METHOD STATEMENT

METHOD STATEMENT FOR COOLING UNIT PRE - COMMISSIONING & COMISSINONING PROCEDURE

Project Name: Sheikh Khalifa Central Hospital – Fujairah

Client: Ministry of Presidential Affairs (MOPA)

Consultant: Consolidated Consultants Group

Main Contractor: Fibrex Construction Group

MEP Contractor: Fibrex MEP Division

Issue date Rev - Prepared by Checked by Approved by

00

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 TABLE OF CONTENTS

SECTION DESCRIPTION

1 PURPOSE

2 SCOPE

3 REFERENCES

4 DEFINITIONS

5 RESPONSIBLE PERSON ON SITE

6 EQUIPMENTS / INSTRUMENTS

7 HSE REQUIREMENTS

8 PRE – COMMISSIONING PROCEDURE

9 COMMISSIONING PROCEDURE

ATTACHMENTS

1. PRE- COMMISSIONING CHECK LIST

10 2. COMMISSIONING CHECK LIST
3. START – UP & PERFORMANCE REPORT
4. RISK ASSESSMENTS

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1. PURPOSE

1.1 The purpose of this Pre – commissioning and commissioning procedure is to be define
the step-by-step method to implement the correct practices of In row DX Cooling Units
through the guidelines contained herein to ensure that the job execution complies with
the project requirements and serves the intended function to satisfactory level.

2. SCOPE OF WORK

This Method Statement cover the procedure of pre – commissioning and commissioning for
Smart modular data center for Sheikh Khaliah Central Hospital project.

3. REFERENCES

• Project Specification Section

• Approved Shop Drawings
• Approved material submittal
• Project Safety Plan
• Project Quality Plan
• Fujairah Civil Defence
• NFPA Standards

4. DEFINITIONS

4.1 PROJECT – SHEIKH KHALIFA CENTRAL HOSPITAL PROJECT.

4.2 MEP CONTRACTOR – FIBREX

4.3 DETAILING ENGINEER – FIBREX

4.4 HSE – Health, Safety and Environment.

4.5 PPE – Personal Protective Equipment.

4.6 AFC – Approved for Construction

4.7 MSU – Material Submittal

4.8 PCCP – Pre – commissioning and Commissioning Procedure.

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5. RESPONSIBLE PERSON ON SITE

5.1 The Project Manager

Shall be responsible for overall execution, quality, and Safety of the Project. The PM reviews
and approves upon satisfaction, the Methodology of execution that constitute in this Project.

5.2 The Construction Manager

Is responsible for overall execution of this work, CM will coordinate with MEP, Safety &
Project Engineer to ensure that the necessary resources are provided to implement the approved
PCCCP and to ensure all construction staff comply with Quality, Health, Safety and Environmental
Management System requirements.

5.3 The Commissioning Engineer

Is responsible to coordinate with commissioning specialist and control the commissioning
activities.

5.4 The Specialist Engineer

Is responsible to check the proper completion and identification, with respect to the project
specification and scope of the work and start up with necessary settings / system operation.

5.5 The Mechanical Engineer / Site Engineer

Is responsible for the execution of the activity in accordance with the project HSE
requirement, approved Method Statement and approved Shop Drawings. He is also responsible to
ensure all required submittals are made and required plant/tools/material and manpower is available
in timely manner.

5.6 The QC Engineer

Is responsible to ensuring the pre- commissioning and commissioning procedure is carried out
as per quality requirements and procedure.

5.7 The HSE Engineer

Is to monitor compliance with the procedure as per method statement and implement all
Health and safety Environment precautions and aspects of works on site. Report any deviations to the
site Engineer for rectification. All precautions that are put in place (as per Risk Assessment) will be
made apparent to all persons relating and persons affected by this activity and situation.

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6. EQUIPMENT / INSTRUMENTS

Following indicative tools list shall be used for the pre- commissioning and commissioning.

1. Clamp Ammeter
2. Portable Hand Tools
3. Tachometer
4. Vane Anemometer
5. Digital Micro Mano meter

6.1. GENERAL REQUIREMENTS

All instrument / equipment using for commissioning / testing shall have valid calibration
certificates will be attached with test reports during commissioning / testing

All the pre – commissioning and commissioning activities shall be performed by specialist / sub
– contractors per approved PCCP

7. HSE REQUIREMENTS

7.1 CONTRACTOR HSE Guidelines and Management Plan.

7.2 Safety Hazard and Precautions

7.3 All persons involved in the scope of work shall be imparted Safety induction on
the first day and toolbox talk daily during the span of the works for the activities
concerned.

7.4 Safety Hazard and Protection

7.5 All opened areas to be safeguarded to protect the workers such as setting out
warning sign and barricades as necessary.

