_____________________________________________________________________________________

King Faisal Air Academy Facilities

Method Statement for Installation of Air-Cooled
Chillers

BSS-0-GE00-

DOCUMENT HISTORY

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Method Statement for Installation of Air-Cooled Chillers (Rev 0) Page 1 of 24
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00 IFR 02.15.21 PFC JAA Mohamed Wahdan Ahmad Jammal

REASON PREPARED BY APPROVED BY
REV NO. DATE STATUS REVIEWED BY QM
FOR ISSUE QA PD

Reason for Issue Status

IFR Issue for IFI Issued for PFC Preliminary for A Approved
Review / Information Comment
Approval
IF Issued for Use SS Superseded
U
PF Preliminary for Project Customization
P

Revision Description List

Rev. Para. Revision Description

00 Issued for Review / Approval

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Contact Details:

Org. Name Position Mobile Email

BSS JV Bakeel Farha Phase Manager 0591424426 b. Farha @bssjv.com

BSS JV Jose Agotilla Asis QA Manager 0570457215 j.asis@bssjv.com

BSS JV Abram Jacobs HSE Manager 0594656182 a.jacobs@bssjv.com

BSS JV Mohamed Wahdan QA/QC Manager 0590646179 m.wahdan@bssjv.com

BSS JV Donald Fraser Stevely Const. Manager 0594717056 f.stevely@bssjv.com

BSS JV Ahmad Jammal Project Director 0590496517 a.jammal@bssjv.com

Table of Contents

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1.0. General................................................................................................................................................................... 6

2.0. Scope...................................................................................................................................................................... 6

3.0. Purpose................................................................................................................................................................... 6

3.1. Abbreviations.......................................................................................................................................................................6

4.0. References.............................................................................................................................................................. 7

5.0. Definitions.............................................................................................................................................................. 8

6.0. Responsibilities....................................................................................................................................................... 8

6.1. Workflow...........................................................................................................................................................................10

7.0. Materials............................................................................................................................................................... 10

8.0. Tools, Plant and Equipment................................................................................................................................... 11

9.0. Work Methodology............................................................................................................................................... 11

9.1. Material Receiving, Handling & Storage............................................................................................................................11

9.2. Prior activities to be completed:........................................................................................................................................12

9.3. Installation of Chiller..........................................................................................................................................................13

9.3.1. Preliminary Checks before Chiller Installation...................................................................................................................13

9.3.2. Lifting Unit..........................................................................................................................................................................14

9.3.2.1. Step Wise Illustration for Work Methodology- Elevated..................................................................................................14

9.3.3. Installation of Vibration Isolators......................................................................................................................................19

9.3.4. Minimum requirements for all standard or complex lifting operations...........................................................................24

10.0. QA/QC Management............................................................................................................................................. 25

11.0. HSE Management.................................................................................................................................................. 26

11.1. Appendix 1 – HSE Risk Assessment....................................................................................................................................26

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1.0. General
Method Statement for Installation of Air-Cooled Chillers are prepared and controlled by BSS JV in
accordance with project specification and client instructions.

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2.0. Scope
This Method Statement describe the methods and standards to be employed in storage,
handling and installation of Air-Cooled Chillers for King Faisal Air Academy project as specified
in the relevant Project Specification Section 15650 – HVAC Air-Cooled Chillers, Approved Shop
Drawings and Material Submittals. The works described in this document will be valid for all
sites within King Faisal Air Academy, AlMajmaah, Saudi Arabia.
The following are covered by this Method Statement:
 To establish site execution work plans according to this method statement and comply with
Quality Management, HSE procedure.
 Checking the actual condition of specified work activities and coordinate to the contractor
prior starting activities
 Establishing and maintain all documents and control data.
 Ensuring all records are properly stored, maintained and retrievable when required.
 Ensuring all materials is/are complying as per approved specification and approved material
submittal.
 Ensure shop drawing to be approved by civil defense before starting the work.

