufacturer’s recommendation.
7. HVAC equipment shall be properly grounded according to Ma’aden Specification and

electrical IFC drawing.
8. All tools and equipment for the handling & lifting such as slings, ropes and pipe rollers
shall be checked and inspected by a competent person before the start of the work.
9. Check and verify if the location/mounting floor foundation of Control Panel are in
accordance with the approved design and layout drawing. Clearance for door opening and
maintenance access of the equipment shall also be observed.
10. Trucks and mobile crane shall be of suitable capacity to that of the HVAC equipment to be
transported and lifted.

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11. Warning signs and barricades shall be provided.
12. For HVAC equipment to be installed on the roof, the equipment shall be lifted by mobile
crane from the truck up to the Roof as per the Vendor/Manufacturer's lifting and rigging
procedure manual/approved drawings.
13. The equipment shall be then moved with the help of suitable number of workers to the
concrete foundation.
14. Flexible canvas duct connection shall be installed between the duct and opening of the
HVAC equipment (supply and return opening).
15. Vibration isolators where applicable should be installed as per manufacturer’s

recommendation.
16. Control conduits, cable tray and wirings for power lines and associated field devices shall
be installed as per the approved electrical design, wiring diagrams and drawings.
17. For small HVAC equipment, such as fans, duct heaters and the likes lifting may be done
by crane or manually whichever the case maybe.
18. For duct inline equipment, procedure for duct installation shall be used, giving extra care
for the weight of the equipment.
19. Tool and equipment for installation.
a. Leveling device
b. Measuring tools
c. Crane, Boom Trucks
d. Drill machine and bits
e. Various Hand tools
f. Pipe Rollers

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5.3.2. DUCTWORKS FABRICATION
1. Ductwork fabrication and construction shall be in accordance to Client-issued IFC drawing,

project specification and SMACNA Duct Construction Standards for Metal and Flexible.
Ductwork fabrication shall be done by the Client approved duct fabrication specialist.
2. Ductwork cutting list and shop fabrication drawing shall be prepared and approved by the
Client prior to start of fabrication.
3. Fabricated ductworks shall be labeled corresponding to the label of shop fabrication

drawing and cutting list.
4. Plenum and big size duct can be fabricated into two or more parts depending on its sizes.
Parts of which shall also be labeled accordingly.
5. Fabricated ducts delivered to site shall be inspected according to fabrication details shown
in the IFC drawing and approved shop fabrication drawing which shall conform to
SMACNA standard.
6.1 Duct sizes and label shall be check accordingly.
6.2 Check for quality and damages. Duct with dent can be repaired at site. Damage duct
beyond irreparable and fabricated ducts of unacceptable quality shall be return to
fabrication shop and be replaced immediately.
6.3 All fabricated ducts delivered to site, with or without damages, shall be recorded in
Material Receiving Inspection.
5.3.3. DUCTWORK INSTALLATION
1. Ductwork sizes, routing and location shall be in accordance to IFC drawing. Any deviation
whereof, due to site condition or for whatever reason, shall be informed to and approved
by Client before execution of such deviation. Deviations are to be submitted by Technical
Query. Deviation may be re-sizing, re-routing, relocation duct or a combination whereof
shall be redlined and shall be reflected on the as-built drawing.

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2. Ductworks receiving inspection shall be completed and accepted prior to installation.
3. Refer to IFC drawing, approved shop fabrication drawing and cutting list for ductwork
layout, assembly and installation.
4. Ductwork shall be properly grounded by means of wire jumper connecting the ductwork to
the equipment opening for both return and supply line.
5. Counter checks each duct for defects which may occur during storage and transport to site,
correct size and duct label.
6. Avoid using ducts of the same size but of different duct line to eliminate confusions. If the
need arises, due to urgency of the works or for whatever reason, proper recording and
notation should be made accordingly.
7. Ducts should be dry and clean, free from dirt, dust, grease or oil before assembly and
installation.
8. Ductworks can be assembled in two or more section on the ground before installing to its
final location depending on the size, weight, working space and manpower required for
installation.
9. Ductwork hangers and support material specification shall be in accordance to

MD-101-SMEM-EG-ST-SPC-0001, MD-101-SMEM-EG-ME-SPC-0001, IFC drawing,
SMACNA Duct Construction Standards for Metal and Flexible.
10. All structural support shall be with hot-dipped galvanized coating, as per Ma’aden
specifications MD-101-SMEM-EG-ST-SPC-0001. Repair of damage galvanized caused by
cutting and welding shall be done according to the mentioned specifications.
11. Verify and coordinate distance of ductworks, hangers and support from walls, ceilings,
columns, beams and clearances from other utilities, discipline and sub-contractor, if any.
12. Hanger and support shall be properly aligned and leveled.

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13. Hanger and support shall be anchored to concrete wall, slabs, under slabs, beams or
columns, wherever applicable and possible using anchorage material.
14. Roof duct support shall conform to drawing details for roof duct support.
15. Scaffolding shall be used when working at heights. All personnel working at height should
have completed working at height training and with safety harness.
16. Concrete Hammer drill machines shall be used for drilling holes on the concrete for the
installation of drop-in anchors.
17. Threaded rods and angle bars shall be cut according to the dimensions required by cut-off
saw or by grinders.
18. Upon completion of duct assembly and supports, ductwork shall be installed carefully on
top of the angular supports.
19. With workers from the ground and workers from the top of the scaffold, the duct is lifted
manually up to the final location of the duct.
20. Use of slings, belts and ropes can be provided for lifting heavy ducts.
21. The section of duct that to be installed shall be in series to another duct for continuity of
jointing the transverse joints. Duct label shall be observed. Refer to the approved shop
fabrication and cutting list.
22. The duct transverse joint shall be connected by clips or flanges as required by IFC drawing
and SMACNA Standard.
23. Ductworks shall be installed parallel to the building structures except where indicated in
the drawings.
24. All openings of the installed ducts shall be covered during construction to avoid entry of
foreign materials and any construction debris.
25. After connection of the duct, all transverse and longitudinal joints shall be sealed by
approved duct sealant to prevent air leakage.

