QUALITY MANAGEMENT SYSTEM

MS for Installation of Refrigerant Cu

piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

PROJECT HPGRDC

EMPLOYER HPCL

PMC EIL

CONTRACTOR VK Building Services Pvt. Ltd

METHOD STATEMENT FOR INSTALLATION OF REFRIGERANT CU

PIPING, INSULATION, LEAK TEST, EVACUATION AND
INSTALLATION OF VRF UNITS

VKBS EIL

Signature:

Date:

Name: Sahayaraj Binod Davis Mohan

Organization: VKBS VKBS VKBS

HVAC Work Method Statement 1

 QUALITY MANAGEMENT SYSTEM
MS for Installation of Refrigerant Cu
piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

INDEX

1. Purpose
2. References
3. Materials
4. Tools & Equipments
5. Safety requirements
6. Procedure tubing and brazing
7. Refnet connection
8. Supporting pipes
9. Installation VRF outdoor units
10. Leak testing of copper pipes
11. Insulation of copper pipes
12. Evacuation of system
13. Records

HVAC Work Method Statement 2

 QUALITY MANAGEMENT SYSTEM
MS for Installation of Refrigerant Cu
piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

1.0 Purpose

The purpose of this method statement is to define the method of installation of refrigerant
copper piping, insulation, installation of VRF unit and related activities.

2.0 References

 Manufacturers instruction manual

 Approved Technical Data Sheets

 Approved Shop drawings.

3.0 Materials

 VRF grade Refrigerant copper tubes and fittings

 Refnet joints
 2% silver alloy brazing rods
 Flux
 Nitrile rubber insulation Class “O” of 13mm thick
 Nitrogen cylinder with nitrogen gas
 Oxygen and Acetylene cylinder with gas
 Anchor fasteners
 Support and clamps
 Anti-vibration mounts

4.0 Tools & equipment

 Refrigeration tools – Tube cutter, Flaring tools, Swaging tools, Reamer, Pipe bender,
manifold with pressure gauges.
 Tool box with tools
 Oxy-Acetylene brazing set
 Vacuum pump
 Calibrated pressure gauges
 Micron gauge
 Impact drill machine
 Drill machine
 VRF outdoor units of approved make and model
 Hydra crane

HVAC Work Method Statement 3

 QUALITY MANAGEMENT SYSTEM
MS for Installation of Refrigerant Cu
piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

5.0 Safety requirements

 Safety Officer will ensure the appropriate safety precautions to avoid any unexpected
events in protection, storage and handling of the material.

 All safety precautions shall be followed as per the established Project safety plan during
the installation of services.

 Proper scaffolding certified by Safety Engineer, safety harness shall be used and
secured, if required.

 Wear clothing of non-flammable fabric.

 Turn off the gas cylinder securely when not in use.

 Keep a fire extinguisher near the area of works.

 Always carry out the brazing procedure in well ventilated areas.

 Store acetylene cylinders in upright position.

 Acetylene becomes unstable and volatile above 15 psig. An acetylene cylinder that has
been laid down should be placed in the upright position for at least 20 minutes before
using.

 Do not allow anyone to stand in front of the oxygen cylinder valve when opening.

 Acetylene cylinder valves should only be opened ½ to 1 turn, and the wrench should
never be removed from the valve during use.

 Oxygen hoses have a right-handed thread, while acetylene gas hoses use a left-handed
thread. Ensure that the adapters are screwed correctly.

 Do not handle acetylene and oxygen cylinders with oily hands or gloves.

 Hard hat, goggles and gloves shall be worn while doing carrying out the brazing process.

 Keep grease away from the cylinders and do not use oil or grease on cylinder attachments
or valves. The mixture of oil and oxygen could cause an explosion.

 When lighting the torch, be sure to wear flame-resistant gloves and goggles; use an
appropriate device, such as a cup-type striker, to light the torch; and point the torch away

HVAC Work Method Statement 4

 QUALITY MANAGEMENT SYSTEM
MS for Installation of Refrigerant Cu
piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

from a person. Always light the acetylene gas first, and then open the oxygen valve on
the torch handle.

 Never use oxygen to purge tubing. An explosion could result when oil and oxygen are
mixed.