3.0. Purpose
The purpose of generating this method statement is to define the procedures step by step to
implement the correct practices for installation of Air Cooled Chillers(HVAC Equipment) for King
Faisal Air Academy Project, so as to ensure that the job execution complies with the
requirements and serves the intend function to satisfactorily level. As well as the necessary
materials to ensure the health and safety of the employees, making sure to comply with
requirements stipulated in the contract documents.
3.1. Abbreviations

 KFAA King Faisal Air Academy

 DAR DAR Al Riyadh Construction Management Services
 BSS JV Al Bawani, Salini Impregilo and Shibh Al Jazeera (BSS) Joint Venture
 ASTM American Society for Testing and Materials.
 HSE      Health, Safety and Environment
 ITP         Inspection and Test Plan
 MSDS    Material Safety Data Sheet
 PPE         Personal Protective Equipment
 QA/QC  Quality Assurance/ Quality Control
 RA           Risk Assessment
 FIR         Field Inspection Request
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 MIR         Material Inspection Request

 TBD         To be Determined
 QMS Quality Management System
 NCR Non-Conformance Report
 PPE Personnel Protective Equipment
 HVAC Heating Ventilation and Air-Conditioning
 AHRI Air Conditioning, Heating, and Refrigeration Institute
 SBC Saudi Building Code
 ANSI American National Standard Institute
 ASHRAE American Society of Heating, Refrigeration and Air-Conditioning
 ASTM American Society for Testing and Materials
4.0. References

 BSS-DAR-GEN-TRN-000037 Health & Safety Plan

 BSS-DAR-PMT-LET-00006 Security Plan
 KFAA-BSS-DAR-PMT-LET Project Management Plan
 BSS-TR-00-GE00-0048 Emergency Response Plan
 Project Quality Plan
 Project Specification Section 15140 Hangers and Supports
 Project Specification Section 15650 HVAC Air-Cooled Chillers
 Uniform Building Code
 Approved IFC & Shop Drawings.
 Project Inspection & Test Plan
 Typical Installation Drawing
 Chiller manufacturer recommendations
 Saudi Building Code

5.0. Definitions

 QCP Quality Control Plan evaluate and modify contractor procedures to ensure by providing the
desired results. Quality control plans are often viewed as a set of instructions that should be
followed.

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 Project Health, Safety and Environment Plan: Provide maximum safety to personnel and

property and avoid any adverse impact on the environment.
 Contractor: Means the person(s), establishment or the company named as contractor in the
tender accepted by the owner, and which signs the contract form with the owner, including the
contractor's representative, the legal successors or permitted assignees.
 Subcontractor: Means any person, corporation, company or any other entity assigned,
appointed or employed as a subcontractor after the approval of the contract.
 Documents: A written or printed instrument that conveys information, and generally refers to a
particular writing or instrument that has a bearing upon specific transactions. plans, schedule,
statement of particulars or instructions, all written documents forming part of the contract and
the like and as may be issued by the consultant and client.
 Drawings: Approved IFC and Shop Drawings.
 Materials: Any specific material used in the execution of works as specified in the project
specification.
 PM/CM or Engineer Representative: The person, establishment, company or corporation
named by the owner under a written authorization to act on behalf of the owner in respect to
exercise of its own rights and authorities under the contract.
 Mockup: The physical samples submitted by the contractor to determine the materials,
equipment, or workmanship. The samples are considered after being approved as the
measurement pursuant to which the owner representative evaluates the Works.

6.0. Responsibilities

 Phase Manager is responsible to ensure that adequate manpower, the required materials,
tools, and equipment’s are made available for the works. He shall also ensure that proper
routing and access is provided.
 QA / QC Manager is responsible for managing the development and implementation of the
QMS for planning duties within QA/QC staff, inspection, documentation, and operations
activities.
 Safety Manager is responsible for monitoring risks and hazards in the workplace and ensuring
the business is legally compliant with all health and safety legislation.
 Site Engineer is responsible for ensuring that all application, testing activities are executed in
accordance with the approved shop drawings and specified requirements. He is responsible for
pre-inspection followed by Engineer representative inspection and approval, he ensures that
safety requirements are implemented, and approved Method Statements are followed.
 QA/QC Engineer ensure the proper implementation of the quality management system (QMS)
are maintained. conduct inspection and monitor field testing, determine and report any non-
conformance and recommend corrective actions. ensuring that all personnel are aware of the
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quality requirement. conduct surveillance and inspection at various stages to

