METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

1 Method Statement
Power Safe Testing and
electromechanical Works to be
Contractor
LLC. carried out
Commissioning of VRF
System
Method statement
DOC-DCI-T&C-1990 Revision no. 00
No.
Method statement for Testing
Title and Commissioning of LG VRF
SYSTEM (MULTI V System)

2 Location of Work
Construction of Block C Sharjah waterfront, bluebay walk
Construction of Block C Sharjah Waterfront City - BlueBay
Start Date Duration
Description of Work (keep sentences short and to the point and use sketches and
drawings where possible)

Work Sequence/Procedure (Testing and Commissioning of Variable Refrigerant

Flow (VRF) AC System)

1.0 Introduction
The purpose of generating this method statement is to define the procedure step by step to
implement the correct practices for VRF System Testing and Commissioning through the
guidelines contained herein to ensure that the job execution complies with specification and
serves the intended function to satisfactory level where applicable in The Constellation, Abu
Dhabi, U.A.E.

2.0 Scope of Works

This method statement covers the Commissioning & Testing of the LG Variable Refrigerant
Flow HVAC Units (LG code MULTIV). It's written by District Cooling International(DCI) who is
the Specialist Supplier.

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 METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

3. Responsibilities

3.1 Project Manager

Has the overall responsibility of the project execution, quality and safety. The PM
will be based on site and will be responsible for the management of the project, both
on and off site, through delegation of duties in accordance with the organization chart
and responsible for the effective implementation of project management system.

3.2 Project Engineer / Supervisor.

Ensures all the works are to be carried out as per standards, and coordinate with
T&C QA/QC engineer for inspection approval. Will ensure all relevant safety
precautions in the execution of the job are always adhered to and implement
company safety standards and compliance.

3.3 QA-QC Engineer

Will oversee the quality requirements and quality control measures for the
project in coordination with the senior project engineer as outlined in the QA/QC
manual.

3.4 Testing and Commissioning Engineer (DCI-Supplier)

Will have responsibility to ensure commissioning checks/commissioning
activities have been completed Ensure hard copy reports are provided at the
time of inspection for signature of all parties and verify that commissioning works
has been carried out as per LG instructions.

3.5 Safety Officer

􀁸 To record site engineer method statement briefing to all involved base on
WMS/RA.
􀁸 To ensure safe system of work will be follow base on WMS/RA requirements.
􀁸 To ensure they acquired work permit system if required on the specific task.

4. List of Abbreviation

 VRF – Variable Refrigerant Flow

 DCI – District Cooling International ( Supplier)
 MUTIV – LG VRF Reference
 IDU – Indoor Unit (Evaporator Coil)
 ODU – Outdoor Unit (Condenser Coil)
 R11 – Trichlorofluoromethane (Freon 11 used for intense flushing)
 N2 – Nitrogen gas (used for leak/pressure test)
 PPE – Personal Protective Equipment
 DC – Direct Current
 AC – Alternating Current
 PCB – Printed Circuit Board
 QA-QC – Quality Assurance – Quality Control
 WMS – Method Statement
 RA - Risk Assessment

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 METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

5.0 Equipment to be Used

 Tool box.
 10-12cfm vacuum machine – 2nos
 Digital vacuum gauge (to check the vacuum)
 Digital portable scale (To check the gas)
 Refrigerant R410A – as required.
 Manifold gauge for R410A (Charging hose unit side 3/8 connector, gauge side ¼) – 2nos

6.0 Sequence & Method

6.1 Safety

 Ensure only trained/ Authorized & licensed persons only shall operate the power
tools and do the Testing job.
 Necessary PPE to be worn while working in energized to be worn while working in
energized circuits.
 Ensure adequate lighting is provided in the working area at night time and if inside
the building area to be well illuminated.
 Ensure service area/work area openings are provided with barricade, tape, safety
nets and warning signage to be provided.
 Emergency evacuation plan and procedure to be developed prior to start of testing.
 Calibrated Instruments only to be used.
 Safety requirements tools such as safety shoes, safety helmet, safety glasses,
fluorescent vest, and electrical safety gloves to insure maximum ability of safe work
and dust mask when required.

6.2 Testing and commissioning procedure:

a) First Pressure Test (Refrigerant Piping leak test without IDU/ODU)-should be

completed on Cu pipe installation stage.
b) Second Pressure Test (Refrigerant Piping leak test without IDU/ODU)
c) System Flushing with R11
d) Pre-commissioning & Startup (includes Testing & Commissioning)
e) Prerequisites

a) First Pressure Test:

1. The test is to check the sealing of welding part of the pipe and branch with
nitrogen N2, all piping (excluding machine connections) shall be pressure tested
for R-410A to 550 psi approx) and held for 48 hrs. and checked for leaks.

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METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

b) Second Pressure Test:

1. A second leak test should be performed after connecting indoor units to the main
pipe with nitrogen N2, work shall be pressure tested for R-410A to 28 ~
38kg/cm2(398~500 psi approx), held for 24 hrs. and checked for leaks.
2. Nitrogen gas should be introduced slowly and sufficiently while simultaneously
checking the pressure with a manifold gauge of R410a.
3. Test results will be deemed acceptable if the pressure has not been reduced after
leaving for about one-two days after completion of nitrogen gas pressurization.

Note: Sudden increase in the nitrogen gas pressure to 28 or 38kg/cm2 may damage the
coil of the indoor unit.

c) System Flushing with R141b:

1. All Units which have brazing shall be flushed with R141b (flushing gas) in the
system and subsequently adding N2 pressure to ensure the R141b is completely
removed. The introduction of R141b is important to remove minor carbon/ dust
particles / moisture from the system.
2. After flushing, vacuum shall continue with Manifold gauge and digital vacuum
gauge. Commissioning team has already been trained for Assembly
arrangement and other procedures.

