Method Statement for Chilled Water Pump (CHW) Installation

The Method Statement for Chilled Water Pump (CHW) defines the guidelines for assessing the activities for installation based on the requirements set forth in the Health, Safety & Environment requirements, and the Project Quality Plan.
This method statement for chilled water pump covers the installation procedure with respect to approved shop drawings & the manufacturer’s recommendations.

Application of Chilled Water Pumps

Chilled water circulation through Heat Exchangers, AHU’s, FCU’s, OHU’s, etc.
The exact location, size, capacity, schedule, model, and other details of pumps are as per approved shop drawings and approved materials submittals.

Description of Work

The pumps will be produced at the manufacturer’s factory in accordance with material submittal documents and approved drawings.

Shipping/Transportation, Handling, and Storage

• After shop drawing approval fabrication drawings will be raised by the manufacturer before commencing the manufacturing process.
• Pumps unit and other related accessories will be handled and transported & unloaded at the site as per strictly manufacturer’s instruction.
• Pump units and other related accessories will be stored at a dry location in the lay-down area. They will be protected and covered by heavy gauge polythene sheeting.
• After delivery materials will be inspected for any damage, shortage, noncompliance with project specification and materials submittal.
• After shop drawing approval fabrication drawings will be raised by the manufacturer before commencing the manufacturing process.
• Up to a total weight of 1500 kgs. or a motor size IEC 280, the units (consisting of pump, motor, coupling, and coupling guard) are supplied completely assembled and mounted on a common base plate/common base frame.
• Units weighting > 1500 kgs. or comprising a motor size IEC 315 and larger are completely assembled at the factory to check the components for correct adjustment, subsequent disassembled again and each major component is packed separately for shipment.
• The pumps and accessories will be tagged, crated, and protected for shipping as per the manufacturer’s recommendations.
• The manufacturer’s recommendation and/or instructions regarding lifting shall be strictly adhered to to ensure the pumps and component units are free from damage.
• Do not use lifting slings on the free shaft end of the pump or on the motor eye bolt.
• All items will be offloaded in an approved offsite storage facility stored on timber sleepers and covered for protection as per the manufacturer’s recommendations.
• For longer periods of storage impellers, shafts, seals, and rotating parts will be periodically inspected.
• All lifting equipment must be rated for the purpose and checked for damage before any attempts are made to lift the pump.
• The lifting equipment rating must under no circumstances be exceeded. The pump weight is stated on the pump nameplate.
• The equipment shall be handled and stored in accordance with the manufacturer’s instructions. One copy of this instruction shall be included with the equipment at the time of shipment, one copy to be faxed to the site prior to the shipment.

Pre-Delivery

An NCI (Notice for Commencement of Installation) will be raised and a hoisting and loading platform request will be raised giving the date, time, weight & dimensions ensuring adequate notice to prepare for lifting and movement.

The shop drawing will have the parts tag numbers printed on the drawing for rapid installation and minimum time wastage. The drawing will be posted in the workforce area.

Delivery

The pumps are factory-packed for transport and should remain so until installation.

All documents will be available with the supplied pumps ie. shipping documents, packing list, delivery notes and test certificates, etc.

Material Inspection Request (MIR) will be raised for delivered materials equipment for approval from the consultant.

Installation of the Pump Unit/Skid

General

• The installer will receive a set of installation drawings from the factory with tag numbers and hoisting shall be executed as per manufacturer recommendations.
• All structural work must be prepared in accordance with the dimensions and loads stated in the dimension table/ installation plan.
• Prior to installation, the pump unit & inertia base will be moved to the correct location by the right logistic crew.
• The pump unit and Inertia base will be carefully loaded onto the transport vehicle and delivered to the hoist or crane area by a truck-mounted crane.
• The concrete housekeeping pad will be made available by the contractor. Pad will have sufficient strength to ensure safe and functional installation in accordance with DIN 1045 or equivalent standards.
• Prior to concrete inertia base installation make sure that the concrete housekeeping pads have set firmly. Its surface shall be horizontal and even. Tolerance will be accepted in accordance with the manufacturer’s recommendations.
• Inertia base frames are delivered at the site completely assembled and supported by an approved vibration isolator and ready to fill with concrete.
• A concrete inertia base will be available at the site before 7 days of the delivery of the pump unit/skid.
• Install Inertia to the designated location.
• Install correct size and model of vibration isolator.
• Pump unit/skid installation on concrete inertia base shall be carried out in accordance with the approved shop drawings, specifications and manufactures recommendation.
• All safety regulations must be observed at the installation site.

Installation

• Before setting up the pump, check the operating data. Ensure that the data on the nameplate matches the required system data. ie. operating voltage, frequency, pumped liquid temperature, etc.
• Ensure flange type, bolt and nuts are matching.
• After placing the pump unit on the Inertia base, alignment of pumps/motor/coupler will be carried out.
• G.I, M.S. shims shall be fitted between the base plate and the inertia base itself; they shall always be inserted to the left and right of the J- bolts and in close proximity to these bolts. All shims must lie perfectly flush.
• Alignment shall be checked by using a feeler gauge or a wedge gauge. A Work Inspection Request (WIR) will be raised to verify alignment with the main contractor/consultant.
• Check pump shaft for easy rotation by hand at the coupling.
• Install coupling guard prior to starting the pump to prevent accidents.
• Check integrity and proper functioning of all connections.

Suction and Discharge Piping

• Flange covers on the pump and discharge nozzles must be removed prior to installation in the piping.
• Piping should always run to the pump.
• Do not move the pump to the pipe.
• A suction lift line shall be laid with a rising slope towards the pump and suction head.
• Lines with a downward slope towards the pump. The pipelines shall be anchored in close proximity to the pump and connected without transmitting any stresses or strains. Their weight will not exert any load on the pump.
• Install an eccentric reducer (straight position should be at the top and taper position towards the ground) in the suction line near to pump suction end so that there will be no air pocket in the suction line when the line will fill with water.
• Installation is to be carried out as per approved shop drawings.
• After installation check for straightness, plumb, and alignment.
• A Work Inspection Request (WIR) will be raised to verify alignment with the consultant.

Quality

The QA/QC Engineer along with Construction Superintendent and Site Engineer will monitor that all components are installed as per contract specifications, approved submittals, and manufacturer’s recommendations.

A Work Inspection Request (WIR) shall be submitted to the consultant after the completion of installation.

List of Main Resources

Materials

Chilled water pumps
Support materials and accessories

Equipment

Chain Blocks
A-frame
Belt/ sling
Pallet Truck
Megger Tester
Torque Wrench
Hand tools box
Forklift
Alignment tools
Dial gauge, Filler gauge

Personnel

Project Engineer
MEP Coordinator
Construction Superintendent
Site Engineer/Site supervisor
QA/QC Engineer
Safety Officer
Site Foremen
Pipefitters
Helpers

Health, Safety, and Environment Measures

The work will commence as per safety regulations laid down in the contract specification and project health, safety & environment plan.

Proper safety harness to be used and secured if required.

All personal protective equipment shall be used as appropriate according to the nature of the job.

Housekeeping shall be of a good standard and all cut pieces and debris shall be removed.

Ensure that proper scaffolding/ladders are available.

Ensure that shafts are adequately blocked above and below the working level so that no fall of debris/materials takes place.

Reference Documents

Project Specifications
Approved shop drawings (latest revision)
Approved Health, Safety & Environment Plan
Project Quality Plan

Attachments-Method Statement for Chilled Water Pump (CHW) Installation

Inspection Checklist for CHW Pump Installation
ITP for CHW Pump installation