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26. Where duct passing through a fire-rated walls and slab openings, it shall be sealed with
non-combustible insulation materials, fire proof sealant and finish with metal flashing.
27. Tool required for installation.
a. Various hand tools
b. Drill machines and bits
c. Leveling device
d. Measuring tools
e. Metal cutting saw
f. Welding machine
g. Sheet cutter
h. Scaffolding
5.3.4. DUCT ACCESSORIES AND DEVICES
1. Air devices, volume dampers, motorized dampers, motorized fire dampers, louvers, sand
trap louvers, back draft dampers, sound attenuators, access doors, among others shall be
installed according to manufacturer’s recommendation, IFC drawing details and
MD-101-SMEM-EG-ME-SPC-0001.
2. Locations of duct accessories and devices shall be installed where indicated in the IFC
drawings.
3. Air devices such as grilles, registers, louvers and diffusers shall be connected to the duct
as describe in the IFC drawing details and as per manufacturers recommendation.
4. Manual Fire Damper and Motorized Fire and Smoke Dampers shall be installed in
accordance with the manufacturer’s recommendation, IFC drawing details and by
SMACNA Standard. Fire dampers shall be connected with a break away connection
specified in manufacturer recommendation and in SMACNA Standard

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5. Access Doors shall be provided in all fire dampers, motorized or not, where indicated in
the IFC drawings. Ensure that access doors can be open and close easily. Access doors
should be installed in conspicuous and unobstructed location and shall be on downstream.
6. Non return damper, over relief damper installation shall be installed strictly as per
manufacturer’s recommendation.
7. Any deviation of location and installation procedure of accessories and devices from IFC
drawing, manufacturer recommendation and in applicable standards due to actual site
condition shall be submitted for Technical Query and should secure approval from
Contractor/Client.

c. Riveter and rivets
d. Leveling device
e. Measuring tools
f. Welding machine
g. Metal cutting saw
h. Sheet cutter
i. Scaffolding
5.3.5. DUCTWORKS INSULATION
1. All ductworks shall be insulated with fiberglass flexible blanket type or rigid board
insulation with 75 mm thickness and a density of 32 kg/m³.
2. For all duct exposed shall be wrapped.
2.1 For exposed indoor shall be wrapped with 0.22 kg canvas jacket fixed in place with

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Benjamin Foster adhesive or approved equal.
2.2 For exposed to atmosphere shall be covered with aluminum cladding jacketing with
water tight sealant application on all joints.
3. The insulation work area shall be clean and housekeeping shall be observed at all times.
FLEXIBLE AND RIGID BOARD FIBERGLASS INSULATION
1. Clean duct surface. It should be dry and free from dirt, dust or grease.
2. Cut insulation to required size to fit around the duct, making sure that edges are straight.
3. Self-adhesive pin with 100mm nail length shall be secured to each face of duct 300mm to
450mm apart and 75mm from the corner of the duct.
4. Apply insulation adhesive to duct surface in strips approximately 150mm wide. Underside
of duct should be completely coated with adhesive to prevent sagging. Adhesive insulation
on side and top of duct shall be applied between the self-adhesive pin.
5. Once adhesive has become tacky, with foil facing up carefully position insulation over the
pins and to the prepared duct surface, making sure that all edge joints are closely butted.
6. Apply uniform hand pressure to outside surface of insulation to obtain good bond.
7. Fit washer over pins, pushing them down until tight against insulation. Snip off any excess
shank from pin. Put on insulation tape on top of washers.
8. Bind all longitudinal and transverse joints with a self-adhesive insulation tape.
9. All self-adhesive insulation tape shall be fitted on top with self-adhesive aluminum foil tape
to show better finish.
10. For additional security, install a ¾” aluminum band/strap. Aluminum band/strap shall be
500mm apart.
11. Seal any puncture points of the insulation with self-adhesive tape.
12. Damage insulation shall be rectified or replaced immediately.

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b. Brush
c. Measuring tools
d. Safety Knife/cutter
e. Wire cutter
f. Scaffolding
CANVASS JACKET INSTALLATION FOR INDOOR EXPOSED DUCT
1. Duct exposed inside the building shall be wrapped with 0.22 kg canvass jacket fixed with
approved adhesive.
2. Clean the duct insulation. It should be dry and free from dust, dirt and grease.
3. Canvass should also be clean and free from stain.

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4. Cut the canvass jacket according to the required size.
5. Apply a tack coat of the adhesive on top of the insulated duct.
6. Use clean paint brush to apply and to spread out the adhesive evenly.
7. Immediately imbed the selected lagging fabric into the wet coating. Smoothened to avoid
wrinkles.
8. Overlap the seams by at least 50mm.
9. Immediately apply a finish coat. The dry film thickness of this application will vary with the
fabric selected.
b. Brush
c. Measuring tools
d. Safety Knife
e. Scaffolding
f. Scissors

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OUTDOOR EXPOSED DUCT JACKET INSTALLATION
1. Clean duct insulation. It should be dry and free from dust, dirt and grease.
2. Install the fabricated aluminum cladding.
3. Connect all cladding joints with aluminum c clips
4. Apply rivet at all cladding joints.
b. Brush
c. Measuring tools
d. Safety Knife
e. Scaffolding

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5.3.6. REFRIGERANT PIPING INSTALLATION AND BRAZING PROCEDURE
1. Refrigeration piping materials and work procedure shall be in accordance to

MD-101-SMEM-EG-ME-SPC-0001 (HVAC Equipment Specification),
MD-101-SMEM-EG-PI-SPC-0005 (Piping Installation), MD-101-SMEM-EG-ME-SPC-0009
(Insulation for Cold Equipment and Piping), MD-101-SMEM-EG-ME-SPC-0006 (Insulation
for Hot Equipment and Piping), MD-101-SMEM-EG-PI-SPC-0007 (Pressure Testing of
Piping), and shall conform to ASME B 31.5 Refrigeration Piping and Heat Transfer
Components.
2. Refrigerant pipes and fittings shall meet ASTM B 280 Seamless copper tube for air
conditioning and refrigeration field service per ASME 31.5 Table 523.1.
3. The filler metal (brazing rod) shall be nonferrous metal or alloy having a melting point
above 840 F (449 C) and below that of the metal being joined which shall conform to
ASME SF A 5.8 or AWS A 5.8 as per ASME 31.5 Table 523.1.
4. Refrigerant piping routing and location shall be in accordance with IFC drawing. Any
deviation to location and routing due to actual site or for whatever reason from IFC
drawing shall be submitted for Technical Query and should secure an approval from
Contractor/Client.
5. Refrigerant pipes and fittings material receiving inspection shall be completed and
accepted prior to installation.
6. All piping material shall be placed off the ground on temporary stand or wooden blocks
during fabrication and storage and shall also be covered to protect from damages.
7. Ensure that correct size of pipe and fitting as per IFC drawing shall be selected for the job.
Ensure that both are clean, in good condition and free from damage and imperfections.