7.6 All ladder, scaffoldings (if required) and temporary stair to be well secured at top
and bottom.

7.7 Worker will wear helmet, safety boots, safety gloves, Eye protection and
protection clothes

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 SAFETY PROCEDURES

Only trained persons shall operate the power tools.

Ensure all concerned personals shall use PPE and all other items as required.

Ensure adequate lighting is provided in the working area.

7.8 EMERGENCY ARRANGEMENTS

Minor Injury: In case of minor injury the safety nurse, Safety officer & Safety Manager
will be informed, and safety nurse will provide the necessary first aid treatment to the injured in
the first aid room.

Major Injury: In case of major Injury the Safety Officer, Safety Manager & Project
Manager will be informed, and Project Manager will inform all the concerned authorities for
external medical assistance. Safety nurse will be available with the injured personnel until the
emergency team arrives. Work will be stopped, and all the workers will be gathering at the
assembly point until further clearance to start the work by the Safety Manager is issued.
Depending on the severity of the incident site investigation will be done by the Safety Manager
and Project Manager.

8. PRE – COMMISSIONING PROCEDURE

INDOOR UNIT

8.1 Implement a comprehensive check on the cabinet. Handle any problems

immediately.
8.2 Make sure the environment meets the requirements before installation, and whether
reconstruction is needed for routing pipes and cables and constructing ventilation
pipes.
8.3 Install the indoor unit in a spacious space. Ensure that a minimum of 600 mm
maintenance space is reserved in front and rear of the indoor unit.
8.4 The equipment room should have good heat insulation, and the walls and floor
should be dampproof.
8.5 Take care to prevent the components and cables from damage during handling.
8.6 Check that the area, height, and ground bearing capacity of the installation position
meet requirements.
8.7 To ensure good ventilation, do not place the indoor unit in the corner of a room or
at the end of a long and narrow room.
8.8 Avoid internal pipeline pollution and oxidation because the NetCol5000-A is
delivered with nitrogen loads.
8.9 During system operation, all doors and windows of the equipment room or
equipment shelter should be closed to reduce the additional load of the air
conditioner.

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 OUTDOOR UNIT

The space requirements for horizontal installation and vertical installation

8.10 When you install the outdoor unit, ensure that air smoothly flows into and out
of the condenser. If you install the outdoor unit vertically, ensure that the air
produced by fans flows in and out in the same directions of the monsoon.
8.11 In high-temperature areas, prevent direct sunlight to the outdoor unit. Take
thermal insulation measures for indoor and outdoor connecting pipes.
8.12 Install the outdoor unit in a clean area and far from residential areas, deserts,
and windy and sandy areas. Prevent sands from entering the condenser.
8.13 Do not move the outdoor unit by holding the copper pipe or electrical control
box and keep the fins intact.
8.14 The device is nitrogen loaded before delivery. If no nitrogen is discharged
during discharge, contact support services

9. COMMISSIONING PROCEDURE

9.1 The water supply and outlet pipes of the electrode humidifier and water pump,
and water automatic drainpipe is unblocked and free of leakage.
9.2 The input voltage and frequency of the primary power supply are within the
nominal range, and the phase sequence is correct.
9.3 Signal cables to the indoor unit and the outdoor unit are correctly connected.
9.4 The voltage jumper is correctly connected.
9.5 Teamwork cables are correctly connected if teamwork networking is required, and
the DIP switches for the main control board are correctly set.
9.6 Cables to the ambient temperature and humidity sensor are correctly connected,
and the DIP switches for the ambient temperature and humidity sensor are correctly
set.
Vacuumizing the Refrigerating System

9.7 In the beginning, the vacuum pump makes loud noises and exhausts white smoke
from the exhaust vent. After 10 minutes, if it still exhausts white smoke, observe it
for another 10 minutes because the refrigerating system may not be sealed properly
or there may be too much refrigerant or water in the refrigerating system.
9.8 After 20 minutes, the pressure gauge pointer should be in the negative area and the
vacuum pump makes small noise. Close and open the pressure gauge alternatively
for several times. The position of the pressure gauge pointer and the sound made
by the vacuum pump do not change. Otherwise, the refrigerating system may not
be sealed properly.
9.9 Check that the time for vacuum pumping is 80 minutes or longer after making sure
that the refrigerating system does not leak, the pressure displayed on the vacuum
pump is less than or equal to 60 Pa, and the indication of sight glass is dry.