 Never try to repair a joint by brazing with the system under nitrogen pressure as this can
lead to an explosion and serious injury.

 Work area shall be maintained neat and clean.

6.0 Procedure for tubing and brazing

 Cut to the exact length required using a tube cutter. Remove all inside and outside burrs
with a reamer, file, or other sharp edge scraping tool. If tube is out of round, it should be
brought to true dimension and roundness with a sizing tool.

 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.

 Proper fluxing is important because the flux absorbs oxides formed during heating and
promotes the flow of filler metal. When using white flux, apply it only with a brush. To
prevent excess flux residue inside refrigeration lines, apply a thin layer of flux to only the
male tubing. Insert the tube into the fitting and, if possible, revolve the fitting once or
twice on the tube to ensure uniform coverage.

 Insert the fluxed tube end into the fitting. Maintain support to ensure the proper
alignment until the brazing alloy solidifies. After brazing maintain support for a few
seconds (or more) depending upon the size of the joint area.

 Bleeding of grade-1 quality nitrogen while brazing is mandatory. Brazing without

nitrogen forms oxide film from inside of the tubing, which forms sludge in presence of
oil and eventually leads to choking of strainers, capillaries, solenoid valves and
expansion valves.

HVAC Work Method Statement 5

 QUALITY MANAGEMENT SYSTEM
MS for Installation of Refrigerant Cu
piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

 Bleed nitrogen at the rate of 3-4 litres per minute (Pressure 6-9 psig). Always use pressure
regulator valves for nitrogen cylinder.

 Adjust the torch flame. 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. Excess acetylene removes surface oxides from the copper. The copper
will appear bright rather than having a dull or blackened surface due to an improper
oxidizing flame

 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.

 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.

 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.

 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.

 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 sweeping 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. Do not continue feeding brazing alloy after
the joint area is filled. Excess fillets do not improve the quality or the dependability of the
braze and are a waste of material
 All fluxes residues must be removed for inspection and pressure testing. 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.

7.0 Refnet connections

 Each refnet is provided with different size pipe connections, on all three sides as
standard. In a VRF system, all combinations of branching are possible.

HVAC Work Method Statement 6

 QUALITY MANAGEMENT SYSTEM
MS for Installation of Refrigerant Cu
piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

 Check the inlet and outlet sizes required. If the outlet size matches with the required size
there is no need to cut the connection.

 Use a tube cutter to cut the joints at the required size to match the installed pipe. Cut off
as far as possible so that maximum length of required pipe is available to insert the pipe.
Make sure that the refnet in free from dirt and other objects while brazing.

8.0 Supporting pipes

 During operation, due to frequent start-stop of the compressor and modulation of inverter
scroll compressor, the refrigerant piping experiences wide pressure fluctuations.
Refrigerant pipes should be properly supported to damp the vibration due to pressure
fluctuations.

 Ensure that the pipes are supported at every 1.2 metre distance (Maximun allowable 2
metre between supports). The copper pipes shall not be in direct contact with metals
parts / supports etc.

9.0 Installation of VRF outdoor units

 Ensure that the foundation for the ODU is made as per required size and as per the
approved shop drawing.
 Place the unit on to the foundation by lifting the unit using a crane.

HVAC Work Method Statement 7

 QUALITY MANAGEMENT SYSTEM
MS for Installation of Refrigerant Cu
piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

 Ensure that the micro processor circuit boards are not damaged during the lifting of unit.

 Ensure that vibration pads are placed between the legs and foundation as recommended by
the manufacturer.

 Ensure that there is a clear space of at least 600 mm between wall and back of the unit so
that there is no obstruction to entry of ambient air and pass through the condensing coil.

 Ensure that there is free space above the unit so that there is no obstruction for hot air to
escape to the atmosphere as the condensing unit fans are at the top.

 Ensure that there are sufficient space around the unit for service and maintenance.

 Anchor the unit to the foundation using anchor fastners of suitable size.

 Connect the copper piping network to the suction and liquid side of the unit by brazing.

10.0 Leak testing of copper piping

 Check visually that all joints are properly brazed.

 Check that all the service valves of the outdoor unit are closed.