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8. All pipes shall be cut as per the measurements specified in the approved for construction
drawings.
REFRIGERANT PIPE CUTTING
1. Refrigerant pipe/tube shall be cut square using a tube cutter. The cutter wheel shall be
sharp and the cutter rollers free rolling to prevent the tube from being deformed. Tube
cutter shall be free of dirt, oil and other debris.
2. If a hacksaw is used to cut the pipe, a fine toothed blade should be used so that the pipe
ends will seat properly in the fitting socket. The cutting of the pipe shall be done in a
manner to not deform the pipe; this could be done by not forcing hardly the hacksaw.
3. Ream all cut tube end and inside the tube to remove the small burr created by the cutting
operation. Special care shall be exercised to insure that no shavings are left in the tube.

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4. Removal of surface oxidation on the inside of the fitting socket shall not be necessary if the
fitting have been cleaned and kept clean until ready for use.
5. Surface particles and dirt shall be removed from the outside of the tube ends, for a
distance slightly more than the fitting cup, using a clean lint free cloth.
6. Clean tube end and inside surface of fitting. The joint surface areas should be clean and
free from oil, grease, or oxide contamination. Surfaces may be properly cleaned for
brazing by brushing with a stainless steel wire brush or by a stiff rubbing with emery cloth.
If oil or grease is present, clean with a commercial solvent. Remember to remove small
foreign particles such as emery dust, by wiping with a clean dry cloth. The joint surface
MUST be clean

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7. Insert tube ends into fitting cup, making sure that the tube is sealed against the base of the
fitting cup.
8. Support the tube and fitting assembly to insure a uniform capillary space around the entire
circumference of the joint.
9. Fit-up inspection per ITP shall be completed and accepted prior to start of brazing
procedure.
BRAZING PROCEDURE
1. Brazing Procedure Specification (BPS) shall be approved by Client. Brazier shall be

qualified by a Third Party Agency.
2. Brazing parameters shall be performed as per Client approved qualified Brazing

Procedure Specification (BPS).
3. Only Qualified Brazing Technicians shall perform the brazing process.
4. The joint shall be brought uniformly to brazing temperature in a short time as possible to
minimize oxidation.
5. Filler metal shall be applied manually. The filler metal shall melt and flow freely with the
desired temperature range and shall wet and adhere to the surfaces to be joined.

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6. During the brazing process, purge gas shall be continuously flowing, and shall continue to
flow until the brazing is cool to touch to ensure that no oxidation forms on the inside the
tube and fitting. Nitrogen shall be used for purge gas.
7. For most brazing jobs using oxygen-acetylene gases, a carburizing or neutral flame should
be used. The neutral flame has a well-defined inner cone. Avoid an oxidizing flame.
8. Always keep the torch in short motion. Then start heating the tube, first applying flame at a
point just adjacent to the fitting. Work the flame alternately around the tube and fitting until
both reach brazing temperature before applying the brazing filler metal.
9. When a flux is used, it will be a good temperature guide. Continue heating the tube until
the flux passes the “bubbling” temperature range and becomes quiet, completely fluid and
transparent and has the appearance of clear water.
10. Direct the flame from the tube to the flange-base of the fitting and heat until the flux that
remains in the fitting is also completely fluid.
11. Sweep the flame back and forth along the axis of the assembled joint, tube, and fitting to
get and then maintain uniform heat in both parts.
12. Apply the brazing alloy. Feed the alloy into the joint between the tube and the fitting. Only
after the base metals have been heated to brazing temperatures should the filler metal be
added. At that time, the flame may be detected momentarily to the tip of the filler metal to
begin the melting process. Always keep both the fitting and the tube heated by playing the
flame over the tube and the fitting as the brazing alloy is drawn into the joint. The brazing
alloy will diffuse into and completely fill all joint areas.
13. Do not continue feeding brazing alloy after the joint area is filled. Excess fillets do not
improve the quality or the dependability of the brazed and it is a waste of material.

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14. Immediately after the brazing alloy has set, quench or apply a wet brush or swab to crack
and remove the flux residues. Use emery cloth or a wire brush if necessary. All fluxes
residues must be removed for inspection and pressure testing.
15. Pinhole leaks in joints brazed can usually be repaired. Clean the joint thoroughly before
soldering.
16. Brazing works shall be inspected per ITP and shall be approved by Client.

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REFRIGERANT PIPE SUPPORT
1. Refrigerant pipe support material specification and installation details shall be installed as
describe in IFC drawing details and plan layout and in accordance to
MD-101-SMEM-EG-ST-SPC-0001 and MD-101-SMEM-EG-ME-SPC-0001.
2. Verify and coordinate distance of refrigerant pipes, hangers and support from walls,
ceilings, columns, beams and clearances from other utilities, discipline and sub-contractor,
if any.
3. Hanger and support shall be properly aligned and leveled.
4. Hanger and support shall be anchored to concrete wall, slabs, under slabs, beams or
columns, wherever applicable and possible.
5. Tool required for installation:
c. Leveling device
d. Measuring tools
e. Tube cutter
f. Blow torch/ Cutting outfit
g. Welding machine
h. Hacksaw
i. Scaffolding

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5.3.7. REFRIGERANT PIPING INSULATION AND JACKETING
1. Insulation material specification and installation procedure shall be in accordance to MD-

101-SMEM-EG-ME-SPC-0001 and MD-101-SMEM-EG-ME-SPC-0009 and shall conform
to manufacturer’s recommendation installation procedure.
2. The insulation and jacketing shall be installed on piping after the pneumatic test was
completed and accepted.
3. The insulation work area shall be clean and housekeeping shall be observed at all times.
REFRIGERANT PIPE INSULATION
1. The insulation shall be performed flexible elastomeric insulation ARMACELL AC type

(25 to 38mmthick).
2. Before application of insulation, all surfaces shall be thoroughly cleaned of slag, rust,
grease, etc. The insulation shall be applied on dry surface.
3. Insulation material shall be kept dry until installed in place and sheathed.
4. Insulation joint shall be installed tightly butted together and staggered
5. Refrigerant pipes, valves, strainers, and fittings shall be insulated.
6. Insulation adhesive shall be applied 150mm in width, 300mm from the edge of the pipe
and 400mm from center thereafter.
7. The insulation is then place with the longitudinal cut should be placed to the underside of
the pipe section.
8. The joint and connection should then be closed with self-adhesive tape.
9. Insulation of elbow, valves and other in-line accessories shall be field fabricated to
maintain insulation thickness.
10. Elbow insulation shall be fabricated from mitered pipe cover.