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 9.10 Close the pressure gauge and vacuum pump after vacuum pumping. Preserve
the pressure for 10 minutes. The pressure should be lower than 90 Pa.
Filling in Refrigerant

9.11 Fill in refrigerant (R410A) after checking that the system does not leak and the
vacuum meets the requirements.
9.12 Fill in refrigerant from the high-pressure needle valve and needle valve after
expansion valve (valve 1 and 2)) to avoid filling in liquid refrigerant to the
compressor. The following describes how to fill in refrigerant.
9.13 Replace the vacuum pump with the steel vessel of the refrigerant and lay the
steel vessel upside down on the electronic balance. Exhaust the air from the pipe
and fill in liquid refrigerant.
9.14 Do not move the pipe or steel vessel when filling in refrigerant. Otherwise, the
value on the electronic balance is influenced.
9.15 Stop filling in refrigerant when you have filled in 10 kg.
9.16 Close the pressure gauge and the valve of the steel vessel after filling in
refrigerant.

Prerequisites
9.17 Check that the voltage valve on the voltage jumper is the same as the input
power.
9.18 Check that the input power of the outdoor unit is the same as the indoor unit.
9.19 The terminals are fastened properly.
9.20 Make sure that the crankcase heater has been heated for over 12 hours before
starting compressor.

Procedure
Step 1 Switch off the other circuit breakers except for the main isolate breaker and turn on the
general power input switch.

Step 2 After the cooling system powers on, the Quick Setting screen is displayed on the
LCD, Choose the following configures.

⚫ Language.
⚫ Date format, Date, Time, Zone.
⚫ Monitor mode.
⚫ Current rated voltage.

If the teamwork networking is to be configured onsite, refer to the parameters in

----End

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 1. Make sure that the main power breaker of outdoor unit has been switched on
before starting compressor.
2. The crankcase heater has been heated for over 12 hours.
3. Remove the refrigerant when the commissioning is completely over.
4. The user type includes Admin, Engineer, Operator, and Guest (the preset
password for Admin, Engineer, and Operator is 000001, and Guest do not need
a password). The permissions for each type of the users are decreasing. Only
Engineer and Admin are permitted to enter the diagnostic mode.

Procedure
Step 1 Switch on the general power input breaker QF1, upper-level circuit breaker QF2 of the
SPD, the compressor breaker QF3 and the transformer circuit breaker QF8. Ensure that
the voltage is within the range of 24 V±10%.

Step 2 Tap Start on the main screen, and then choose Maint > Diagnostic > Enter to enter
the diagnostic mode. shows the operation guides of the diagnostic mode.

Step 3 Switch on the fan circuit breakers QF6 and QF7. Change the input percentage of
indoor fan speed to 30% and ensure that the fans rotate properly.

Step 4 Switch on the electric heater circuit breaker QF4. Tap on to make electric heaters start.
Measure all the phase currents of the electric heater after the electric heater starts
automatically. After measuring the current, close the electric heater in the diagnostic
mode.

Step 5 Switch on the humidifier circuit breaker QF5 and pump breaker QF9.

1. Start the humidifier to 100%, and the fan and the condensate pump automatically
start as required. Make sure that the water supply valve works properly, and the
water supply pipes do not leak.
2. Change the humidifier to 0% and press the button on the side of control box to
drain water. Make sure that the water outlet valve works properly, and the outlet
pipes do not leak.
3. Tap Running > Device Details > Drain Device to ensure the pump works
properly.

Step 6 Switch on the outdoor unit circuit breaker.

1. The yellow light of phase protection is on. If it's not on, make sure the phase
protection lines are connected properly.
2. The condensate pressure would be displayed on the speed controller. The outdoor
fans would not run if the condensate pressure is below 22.6 bar.
3. Turn on the outdoor fan in the diagnostic mode and check whether the outdoor
fan works properly.

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 Step 7 Adjust the compressor as the following steps.

1. Set the speed of compressor to 1500 rpm and make sure the liquid solenoid valve
is on.

2. Set the speed of compressor to 1500 rpm and make sure the liquid solenoid valve
is on.

3. Add the refrigerant from the high-pressure needle valve and needle valve after
expansion valve (valve 1 and 2) of the refrigerating system in small or
intermittent flow.
4. Tap Running > Device Details > Compressor to ensure the phase currents in the
range of 18 to 24 A.
5. Check whether the suction and discharge pressure are in a reasonable range.
reasonable discharge pressure ranges, and suction pressure reasonable range is
from 0.7 MPa to 1.2 MPa. Adjust the supercool degree to 4°C–6°C by filling or
draining refrigerants if it's allowed. Drain the refrigerant from the high-pressure
needle valve. No bubble should exist in refrigerants.

Power Off

Procedure
Step 1 Tap Shutdown to stop running. Restore the preset temperature after the test.

The unit is still on. Pay attention to it.

Step 2 Switch off the general power input breaker QF1.