 Attach a manifold valve with pressure gauge and dry nitrogen gas cylinder to both the
suction and liquid ports of ¼” service valve located at the bottom of the outdoor unit.

 Use a Tee connection for connecting both the liquid and suction valves.

 Always pressurize both the liquid and suction side of the system.

 Copper pipe shall be pressure tested with dry nitrogen gas. The test pressure for high
pressure side shall be 46 Kg/Sq.cm (675 psig)

 Pressurize the system in steps of 100, 200, 300, 400, 550 and 675 psig. Check for any leak
at each step using soap bubbles. The pipe shall hold the pressure for a minimum period of
24 hours without revealing any leakages.

 Do a leak test of all the joints of the piping. Any bubbles indicate a leak. Wipe off the
soap bubbles after the leak test.

 Hold the pressure for at least 24 hours and check for any drop in pressure.

HVAC Work Method Statement 8

 QUALITY MANAGEMENT SYSTEM
MS for Installation of Refrigerant Cu
piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

 After ensuring the system is free from leaks, release the nitrogen pressure by loosening
the charging hose at the nitrogen cylinder.

 After leak test has been completed successfully, the pressure due to the nitrogen gas in the
pipes shall be used to flush-out the system.

 When the system pressure reduces to normal, disconnect the hose from the cylinder.

 The pipe shall then be dehydrated by drawing a deep vacuum. The vacuum achieved shall
be at least as deep as 500 microns and shall be maintained for a period of at least 24
hours after the vacuum pump has been shut off.

11.0 Insulation of copper pipes

 Nitrile rubber tubular insulation class “O” of thickness as mentioned in the below table is
used for insulation of refrigerant copper pipe.

 The insulation tubing is slide over the copper pipe before setting and brazing the joints.
The insulation is left at the joints, which is done after the leak test. Sufficient gap is left at
the pipe and refnet joints to ensure that the insulation is not damaged during brazing.

 The brazed joints are insulated after the pressure test and ensuring there no leaks in the
system.

 The insulation is covered with insulation tape, avoid any air pockets. Air pockets bring
moisture in cavities and damage the thermal insulation.

Pipe diameter Insulation

thickness
Inch mm mm
Φ1/4 6.35 ≥13
Φ3/8 9.52 ≥13
Φ1/2 12.7 ≥15
Φ5/8 15.9 ≥15
Φ3/4 19.1 ≥15
Φ7/8 22.2 ≥20
Φ1-1/8 28.6 ≥20
Φ1-3/8 34.9 ≥20
Φ1-5/8 41.3 ≥20
Φ2-1/8 54.0 ≥20
12.0 Evacuation of system

HVAC Work Method Statement 9

 QUALITY MANAGEMENT SYSTEM
MS for Installation of Refrigerant Cu
piping and VRF units
DOC.No: VKBS/HPCL/HVAC/011

 The system is evacuated to ensure that there are no moisture present in the system. The
oil used in the compressor is synthetic (Poly Ester or Poly Oly Ester) which is highly
hygroscopic. Therefore ensuring evacuation of moisture is highly important.

 Ensure to use a two stage vacuum pump of capacity 200 LPM.

 Connect the liquid and suction side to the gauge manifold through a micron gauge. The
gauge manifold is then connected to the vacuum pump.

 Open the low side knob (connected to the compound gauge) of the manifold – generally
blue in color.

 Close the high side manifold gauge.

 Open the suction service valve.

 Open the liquid service valve.

 Run the vacuum pump.

 Evacuate in first stage upto 2000 microns. Hold for 15 minutes. If Ok then proceed. If
vacuum is raising fast then there is leak in the system. Redo the pressure testing and
again evacuate.

 Charge nitrogen upto 2-4 psig. Evacuate upto 500 microns and hold for 24 hours.
Vacuum should not raise above 600 microns in 24 hours.

 When the vacuum of the system is finished the system can be charged with refrigerant.

13.0 Records

 Signed off checklist for copper pipe installation

 Signed off check list for insulation works leaving joints

 Signed off check list for leak testing and clearance for insulation of joints

 Signed off check list for installation for VRF outdoor units and piping connections

 Signed off check list for system evacuation.

HVAC Work Method Statement 10