Note: ODU service valve should be in closed mode, as the system contain the R410a
refrigerant.

d) Pre-commissioning & Start-up:

1. Vacuum drying should be made from the service port provided on the outdoor
units’ service valve to the vacuum pump commonly used for liquid pipe and gas
pipe.
2. 500 microns vacuum is required for each unit. The gauge should be kept idle for
half an hour to achieve stable reading.
3. Snapshots of the machine chassis, Digital gauge stable reading should be taken
during the Vacuum.
4. Readings should be noted down and hand over to T&C engineer.
5. Vacuum procedure shall be carried out with precise accuracy and with
responsibility and evidence should be available for each step.
6. Calculation of the additional charge should consider the length of pipe and CF
(Correction factor) value of the indoor unit.
7. Manifold, refrigerant vessel and scale should be arranged.
8. Manifold connected to gas pipe service valve of ODU
9. Purge hose and manifold
10. Extra qty of refrigerant should be added as mentioned in LATS tree diagram.
11. Finally, open the service valves of liquid and gas.

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METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

Note: Pre- start-up procedure should be LG standard like leak test, flushing with
system with R141b, vacuum procedure -air evacuation with vacuum pump is must up
to 500 – 600 micron or else air and moisture remaining in system cause serious
damages to product like low cooling and corrosion inside the heat exchanger,
compressor parts rusty and leak due to remain humidity inside, which we do for large
system to avoid the technical issue, even flushing of carbon may not be 100% but this
protects the system.

e) Operating Parameters:

1. Main Objective:
Control of high or low pressure corresponding to operation mode
2. Target pressure:
 High Pressure (Heating): 2500 ~ 3000 kPa*
 Low Pressure (Cooling): 700 ~ 900 kPa*
3. Inverter Frequency Limit
 Minimum Frequency:
Single Compressor Operation
Cooling: 15 Hz & Heating: 20Hz or Else 25 Hz
 Maximum Frequency:
Single Compressors On: 150 Hz or Else 90Hz
4. Starting Frequency: 30Hz

Note: Unit of pressure is gage pressure.

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 METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

f) Control Cycle Strategies:

Usually, the heat emitted or absorbed can be expressed by the formula:

By adjusting mass flow rate, the heat exchanged can be controlled and achieved the
desired room temperature

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METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

Cooling Mode Heating Mode Stop

Comp Low Pressure High Pressure Stop
Fan High Pressure Low Pressure Stop
Main EEV Full open. Not Controlled Superheat control Full Close
Indoor EEV Superheat control Sub-cool control Fully close
SC EEV Superheat of Sub Cooling Superheat of Sub Cooling Fully close

g) Prerequisites:

1. Make sure completion of All door and civil works such as painting, ceiling,
thermostat location, access of IDU and free from dust etc. before the
startup
2. Enduring power source for the startup.
3. Vacuum should be performed by using digital gauge until its degree
reaches to 5Torr, and then it needs an additional vacuum for 1 Hour. use
the one-way valve to prevent the flow of pump oil into the unit

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 METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

Risk Hazards
3
Hazard Identification Yes No Hazard Identification Yes No
Slips and Trips Yes COSHH No.
Manual handling Yes Noise No
Hand tools Yes Work at Height Yes
Excavations No Dust/Fumes No.
Machinery/Lifting equipment Yes Lighting No.
Fire Yes 3rd party (Contractor) No.
Fall of material Yes Environmental No
Electrical Yes Other

Who might be harmed?

Yes No Yes No
Own Personnel Yes Office Staff or Visitors Yes
Other Contractors Yes Members of the Public No
Proposed Control Measures to Reduce the Risks (use additional sheet if
4
necessary)
Permits Required: Use of Mobile Crane Assessments Required (Attach If “Yes”)
Yes No Yes No
Hot works No COSHH No
Crane check list No Noise No
Excavation No Manual handling Yes
Confined space entry No Other (state)

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 METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

Riser shafts No
Further Control Measures / Security Requirements.
Nil

Training Certificates Required

Yes No Yes No
Scaffold Yes JCB No
Forklift No Mobile Access Towers No
Welding No Banks man / Flagman No
Excavator No Abrasive Wheels Yes
Others (Please state):Crane operator
Overall Assessment of Risk after the Implementation of Control Measures (tick one)
Low Moderate Substantial High


Personal Protective
5 Equipment
Yes No Yes No

Safety Helmet Yes Gloves Yes

Protective Footwear Yes Hearing Protection Yes
High Visibility Clothing Yes Overalls Yes
Eye protection Yes Body Harness Yes
Face Respirator No Other? Face Shield Yes

6 First Aid Measures Required Rescue / Security Measures Required

Yes – as per Emergency Preparedness Yes – as per Emergency Preparedness
Plan. plan
One HAAD License Male Nurses available
on site on call.
Nearest Hospital -

Rescue Spillage control requirement

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 METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

By
Spill kits and spill response team on site to
attend spills if applicable

Who

7 Contractor Information control

Method statement checked by
Method Statement review date Revision no. 0
Who is authorised to update /
amend the Method Statement
and under what circumstances.
Confirmation of briefing from Persons Carrying out the Work
Print Name Signature Date

8 Contractor monitoring & compliance

Who is accountable for monitoring compliance with the
Chicku John George(Sr Senior Engr)
method statement?
Will any test / sampling requirements impose compliance
Yes No No
standards?
If Yes who will carry them out
and with what equipment?

9 Environmental Controls

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 METHOD STATEMENT FOR T&C OF LG VRF SYSTEM

01. Not Applicable.

10 Start Up Check List

01. Checklist Attached.

Signature of Subcontractor Date

Signature of Main Contractor Date

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