ensure compliance with ITP.
 HSE Officer ensure enforcement of safety procedures in accordance with the approved HSE
plan. He will be closely monitoring the site engineer’s strict implementation of the work Risk
Assessment.
 Surveyor carry out pre-construction survey to fix the locations and corresponding elevations as
per the approved shop drawings. Ensure the quality and compliance during phases of surveying
works and the regular checking of the surveying equipment or periodic calibration from the
third party. 
 Survey Aide assist surveyors in taking measurements, record measurements manually or
electronically, and peg out boundaries.
 Equipment Operator the authorized person to operate any equipment used in the project.
 Rigger assists in the movement of heavy equipment and loads to be lifted by giving signal
or verbally direct workers engaged in hoisting and moving loads, in order to ensure the safety
of workers and materials.
 Signalman guides the equipment operator for the safety movement & control of equipment
during the progress of work.
 Site Foreman a person who is responsible to ensure that all adequate tools are available,
responsible for daily monitoring installation activities, to monitor the quality of work.
 Skilled worker who is skilled in the Mechanical works.

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6.1. Workflow

7.0. Materials

 All the materials received at site should be as per the approved technical material submittal for
chillers to be inspected upon receipt and approved by the engineer prior in proceeding with the
installation. Any discrepancies, damages etc .... , should be reported to the supplier for
rectification or replacement and to be removed from site immediately
 All construction preliminary inspection/testing work should be carried out in accordance with
the approved manufacturing drawings, specifications and to be done by Mechanical Engineers
and should be checked and approved by DAR Engineers.

Chiller Type & Model shall be as per approved MAR

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8.0. Tools, Plant and Equipment

 Tool Box complete with hand tools including hammer, wrenches, screw drivers, etc.
 Lifting Equipment (Boom Truck / Crane / Manlift / Telehandler / Slings / Ropes / Chain Blocks /
Shackles / Lugs)
 Basic Electrical Tools
 Measuring Tape
 Hack Saw Blade
 Electric Drill Machine
 Spirit Level
 Electrical Grinding Machine
 Ladders
Notes:

 All tools and equipment shall be functionally safe and checked regularly. Third party certificates
must be available as per approved Safety Plans
 All tools and equipment shall be free from any defects before delivery to site.
 Mandatory PPE items (safety footwear, helmet, High visibility Vest & Eye protection) are not
included in the above materials. However, PPE kit is mandatory for all site works. Any additional
safety items apart from the standard kit shall be utilized as task dictates and according to Work
Permits and Risk Assessment.

9.0. Work Methodology

9.1. Material Receiving, Handling & Storage

 Delivery of chiller as a factory-assembled module with protective crating and covering.

 Special care must be taken to ensure that units are free in damage during the offloaded of
units. Rough handling can result in damage to the unit.
 Use appropriate type of vehicles in transporting the units and that they are protected against
mechanical and weather damage. Lift and support units with manufacturer's designated lifting
or supporting points
 Once the chiller units arrived at site, raise immediate inspection to the consultant and inspect
thoroughly for damage. Hence, in case of transit damage, supplier/manufacture must be
informed immediately.
 Ensure that the units have been inspected and accepted by the consultant as per approved
manufacturing drawings prior.
 The QC Inspector shall carry out inspection of materials upon delivery at site. The inspector
shall ensure the material conforms to the project specifications and drawings.
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 The inspector shall ensure all materials are free from damage. Any damage noted shall be
identified.
 Immediate attention investigation shall be made by the material receiving assigned person and
QC Inspector, on materials delivered which have obvious damage to the outer shell or wooden
casing. i.e.: Crates etc.
 Ensure that the storage location of the units has solid foundation and vibration free.
 It is much recommended not to remove the plastic coverings or packaging materials during the
delivery to avoid any corrosion and deterioration
 Ensure that all openings, such as pipe connections, are securely capped.
 The condensers should be covered to protect the coils and fins from potential damage and
corrosion, particularly where building work is in progress.
 The unit should be stored in a location where there is minimal activity in order to limit the risk
of accidental physical damage.
 Avoid any mechanical shocks and strokes during handling operations.
9.2. Prior activities to be completed:

 Supervisors shall deliver tool box talk relevant to these activities to staff involved in installation
process.
 All staff involved in this installation shall be briefed about this method statement.
 All site safety rules and regulations are maintained as per site safety plan and as instructed by
site safety officer. This includes but not limited to;
o Provisions for warning signs, barricades, warning tapes and site lighting as necessary. The
location of the lifting area shall be barricaded/ taped off with warning tape and only
authorized personnel can enter the demarcated zone.
o Lifting plan is in place.
o The lifting operation is conducted in clear weather and accepted wind speed.
o Working area is clean.
o All PPE gear is utilized.
 For the crane operation, the following shall be assured to safely control this operation;
o All staff /labor involved in this operation must be qualified for this task and have received
the required induction, training and are 3rd party certified as necessary. All certificates must
be current.
o The crane has a valid 3rd party certificate.
o All tools utilized in this operation are of the correct load rating for the job and are 3rd party
certified as necessary.
 Work Clearance is obtained from the civil contractor. Concrete Pads (Plinths) are cast and
approved by DAR.
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 The chiller unit MIR is approved by DAR.

 Make sure that the unit is free of any damages that might have been caused during the
transportation of the chiller unit to its final location/area for installation purpose.
 All relevant approved shop drawings must be present at the time of installation to assure that
the chiller is installed at the correct position maintaining all set outs and clearances from as per
the shop drawings.
 Make sure that the vibration Isolators are installed/anchored at the correct positions on the
concrete pad.
9.3. Installation of Chiller

 Supervisors will deliver tool box talks, relevant to these activities to all operatives involved in
the installation.
 All site safety rules and regulation should be complied.
 Only competent, experienced and trained personnel should perform all the required activities
stated in this method statement.
 During installation, display warning sign boards to be provided and barricade the area
whenever necessary. Close monitoring by the site engineers during installation is much highly
recommended.
 Ensure that all operative fully understand the method of these activities.
9.3.1. Preliminary Checks before Chiller Installation

 Supervisors will deliver tool box talks, relevant to these activities to all operatives involved
 Determine whether the units occur damages during the storage and shifting of location
 All relevant approved shop drawings for the installation of the equipment should be available at
the time of Installation
 Installation activities should only commence when all concrete pads by the civil has been
completed.
 Before commencement of installation activity, the supervisor/ engineer must make sure to
respect minimum distances on all units in order to ensure optimum ventilation to the
condenser coils.
 To ensure best performance on the installation site, the following precautions and instructions
must be followed:
o Avoid air flow recirculation.
o Make sure that there are no obstacles to hamper air flow.
o Make sure to provide a strong and solid foundation to reduce noise and vibrations.
o Avoid installation in particularly dusty environments, in order to reduce soiling of
condensers coils.
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9.3.2. Lifting Unit

 Supervisors will deliver tool box talks, relevant to these activities to all operatives involved
 Determine whether the units occur damages during the storage and shifting of location
 All relevant approved shop drawings for the installation of the equipment should be available at
the time of Installation
 Stepwise procedure is illustrated which is typical for all stations
9.3.2.1. Step Wise Illustration for Work Methodology- Elevated
Chiller Location - Roof Level
Step: 1
Lifting & mobilization of chiller shall be as per approved ton capacity crane is used to lift the
chillers from the transit truck to its location as per the shop drawing. Chiller shall be hanged
with the help of Sling belt as per the manufacture’s recommendation.
As shown in the schematics (Step -1), chiller shall be suspended through the accessibility path.
Thereafter it shall be tied to the manual chain hoist with the help of the manlift.
Step: 2
Manual chain hoist shall be hanged to the structural beam as mentioned in the schematics.
Other end of the manual chain hoist shall be clamped to the bottom as shown in the
schematics. chiller is in suspended position. As detailed in the schematics (step-2)

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Step: 3
Proper coordination shall be done between the crane and the 4-manual hoist, so that the
chiller shall be pulled inside without placing in the ground. After it is pulled to about 1.4 meters
inside, it shall be placed on the floor level, the crane shall be disengaged from the chiller. As
detailed in the schematics (Step-3)
Step: 4
Hook of the crane shall be repositioned after the supporting beam. After the crane is hooked to
the chiller, manual chain hoist shall be detached from the chiller

Step: 5
Chiller shall be lifted and placed exactly as per the approved shop drawing. After placing the
chiller, hook of the crane shall be disengaged.