----End

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 1. PRE - COMMISSIONING CHECK LIST
PRE - COMISSIONING AND INSPECTION REPORT FUSION MODULE 2000
SMART MODULAR COOLING UNITS
INSPECTION REPORT NUMBER INSPECTION DATE & TIME EQUIP LOCATION DISCIPLINE

JOB DESCRIPTION AREA DESCRIPTION

SYSTEM NUMBER (IF APPLICABLE) SUBCONTRACTOR/SUPPLIER

Identification No. System Voltage

RESULT
NO. INSPECTION
ACCEPT REJECT N/A.

1 No damage has been found to all cabinets and each component

Ensure that the system installation is complete and mechanical completion is

2
approved & all comments the installation are incorporate
3 All cabinets Panel supports are correctly installed

4 Correct level / alignment / orientation as per OEM

5 Replace damaged components if any

6 Bolts and nuts are tightened properly as per vendor recommended torque value

7 Door locks operation / padlock facilities correct installed

8 Seal, gasket, openings installed correctly

9 Check ground connection and all power fuses for continuity

10 Check all switches /breakers are in open position
11 Check on missing or loose part of each component correct
12 Check the system is interfaced with the management system
13 Adequate protection of equipment and cleanliness is accepted internal and external.
14 Equipment is installed in controlled atmosphere
15 Cable entries are properly sealed
16 Check ventilation system is clean, free from blockage

REMARKS:

SUBCONTRACTOR CONTRACTOR COMPANY

NAME NAME NAME

SIGNATURE SIGNATURE SIGNATURE

DATE DATE DATE

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 START – UP & PERFORMANCE REPORT

Test Test Tolerance Actual

INTEGRATED UPS PDU SOURCE -B FOR CCU
Description Level Reading

396 V to 404v
L1-L2 Voltage
AC
396 V to 404v
L2-L3 Voltage
AC
396 V to 404v
L3-L1 Voltage
AC
227V to 233v
1 Check 3QF 1 - 3QF1 8 Output voltage supply from UPS -B L1-N Voltage
AC
227V to 233v
L2-N Voltage
AC
227V to 233v
L3-N Voltage
AC

N-E Voltage Less than 5V

Cooling Unit

Name of Equipment Model no Serial no Capacity

COOLING UNIT-1 NetCol5000-A050 46KW

COOLING UNIT-2 NetCol5000-A050 46KW

COOLING UNIT-3 NetCol5000-A050 46KW

COOLING UNIT-4 NetCol5000-A050 46KW

COOLING UNIT-5 NetCol5000-A050 46KW

COOLING UNIT-5 NetCol5000-A050 46KW

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 Visual Inspection

Sr.No Test Description Result

1 Check Cooling unit configuration whether it is configured with N+1

Check both cooling unit operation as 1 unit is working and other one is
2 standby mode

Power Off working cooling unit, stand by cooling unit should come to
3 online immediately

DX Cooling Unit 1

Sr.No Test Description Result

1 Check Supply air temperature

2 Check Return Air Temperature

3 Check the Humidity reading

4 Check the refrigerant pressure

5 Check the Refrigerant pipe and ensure there is no leakage

6 Check the Drainage pipe connection and ensure there is no leakage

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 DX Cooling Unit 2
Sr.No Test Description Result

1 Check Supply air temperature

2 Check Return Air Temperature

3 Check the Humidity reading

4 Check the refrigerant pressure

5 Check the Refrigerant pipe and ensure there is no leakage

6 Check the Drainage pipe connection and ensure there is no leakage

DX Cooling Unit 3

Sr.No Test Description Result

1 Check Supply air temperature

2 Check Return Air Temperature

3 Check the Humidity reading

4 Check the refrigerant pressure

5 Check the Refrigerant pipe and ensure there is no leakage

Check the Drainage pipe connection and ensure there is no

6 leakage

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 DX Cooling Unit 4

Sr.No Test Description Result

1 Check Supply air temperature

2 Check Return Air Temperature

3 Check the Humidity reading

4 Check the refrigerant pressure

5 Check the Refrigerant pipe and ensure there is no leakage

Check the Drainage pipe connection and ensure there is no

6 leakage

DX Cooling Unit 5

Sr.No Test Description Result

1 Check Supply air temperature

2 Check Return Air Temperature

3 Check the Humidity reading

4 Check the refrigerant pressure

5 Check the Refrigerant pipe and ensure there is no leakage

Check the Drainage pipe connection and ensure there is no

6 leakage

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 DX Cooling Unit 6

Sr.No Test Description Result

1 Check Supply air temperature

2 Check Return Air Temperature

3 Check the Humidity reading

4 Check the refrigerant pressure

5 Check the Refrigerant pipe and ensure there is no leakage

Check the Drainage pipe connection and ensure there is no
6 leakage

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