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11. Insulation for all valves shall be installed in butt joint construction and all joints shall be
completely sealed with joint sealer. The minimum thickness of insulation over the valves
shall be equal to the thickness of insulation required at adjacent piping. The resultant
cavity between the piping insulation and the flange or valve is to be packed tightly with
glass fiber.
12. All connection, joint, punctured points shall be sealed with self-adhesive tape.
13. All damaged insulation shall immediately rectify, if not replaced.
b. Brush
c. Measuring tools
d. Safety knife/ cutter
e. Scaffolding
ALUMINUM METAL JACKET
1. All insulated pipes shall be clad with anodized 0.5 mm thick aluminum sheets which
ASTM B209/B209M.
2. No painting is required above the aluminum cladding.
3. Longitudinal joints and circumferential joints of metal jacketing shall be overlapped.
4. The overlap of the metal jacketing shall be 50 mm minimum, and at longitudinal joints they
shall have the outer portion facing downwards to allow for draining rain water.
5. The metal jacketing on elbow shall be mainly installed with mitered metal jacket segments.

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6. Valves metal weather barrier shall be field fabricated with no openings in the jacket. The
jacket shall be applied with lock seam in all joints to shed water Tool required for
installation.
c. Leveling device
d. Measuring tools
e. Sheet cutter
f. Scaffolding
5.3.8. HVAC CONTROL PANEL INSTALLATION
1. HVAC Control Panel shall be installed according to manufacturer recommendation and in

accordance to MD-101-SMEM-EG-EL-SPC-0001 Electrical and Instrumentation
Installation.
2. Installation, transporting, lifting, hoisting and rigging of HVAC equipment shall conform to
MD-101-SMEM-EG-ME-SPC-0002 – Mechanical Equipment Installation Specification. Any
special requirement mentioned hereto shall be strictly observe and adhere to.
3. Check and verify if the location of Control Panel are in accordance with the approved
design and layout drawing. All other disciplined IFC drawing shall show the same location,
position and orientation of the HVAC Control Panel.
4. Space for air circulation shall be allowed according to the manufacturer instructions. In an
absence of manufacturer instruction, conform to Ma’aden Specification for minimum
requirements. A minimum of 600 mm shall be allowed between adjacent units on sides,
which have removable panels for maintenance access. Clearance between the units being
installed and any equipment on the opposite side of the access way shall be a minimum of
600 mm with equipment doors can be open completely.

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5. Control Panel mounted on mounting plates and brackets. Mounting plates and brackets
shall be free of burrs and sharp edges and shall have adequate space to attach equipment
identification and descriptor labels.
6. Standard design mounting brackets or mounting stands shall be used for mounting of
equipment wherever possible. Where a standard mounting bracket or stand is unsuitable
for the application, special supports may be manufactured to suit the particular
requirements. The design shall allow for adjustment of mounting height of equipment.
7. Stands may be installed by bolting to steelwork or fixing to concrete and grouting if

required.
5.3.9. HVAC CONTROL CABLE TRAY INSTALLATION
1. Cable Tray installation shall be in strict accordance with the applicable National Electrical
Codes, project specifications and requirements in associated with the drawing.
2. Cable tray must withstand direct sunlight in a corrosive, humid chemical plant environment
with extremes of ambient temperature ranging from -34 °C to 46 °C (-30 °F to 115 °F)
during the year and shall not be affected as to load span or structural strength.
Temperature of conductors supported on tray rungs shall not exceed 82 °C (180 °F).
3. Cable tray accessories, such as hold down clamps, hangers or support clamps, shall be
metallic corrosion resistant materials and weather proof type as per the typical. Nuts, bolts,
and washers shall be as specified on the Buyer's Data Sheet.
4. Cable tray should be run parallel to building walls and structures as well as control board,
motor control centers, switchgear and other control apparatus.
5. Cable trays should be routed to minimize the potential to fire exposure and also to
minimize the consequences of fire propagating along the tray.

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6. Cable tray should be located above all process piping and other process facilities. When
routing beneath process piping is unavoidable, covers may be necessary to protect cables
from potential leaks.
7. Piping system pressure relief devices in close proximity to a cable tray system must be
fitted with deflectors or stack extensions to protect cable when protection devices release.
8. Cable Trays shall not have sharp edges, burrs or projections that could damage the
insulation or jacket of the wiring.
9. Touchup paints shall be applied to the scratches/damaged surface of cable trays. Repair of
damage galvanized caused by cutting and welding shall be done according to the
mentioned specifications.
10. Routing should be carefully chosen to avoid passing close to equipment such, resistor
grids or any process equipment which is capable of producing temperatures injurious to
the cable tray or the cables. Ambient temperature at any cable tray location should not
exceed 50°C (122 °F).
11. Additional physical protection in the form of barriers or covers should be located above the
cable tray where routed beneath grating-type walkways or similar facilities.
12. Where cable tray is located directly above the motor control center, switchgear, etc., the
vertical distance from the top of the equipment to the bottom of the tray should be a
minimum of 900mm (3 feet); 1200mm (4-foot) separation is preferred. Never locate the
tray closer than 300mm (12 inches) above any other electrical apparatus.
13. Extend through a fire wall unless an adequate fire seal can be developed for the specific
application. Select a fire seal shall be equal to the fire rating of the fire wall being
penetrated.
14. Cable trays passing vertically through floors should be protected with a concrete curb or
metal kick-plate at the floor level and be totally enclosed to a distance of 2 meters (6 feet)
above the floor or platform. Expanded metal may be used for this purpose.

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15. Cable trays entering a building should be sloped away from the building so rain water will
not be conveyed into the building by tracking along the cables. Use a slope of 40mm per
meter (1/2" per foot) minimum.
CABLE TRAY SUPPORTS
16. Cable tray shall be adequately supported by non-combustible racks, hangers or other
reliable means (such as structural steel of pipe ways) at intervals compatible with the
building structure and lengths of cable tray sections.
17. Supports should be located in such a manner and the tray installed so as to avoid
supporting the tray at the end of each section. Connections and splices between horizontal
sections of tray should fall at the quarter point of the span.
18. Do not cantilever any section. Provide additional structural support at the section end or
continue the section to the next structural support.
19. Horizontal supports should provide adequate bearing surface for the tray as well as
provisions for hold down clamps or fasteners. A minimum recommended bearing surface is
45mm.
20. Expansion guides should be used at a distance of 18M except where the tray is hung with
rods. For each 18 meter, the Cable tray should be connected to the ground pad.
21. Supports for vertical cable tray should provide secure means, other than friction, for
fastening the cable tray to the supports. Expansion guides will not support the vertical load
of a cable tray. Bolting shall be through the side rail. If the tray is fiberglass, this bolting
through the flange may split the fiberglass. In this case, angles or channels turned at right
angle to the tray run with thru-bolting through the side rails of the tray will provide the
secure support for the loading.
22. Ground continuity must be maintained by proper bonding jumpers between tray, flexible or
expansion connectors and all utilizing equipment and steel framing of all buildings.