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9.3.3. Installation of Vibration Isolators

 Vibration Isolator to be used shall be in accordance with the manufacturer's recommendation.

 Identify each mount and correct location of the unit as per shop drawing / installation manual
shipped with the unit in the information pack.
 Place each mount in its correct position and lower the unit carefully onto the mounts ensuring
the mount engages in the mounting holes in the unit base frame.
 Before lowering the units into the vibration isolators secure the isolators to the mounting
surface using the mounting slots in the isolator base plate. Align the mounting holes in the base
of the unit. Level the unit carefully.
 On the adjustable mount, transfer the unit weight evenly to the springs by turning the mount
adjusting nuts (located just below the top plate of the mount) counterclockwise to rise and
clockwise to lower. This should be done two turns at a time until the top plates of all mounts
are clear of top of their housing and the unit base is level.

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Sequence of Work for Lifting the chiller

There will be different methods to lift the chiller. Selecting the proper methods depends on site
constraints and final location of equipment.
In all the different methods the following Pre-Lifting Checks shall be followed:

 Tool-Box Talk before the start of work.

 Check whether the working area is safe with all necessary warning sign, secured against
unauthorized access.
 Ensure that all safety requirements are in place in accordance with project safety plan.
 All required tools and equipment to be inspected prior to use. Third party certificates are valid
for all necessary equipment and tools in compliance with the site safety plan.
 Ensure that all mandatory PPE are available.
 Ensure that only certified drivers, riggers or operators can perform the work.
 Ensure that labors are inducted for Work at Height training for all installations where work at
height is applicable.
 Work permit shall be issued prior to start work.
 All lifts should begin with a plan - written by a lift supervisor.
The following lifting methods can be considered when installing the chiller. More than one
method can be used simultaneously according to site requirements.
In all methods, the manufacturer's recommendations and precautions shall be considered to
avoid any improper procedure that may cause damage to the equipment.
1. Lifting Procedure using Crane
 The equipment shall be delivered directly to site, where they will be inspected in compliance
with the QA/QC procedures. Each item of equipment will be inspected for conformance with
the specifications and compliance with the terms and conditions as set out on the purchase
order.
 The equipment will be unwrapped to allow for visual inspection against any defects or
damages.
 The truck will proceed to the unloading or lifting area. If the unloading area is not the same as
the lifting area, a forklift, boom truck or a telehandler can be utilized to shift the equipment to
the lifting point in case the truck is unable to access the lifting area due to site conditions.
 The vibration isolators will be correctly placed and aligned before the lifting of the equipment.
 Ensure that all the lifting equipment used is properly rated for the weight of the unit being
lifted.

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 Each of the cables (chains or slings), hooks and shackles used to lift the unit must be capable of
supporting the entire weight of the unit.
 Lifting cables (chains or slings) may not be of the same length. Adjust as necessary for even unit
lift.
 A crane will be used to lift the equipment to its final location. The lifting shall be conducted
using suitable lifting beams, spreader bars and all associated accessories.
 The crane operator shall operate under the instruction of a rigger who is positioned as such
that he has a clear and unobstructed view for all the surrounding area.
 The lifting area shall be secured with warning tape and only essential personnel may enter in
the demarcation zone.
 All personnel within the demarcation zone will function as directed by the rigger. A banksman
can be allocated to control the traffic at the lifting area if necessary.