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CABLE TRAY FITTINGS
23. Changes in direction of cable tray should normally be made with a simultaneous change in
elevation of 1.0 meter or less. No fittings are required for this transition.
24. Horizontal elbows should be used whenever a change of direction is necessary at the
same elevation.
25. Outside elbows should be used whenever the vertical drop exceeds 1.50 meter.
26. Cable tray fittings are available in standard radii of 300mm, 600mm and 900mm.
27. Cable tray elbows and similar fittings should have a minimum radius of 300mm, although
600mm is preferred.
CABLE TRAY SPACINGS
28. Vertical tiers shall be separated by a clear space of not less than 450mm. Where less than
450mm to be used, a non-combustible solid barrier supported so as not to obstruct
ventilation should be provided between tiers. When the total combined width of any level
exceeds 900mm, the vertical spacing between tiers should be increased to a minimum of
600mm.
29. A minimum vertical clearance of 300mm should be maintained from the top of the tray to
the bottom of ceilings, beams and other obstructions. This distance should be increased to
450mm where the total width of a tier exceeds 900mm.
30. Sufficient horizontal space should be provided for locating the tray on the supports so that
there is ample space to attach clips and bolts. Normally, a 75mm space between adjacent
trays and a 75mm space between the side of a tray and any vertical support provides
adequate horizontal space to locate the trays properly.
31. Tools required for installation:
a. Metal Cutting Saw
b. Open End wrench

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c. Leveling Device
d. Screwdrivers
e. Tape Measure & Square
f. Drill Machine with Bits
g. HILTI X-BT powder-actuated tool
h. C-clamp
i. Ratchet Wrench
j. Scaffold
k. Ladder
l. Welding Machine
m. Boom Truck or Trailer or Crane or Man Lift
n. Grinder
5.3.10. HVAC CONTROL CABLE INSTALLATION, TERMINATION AND TAGGING
HVAC CONTROL CABLE INSTALLATION
1. Cable tray/conduit route length shall be verified to its directions and ensure that properly
supported with approved type materials.
2. Cable tray/conduit shall be free from any sharp edges, foreign objects and unnecessary
bends. Before installing cables, remove foreign objects, burrs and moisture from conduit
and equipment enclosures.
3. Electrical power cables shall be routed separately from instrument cables.
4. Handling of cables in accordance with applicable preservation plan to avoid damage.

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5. Cable sizes and voltage ratings are supplied in accordance with project standard
specification.
6. Cables shall be meggered, drum tested and continuity checked before installation.
7. Ensure that the cable bending radius during pulling is as per the standards of
manufacturer’s recommendation.
8. Cables of 38mm and smaller shall be pulled manually by hand.
9. Prior to cable pulling ensures proper cable tray tag given in the cable routing of Cable
Schedule.
10. The required length as per the cable route shall be measured physically and leaving
sufficient length for final connection, loop at both end termination, and number of straight
through joints etc., shall be finalized before pulling and cutting the cable.
11. Where cables are pulled in conduits or ducts, cables are free from foreign debris. A
suitable pulling compound shall be used while cables are being installed in conduits or
ducts.
12. Pull the cable on main cable tray and to its branches in safely manner avoiding possible
mechanical damages and stress to cable. Arrange the cable on tray and fasten properly by
using approved type cable ties firmly fixed to cable ladder.
13. Cable ties are installed on cable trays after cable pulling. The minimum interval between
cable ties shall be 1,500 mm in the horizontal plane and 750 mm in the vertical plane.
14. Preventing overstress of conductor correct conduit sizing is necessary to prevent

overstressing of the conductor due to excessive tension and/or damage to the conductor
insulation during the pulling operation.
15. In conduit, the wire and cable shall be installed that there are no cuts or abrasion in the
insulation or protective covering in the conductors. Approved lubricant shall be used for
cable pulling through conduit.

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16. Cables shall not be fixed directly to lagged, tiled or other special finished surfaces.
17. Cables installed in external cable ladders shall be shielded from direct sunlight by using
tray covers.
18. Cable segregation shall be installed in accordance with project specifications.
19. Cables shall be secured to cable ladders and trays every 2 meters and before and after
each bend on horizontal runs and every 600 mm on vertical runs using cable ties.
20. Cable ties shall be UV resistant and should be one of the following:
a. Nylon (11 or 12)
b. Polypropylene
c. UPVC coated stainless steel
21. All ends of cables are to be protected from dirt and moisture prior to joining or termination.
22. All cables are tied with identification tags as specified in the project specification.
HVAC CONTROL CABLE TERMINATION
1. Before cable termination, temporary cable tags will be used to identify cables.
2. Ensure that the cable has been inspected and tested prior to termination.
3. Copper cable cores shall be terminated with tinned copper compression tube connector
lugs or termination pins, as appropriate, approved as standardized components. Aluminum
cables shall utilize either aluminum lug or bimetallic cable lugs.
4. The connector lugs and termination pins etc. shall be installed using tools of the correct
type and size as recommended by the manufactures.
5. Once the cable is cut for the purpose of termination, the work involve shall be completed
without interruption; if for any reason the work cannot be completed, then the cable ends
shall be sealed with heat shrinkable sleeve or self-sealing end caps.

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6. Prior to fit-up of cable glands, ensure that the cable gland conforms to its correct size, type
and area classification. Where glands are to be installed in hazardous areas, the
certification of the gland shall be verified.
7. Terminate the steel wire armored cable and lead-sheathed cables with appropriate gland
ensuring the correct sealing and clamping components are supplied and properly fitted.
Cable gland shall be selected and fitted as specified for each cable size. Gland shall be
completed with an outer PVC shroud. Ensure that correct tools shall be used in termination
works. Compression tool dyes shall be embossed with the dye type or cable size.
8. All cables, with the exception of lighting sub-circuits, shall be identified at each cable gland.
The tags shall be permanent non-corroding materials with the cable reference number, as
noted in the cable schedule, clearly visible.
9. Cable glands should not be over tightened.
10. Proper crimping procedure shall be done to ensure tightness of all cables and wiring
terminal connections and End to End wire connection shall be re-checked to avoid
incidental misconnection of contacts from panels to field devices terminal
CABLE TAGGING
1. Permanent cable numbering will be executed when cable termination.
2. Each cable will be labeled with cable numbers that correspond with the relative cable
schedules. Cable labels shall be attached to cables, with black cable ties, in accessible
positions or by shrink labels.
3. Individual Control cables/ wires shall be identified by two labels at each end. The first label
(closest to the end of the wire) shall identify the number of the terminal to which the wire is
connected. The other label shall identify the terminal of the opposite end of the wire.

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4. Tool and equipment;
a. Boom Truck
b. Fork Lift
c. Trailer
d. Crane
e. Roller
f. Cable winch machine
g. Hydraulic Cable Cutter
h. Hydraulic Crimping Machine
i. Jack stands
j. Pulling sock
k. Electrical tools kit
l. Termination tools
5.3.11. HVAC CONTROL FIELD DEVICES AND ACTUATORS INSTALLATION
1. HVAC control field devices installation shall conform to manufacturer’s recommendation

and in accordance to MD-101-SMEM-EG-EL-SPC-0001 for Electrical and Instrumentation
Installation.
2. Field devices shall be mounted to the manufacturer supplied mounting kit. Otherwise,
mounting shall conform to the manufacturer’s installation instruction.
3. All field devices shall be handled with utmost care and covers and plugs shall not be left in
place until installations are made.
4. All field devices and actuators are Contractor supplied and presumed suitable to use in
this Project.

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5. Field devices location shall be according to IFC drawing.
6. In-line refrigerant piping instruments and devices shall not be subject to pressure test.
These instruments and devices shall be installed only after completion of pressure test.
7. Install the actuator on the mounting block of the damper. Damper blade shall be close
when locking/tightening the actuator’s locking mechanism to the jackshaft of the damper.
Actuators are normally close when there is no supplied power. Manually open and close
the damper to check if the damper is fully opening and closing.
8. Refer to all instruments and actuators manufacturer’ IOM/catalog for cable connection
details.
9. For field devices that has probe, care should be observed during installation so as not to
damage the probe.
10. All power and control cables shall be properly tag for field devices connections.
5.4. PRE-COMMISSIONING
1.1. Factory start-up and checked-out completely with report submitted from the
Manufacturer.
1.2. Pre-start-up and commissioning of equipment, HVAC control panel commissioning

shall be done by manufacturer representative with the aid of the construction group.
1.3. Manufacturer Representatives shall demonstrate operation of all HVAC Units and
HVAC Control prior to handover to Client and GAC for whatever work needed to be
done thereafter.
1.4. Any pending Punch list shall be completed and duly signed of prior to start of
commissioning.
1.5. Visual inspection all system, such as equipment, piping, ductwork and controls,
especially for unintentional unreported damages incur during construction by other

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discipline, utilities and other sub-contractor. Line check should be done accordingly to
ensure the integrity of all system.
5.4.1. HVAC EQUIPMENT
1. Check all equipment and its accessories are properly installed and accepted. Documents
pertaining to inspection and testing, if applicable, should be available upon request. List of
accessories is as per equipment requirements.
2. Factory packing and transport materials had been removed.
3. Vibration isolators should be installed properly as per manufacturer recommendation.
4. Flexible connection shall have no leak. Proper distance from duct to machine connection
shall be checked.
5. Wire and cables are tightly fitted.
6. Equipment grounding. All equipment should be properly grounded.
7. Grounding to duct & equipment. Ensure that wire jumper was connected between the duct
and the equipment.
8. Air filter shall be installed and clean.
9. Condensate drain should be fitted properly.
5.4.2. REFRIGERANT PIPE
1. Check all equipment and its accessories if properly installed and accepted. Documents
pertaining to inspection and testing should be available upon request.
2. Refrigerant pipe and its accessories should be complete and was tested.
3. Solenoid valves
4. Sight glass
5. Expansion valves
6. Filter dryer

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5.4.3. DUCTWORK
1. Check all ductworks and accessories are properly installed and accepted. Documents
pertaining to inspection should be available upon request.
2. Ductwork should be clean. There should be no debris inside the duct.
3. Ductwork should be practically leakage-free.
4. Damage duct and insulation shall be repaired.
5. Access doors shall be fitted on all fire dampers and motorized dampers. It should be
accessible and can be open and close freely.
6. Volume dampers shall be in full open position. Air balancing will determine its final position.
7. All duct opening cover, air devices cover shall only be removed if the HVAC equipment is
ready for operation.
8. Diffusers, supply, return and exhaust. Its opposed blade dampers can be adjusted freely.
9. Blast proof dampers should be snug tight against the wall. Manufacturer installation
procedure should be strictly followed.
10. Wall around the fire damper shall be sealed off properly with fire retardant sealant.
Actuator should be tightly installed against the damper jackshaft. Blade should completely
close during power loss.
11. Motorized volume dampers. Actuator should be tightly installed against the damper
jackshaft. Blade should completely close during power loss or during change-over if the
damper served for 1-duty/1-standby system.
12. Among other accessories such as, but not limited to, back-draft damper, sound attenuators,
flexible ducts, etc. should be installed properly.

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5.4.4. HVAC CONTROL
Check all cables, cable trays, field devices and other accessories are properly installed and
accepted. Documents pertaining to inspection and testing should be available upon request.
1. Cable should be check with the following;
1.1. Continuity check
1.2. Labeling of the cable on both side
1.3. Proper cable termination on panel side with the corresponding terminal block
1.4. Proper cable termination on the field level side
2. Field devices should be check with the following;
2.1. Field device assigned number and tag is correct with respect to IFC drawing
2.2. Field device proper installation of the
3. Point to point checking will be done from panel terminal block to the field devices point to
verify that the terminations on the field device are interface at the correct terminal at HVAC
control panel.
4. Performance test shall be conducted to verify all controls are functioning properly.
5.4.5. TESTING, ADJUSTING AND AIR BALANCING
1. Testing, Adjusting and Air balancing shall be done by a TAB Agency Certified by locally
recognized agency, such as NEBB (National Environmental Balancing Bureau) or AABC
(Associated Air balance Council).
2. Pre-start up and commissioning of all HVAC equipment should be completed prior to start
of TAB works.
3. All volume dampers, motorized volume dampers, motorized fire dampers should be fully
open prior to start of air balancing. Line check should be done accordingly.

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3.1. Volume dampers will be adjusted during the TAB works. It should be freely adjustable.
3.2. Fire dampers should be kept open in the entirely of TAB works.
6. INSPECTION AND TEST
1. Inspection and Testing for HVAC works, such as ductworks, piping works, HVAC control,
equipment installation and other related works, shall be carried out as per approved ITP.
2. All inspection data/reports shall be recorded in approved inspection forms and shall mutually sign
by GAC and PMC.
3. Inspection of materials shall be performed either at the Vendor’s works or in the field. Laboratory
test results for various insulation and ancillary materials obtained by independent test laboratories
shall be submitted prior to the commencement of the work together with the data sheets, Vendor’s
instructions and method statements of the Contractor. Compliance Certificate shall be submitted
certifying that the materials are in accordance with the technical specifications.
4. Inspections per ITP shall be carried out on material, installation and testing to ensure compliance
with the Ma’aden Specifications and applicable standards.
5. Inspection during construction shall be carried-out to ensure that the ongoing construction activity
is within merits of IFC drawing, project specification and applicable standards.
6. Upon completion of erection, be in part or as a whole, HVAC works shall be visually inspected per
ITP for completeness, workmanship, proper support installation, sealant on duct joints, proper
brazing for copper pipe, correct cable erection, among other items that are necessary in the
installation.
7. Inspection per ITP shall check the following, but not limited to, elevation and location, visual
inspection, dimensional check, workmanship, bolt and nut tightness, pressure test, leakage,
construction procedure as per manufacturer recommendation or as per specification and
applicable standards, room condition test, etc.