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Typical Banksman Signals

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9.3.4. Minimum requirements for all standard or complex lifting operations

1. Introduction
a. Scope-over view of lifting activity
b. Purpose --- for which purpose made this LMS
c. References---- Lifting procedures and other relevant references if required.
2. Roles and Responsibilities: It is essential that responsibility and authority are clearly defined
a. Site Manager
b. HSE Manager
c. Banks man
d. Crane Operator
e. Riggers
3. Lift Calculations
a. Load details: Weight of the load and dimensions/sizes
b. Lifting Accessories Details: details of slings (wire rope, webbing and chain) shackles,
eyebolts & spreader beams
c. Crane radius and capacity
4. Sketches of the lifting operation
a. Crane Positioning (lift plan)
b. Rigging arrangement Diagram
c. Sketch indicating net capacity (crane) used
5. Crane documentation valid
a. Proof Load Test Certificate and Thorough Examination Certificate
b. Relevant Crane Load Chart
6. Lifting accessories documentation valid
a. Nylon Sling Certification
b. Wire Rope Sling Certification
c. Bow Shackles Certification
d. Lifting or spread beam Certification
7. Lifting Crew (Valid license and Permit details):
a. Person in Charge/ Banks man
b. Crane Operator
c. Rigger/ Slingers
8. Communication: verbal, hand signals, Radio. In case of hand signals, because of existing
different systems, a picture of hand signals to be included.
9. 10 Questions for A Safe Lift
Prior to any lift commencing, the Person in Charge must ask and be happy with the answer
to the following 10 questions for a safe lift:
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a. Is everyone aware of and do they fully understand the lifting and hoisting procedures
applicable to the lift?
b. Has everyone attended the toolbox talk?
c. Has a pre-use inspection of the Lifting Equipment been carried out and are the Lifting
Accessories tagged or marked with:
d. Safe Working Load

10.0. QA/QC Management

 The Construction Department shall inform the Quality Assurance/Control (QA/QC) Department
of the installation activities by issuing an Field Inspection Request Form (FIR).
 When the QA/QC Department is satisfied that the work detailed in the Construction FIR is
completed, they will initiate to DAR.
 The Inspector shall verify the installation of work by performing inspections as per the
Inspection and Test Plan (ITP) and shall record his findings on Quality Record (QR). Any defects
noted during the inspection shall be forwarded to the Construction Department (Project
Manager) through an Inspection Report.
 The Inspector shall use the QR as a checklist and ensure all points on the checklist are complete.
The QR shall be the quality record document to identify that the inspection has taken place and
the installation is in full compliance with the project.
 Verify that the installed unit is free of any visual damages and is installed complete with all
vibration isolators and all connections including pipes and electrical connections as per
approved IFC drawings, specifications and manufacturer's recommendations.
 Check clearances provided for service access and air circulation around equipment is
satisfactory as per manufacturer's recommendations.
 Check chiller properly piped and pipes are leak tested.
 Raise Inspection and Test Request to the Company to get approval for all installations.
 All Pre-commissioning works including system flushing, system's purging and refrigerant
charging, etc. must be conducted in accordance to the relevant T&C Method Statement.
 Surveillance should be made to monitor the activity for the item installations
 Upon completion of installation and inspection has been done with accepted remarks prepare
for testing
 Test Report - A certified test report of all data should be forwarded to DAR for approval prior to
project acceptance. Calibration curves and information sheets for all instrumentation should be
provided.

11.0. HSE Management

 Health and safety training should be provided to personnel on working at height.

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 Health and safety training should be provided to personnel for the proper handling of materials
(required Material Safety Data Sheets or MSDS}.
 Health and safety training should be provided to personnel in the Control of Substance
Hazardous to Health (COSHH).
 Health and safety training should be provided to personnel who will perform work within a
confine space and or hazardous areas.
 Health and safety training e.g. on the job training, fire extinguisher training, scaffolds erection
training and first aid training relevant to electrical safety work practices and safety condition
implemented when undertaking installation of Jet Fan.
 Conduct Training and supervision of workers in the implementation of electrical safety
procedures to eliminate electrical hazards and electrical risks during the installation of Jet Fan
as per electrical safety training and workplace health and safety training requirements.
11.1. Appendix 1 – HSE Risk Assessment

BSS-0-GE00- Rev: 00 (02/15/2021)

Method Statement for Installation of Air-Cooled Chillers (Rev 0) Page 24 of 24