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8. All parties involved when the system is considered complete or as soon as possible there after
shall conduct a final inspection. It should then release for the succeeding works, i.e. leak test or
insulation as the case may be.
9. Testing is carried-out to ensure that the system is working to the limits of the design criteria, project
specifications and to applicable standards and to verify the integrity material installed are in safe
working condition and was not compromise during construction.
DUCT LEAK TEST (LIGHT TEST)
1. Per project specification MD-101-SMEM-EG-ME-SPC-0001, Visual examination shall be

performed to detect any leaks or defects.
2. Light Test Method to be used to detect air leakage in ductworks by visual examination.
3. Barricade the area of testing.
4. Post signage “Light Test on Progress” in any conspicuous location and in entry and exit point in the
area of testing.
5. Ensure that visual inspection of ductworks installation has been completed and approved before
start of any lighting test.
6. Make sure that all joints and seams had been caulked properly by approved duct sealant.
7. Blank-off all duct opening. Make sure that there will be no light coming out from this blank-off.
8. Scaffolding shall be provided for inspecting top of the ductwork. All personnel working at height
should have completed working at height training and safety harness.
9. Provide a number of flashlights or a low wattage light, which can be readily switched on or off, to
light off the path of the Inspection Team or for whatever intended used.
10. Ductworks shall be tested in part or in whole of the ductwork system. Mark off the IFC drawing the
ductwork to be tested.

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11. A number of lights to be provided inside the ductwork will be determined on site depending on the
size and length of the ductwork to be tested.
12. The area or room should be completely dark, so that traces of light can easily be seen from the
outside of the duct if there is any leakage
13. Light test can be done during daytime provided that darkness of the surrounding is sufficient. Light
test during night time is the best option.
14. All joints and seams shall be carefully inspected. Leakages found during inspection shall be
rectified immediately by applying approved duct sealant.
15. The test will only be completed if the Inspection team were satisfied of the results.

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PNEUMATIC TEST FOR REFRIGERANT PIPE
1. Pneumatic Test shall in accordance to MD-101-SMEM-EG-PI-SPC-0007 and shall conform to

ASME B31.5.
2. Piping systems shall have been completely checked and released for testing.
3. Refrigerant piping erected on the premises shall be pressure tested and leak tested after
installation and before operation.
4. Barricade the area of testing. A limited access area and pressure control point shall be established.
Signs which read “Pneumatic Test in Progress – Access by Permission Only” shall be posted
around the perimeter of the limited access area.
5. Only testing personnel involved in the particular operation being performed may be within the
limited access area, e.g. during system pressurizing, testing personnel who will be examining the
system shall be outside the limited access area.
6. Pneumatic tests shall not be performed in the rain, or whilst the piping is wet. Tests shall preferably
be carried out during daylight hours.
7. All joints to be tested shall be exposed, not insulated, unpainted, and free of rust, dirt. oil, and other
foreign materials.
8. Piping shall be examined before pressure is applied to ensure that all pipes are tightly connected.
9. All items not subject to the pressure test shall be disconnected or removed, blanks, plugs, or other
suitable means.
10. Test instrument and devices required for testing;
a. Pressure limiting device or pressure reducing device,

b. Pressure Relief Valve, set above the test pressure but low enough to prevent permanent
deformation of any of the system component.
c. Pressure Gage, located at the outlet side.
d. Gage Manifold.

Page 46 of 52
PROJECT
COMPANY LLC.
Rev. No.: A01
11. Test medium to be used shall be Nitrogen( N2).
12. For locating major leaks, a preliminary test with 25 psi gauge pressure may be applied, prior to
start of other testing.
13. After preliminary test was done and major leaks were rectified, pneumatic test can be done with
test pressure of at least 110% and shall not exceed 130%.
14. For large systems that are not completely visible to the testing operator, the pressure in the system
shall be gradually increased to one-half of the test pressure, after which the pressure shall be
increased in steps of approximately one-tenth of the test pressure until the required test pressure
has been reached.
15. The test pressure shall be continuously maintained for at least 10 minutes. It may then be reduced
to leak test pressure.
16. Leak Test shall be performed after the completion of pneumatic test. Leak test pressure shall be
the same with design pressure.
17. Examination of leaks shall bubble the gas and bubble formation testing. The bubble forming
solution shall be used that produce a film which does not break away from the area to be test and
bubble form shall not break rapidly due to air drying or low surface tension. Household soap and
detergent are not permitted as substitute for bubble testing solutions.
18. All joints and connections shall be examined thoroughly.
19. Leak Test shall continue until all joints and connections do not show evidence of leaking.
20. All leaking joints shall be repaired and retested.
21. Depressurized the system before repairing leak.
22. Leak brazed joints shall be repaired by cleaning the exposed area, re-fluxing and re-brazing.
Purging gas should be continuously flowing while re-brazing the leak joints.

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PROJECT
COMPANY LLC.
Rev. No.: A01
CABLE TESTING PROCEDURE
The following tests shall be performed for cables and recorded on the Employer pre-commissioning
form. Testing is done to ensure that cables are installed in accordance with design specifications that
their characteristics are within applicable standards and manufacturer’s tolerances.
1. Visual and Mechanical Check
1.1. Compare cable data with drawings and specifications.
1.2. Inspect exposed sections of cables for physical.
1.3. Inspect for shield grounding, cable support, and termination.
1.4. Inspect for correct identification and arrangements.
2. Cable Continuity Test
Test equipment: Digital Multi meter

Page 48 of 52
PROJECT
COMPANY LLC.
Rev. No.: A01
2.1. The continuity of each core shall be checked.
2.2. Using a multi meter, measure the continuity of each core to ground as in fig.1 and between
cores.
Figure 1
3. Insulation Resistance Test
Test equipment: Meg ohmmeter; Thermometer; Humidity meter
3.1. Measure and record the ambient temperature and humidity.
3.2. Discharge all stored capacitance in the cable by grounding it before testing.
3.3. Disconnect the cable to be tested from other equipment and circuits.
3.4. Test voltage shall be as recommended by the manufacturer or as per Employer test form.
3.5. The test duration shall be one minute.

Page 49 of 52
PROJECT
COMPANY LLC.
Rev. No.: A01
Figure 2
3.6. Measure the insulation resistance of each phase to ground as in Figure 2 and between
phases. The guard terminal of the Meg ohmmeter can be used to eliminate the effects of
surface leakage across exposed insulation or leakage to ground.
3.7. After completing the test, ground all conductors in order to discharge the stored energy.
3.8. The measured insulation resistance must be compared with the value recommended by the
manufacturer. The IEEE standard 690-1984 and 422-1986 recommend an insulation
resistance field acceptance limit of:
IR=1000 (KV + 10)/ L
Where: IR……… is insulation resistance Meg ohms per 1000 feet
KV ……...is insulation voltage rating
L ….…….the cable length in feet.

Page 50 of 52
PROJECT
COMPANY LLC.
Rev. No.: A01
7. QUALITY CONTROL
1. Upon completion of inspection, relevant inspection report as specified in ITP shall be signed and
accepted and comments to be made on the inspected works for our understanding and reference.
2. The QC personnel shall review and advise in developing the procedures to ensure that inspection
and tests are verified and fulfilled as per the project specification concerning HVAC system
installation.
3. QC Inspector shall organize, supervise and verify the implementation of the testing schedule. Any
defects or variances from the approved specifications and standards will be noted during the
testing and shall be informed to the Construction Department by Inspection Report.
4. Material receiving inspection shall be conducted for the traceability of the materials and per
approved material/documents.
5. Request for inspection will be notified in advance. Inspection will be conducted by QC inspector
with Client to witness, recorded and approved all the required quality control procedure documents
and as per MD-512-5300-QD-QC-ITP-2042 - ITP for HVAC.
8. SAFETY
1. All construction personnel involved directly in HVAC work activities shall undergone safety
orientation/training prior to work at site.
2. All the activities will be envisaged a week in advance and job safety requirements will be worked
out by analyzing the likely hazards and resorting to preventive measures. A job safety analysis is
thus carried out.
3. All electrical equipment shall be tagged and checked before using by competent personnel.
4. Housekeeping must be strictly observed at all times during the entire works. Different types of
waste generated from such activities shall be segregated and disposed accordingly.
5. GAC Safety Supervisor shall carry out the safety site inspections to ensure that safety
requirements laid out in the safe work plan are followed during and after the work. GAC Safety

Page 51 of 52
PROJECT
COMPANY LLC.
Rev. No.: A01
Engineer / Supervisor shall review Safety Plan and secure Work Permit if necessary prior to start
of any activities.
6. Warning signboards and barricades shall be provided where necessary to isolate the working and
testing area and prevent unauthorized personnel from entering the site.
7. All equipment and tools used for all HVAC works shall have to be inspected by GAC Safety
Engineer / Supervisor prior to use at site to ensure their safe worthiness and properly color coded.
8. Regular Tool box meeting will be conducted at site before starting the work.
9. Copies of MSDS for all chemicals use at site shall be available at work area and instructions stated
in the MSDS shall be followed strictly.
10. Sufficient lighting system shall be provided all the time for indoor activities and for outdoor activities
during night shift as well.
11. Proper first aid facility will be provided at site offices.
12. Necessary work permit system shall be followed during construction.
9. DOCUMENTS
Vendor Prints of Material Data Sheets and Installation and Operation Manual. Project Specification and
applicable Standards.
_________________END_________________

Page 52 of 52

MD-512-5300-CN-HV-MST-2001 A01. MST For Hvac System Installation and Testing

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UMM WU’AL PHOSPHATE

METHOD STATEMENT FOR

Rev. Description Prepared Approved By

METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

4. APPLICABLE CODES AND STANDARDS

5.1. GENERAL REQUIREMENTS

5.2. MATERIAL RECEIVING

6. INSPECTION AND TEST

METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

1.1. Fabrication, installation, testing and insulation of ductworks and accessories.

1.4. Installation and pre-commissioning of HVAC equipment and control panels.

3.1. Construction Manager / Superintendent

METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

3.2. Site Supervisor/ Foreman

3.3. QC Manager / QC Engineer / QC Inspector

3.4. Safety Department / Supervisor / Officer

4. APPLICABLE CODES AND STANDARDS

4.1. Project Specifications

MD-101-SMEM-EG-ME-SPC-0001 HVAC Equipment

MD-101-1000-EG-AR-SPC-00002 Plant Buildings Specifications

METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

MD-101-SMEM-EG-ME-SPC-0002 Mechanical Equipment Installation Specification

MD-101-SMPM-PM-QA-PEI-0001 Contractor Quality Requirement

MD-101-SMEM-EG-PI-SPC-0005 Piping Installation

MD-101-SMEM-EG-PI-SPC-0007 Pressure Testing of Piping

MD-101-SMEM-EG-ME-SPC-0009 Insulation for Cold Equipment and Piping

MD-101-SMEM-EG-ME-SPC-0006 Insulation of Hot Equipment and Piping

MD-101-SMEM-EG-EL-SPC-0001 Electrical and Instrumentation Installation

4.2. IFC Drawings issued by Client/Contractor.

4.3. Sheet Metal and Air Conditioning Contractors National Association

4.4. American Society for Testing and Materials (ASTM)

Standard Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-

ASTM A 480 Standard Specification for General Requirements for Flat-Rolled

Standard Specification for Seamless Copper Tube for Air Conditioning

Hand Book of HVAC Applications

METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

Hand Book of HVAC Systems and Equipment

4.6. American Society of Mechanical Engineers

ASME B31.5 Refrigeration Piping and Heat Transfer Components

4.7. Air Movement and Control Association (AMCA)

4.8. Air-Condition and Refrigeration Institute (ARI)

4.9. National Fire Protection Association

NFPA 90A Standard for Installation of Air-conditioning and Ventilation System

NFPA 70 National Electrical Codes

5.1. GENERAL REQUIREMENTS TO HVAC WORKS

2. Equipment installation shall conform to the Manufacturer’s recommendation and govern by

METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

5. Defects or leakage exposed during testing shall be rectified immediately otherwise if

Recommendation and in applicable standards due to actual site condition shall be

5.2. MATERIAL RECEIVING

METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

8. Equipment supplied primed or painted shall be scrutinized to examine any physical

5.3.1. EQUIPMENT INSTALLATION

METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

6. Equipment installation shall be in accordance to manufacturer’s recommendation.

7. HVAC equipment shall be properly grounded according to Ma’aden Specification and

METHOD STATEMENT FOR HVAC SYSTEM INSTALLATION AND TESTING

11. Warning signs and barricades shall be provided.

15. Vibration isolators where applicable should be installed as per manufacturer’s

19. Tool and equipment for installation.

c. Crane, Boom Trucks

d. Drill machine and bits