Method Statement for Air Leak Test for HVAC Duct System (Light Test)

ORIGINATING COMPANY: RENCO-KAT

DOCUMENT NUMBER:

PROJECT: KASHAGAN DEVELOPMENT EXPERIMENTAL PROGRAM

KE01-A1-000-RK-M-TT-0002-000

CONTRACT DESCRIPTION: SIS BUILDING CONSTRUCTION PROJECT AGIP KCO CONTRACT NO:

CONTRACTOR’S JOB NO:

2007-0757 DOCUMENT TITLE:

HOLDS

N/A

SHEET NO.

1 OF 17

CONTRACTOR’S DOCUMENT NUMBER:

METHOD STATEMENT FOR AIR LEAK TEST FOR HVAC DUCT SYSTEM (LIGHT TEST)

ABSTRACT: This method statement is the document detailing how HVAC Ducting system are tested (Light Test) for KEP SIS (Kashagan Experimental Program – Satellite Instrument Station) Building (Oil, Gas & Sulphur) Construction Project

C01

17.11.2008

Issued for Construction

AHD

A.Dhakan

D.Belpassi

P01

21.10.2008

Issued for Review

AHD

A.Dhakan

D.Belpassi

REV

DATE

REASON FOR ISSUE

PREPARED

CHECKED

APPROVED

REVISION DESCRIPTION SHEET

COMPANY

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 2 of 18

Rev.

Para.

Revision Description

P01

-

Issued for Review

C01

-

Issued for Construction

Para.

Description of Hold

Hold No.

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 3 of 18

AGIPKCO KASHAGAN DEVELOPMENT EXPERIMENTAL PROGRAM

RENCO-KAT METHOD STATEMENT FOR AIR LEAK TEST FOR HVAC DUCT SYSTEM (LIGHT TEST) KE01-A1-000-RK-M-TT-0002-000 rev C01

November 2008

LIST OF CONTENTS

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 4 of 18 1.0

PURPOSE........................................................................................................................................................................5

2.0

SCOPE.............................................................................................................................................................................5

3.0

REFERENCES :.............................................................................................................................................................5

4.0

DEFINITIONS AND ABBREVIATIONS....................................................................................................................6

5.0

ROLES AND RESPONSIBILITIES.............................................................................................................................6

6.0

HSE..................................................................................................................................................................................7

7.0

METHODOLOGY.........................................................................................................................................................7

8.0

QUALITY ASSURANCE AND CONTROL PROCEDURE.....................................................................................8

9.0

ATTACHMENTS............................................................................................................................................................8

1 2 3

REQUEST FOR INSPECTION...................................................................................................................................... 8 RISK ASSESSMENT................................................................................................................................................... 8 ATTACHMENT FROM SMACNA (HVAC DUCT CONSTRUCTION STANDARDS).............................................8

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 5 of 18

1.0

PURPOSE The purpose of the method statement is to describe the method of testing HVAC Duct system for air leak (by light test) that will be performed in the scope of SIS buildings at Kashagan Field Development Project Finishing of Satellite Instrument Shelter Buildings (Oil, Gas & Sulphur). This statements made shall be followed by Supervisors and Foremen without omissions.

2.0

SCOPE The Method Statement defines the methodology of carrying out air leak test by light in HVAC Duct system related to Satellite Instrument Shelter Buildings (Oil, Gas, Sulphur).

3.0

REFERENCES : KE01.A0.690.KD.C.SF.0001.000

Functional Specification for HVAC and Building Utility Industrial Building Areas

KE01-A1-690-KD-C-SP-0012-000

Ductwork Specification

KE01-A1-690-KD-C-SP-0006-000

Dampers Specification

KE01-A1-690-KD-C-SP-0009-000

Air terminal devices specification

KE01-A1-690-KD-C-SP-0016-000

Sound attenuator specification

KE01-A1-690-KD-C-SF-0007-000-F02

Specification Oil area buildings

KE01-A1-690-KD-C-SF-0009-000-F02

Specification Gas area buildings

KE01-A1-690-KD-C-ST-9501-000

Technical specification buildings electric substation and compressor house

KE00.KPD.CIO.GL.0001.000

Guidelines for HVAC Codes and Standards

KE01.A0.690.KD.C.HF.0040.001

HVAC Legend and Symbols

KE01-A1-000-RK-M-TT-0001-000

Method Statement for Installation of HVAC System

KE01-A1-000-RK-Q-QC-0010-000

Inspection and Test Plan for Installation of HVAC System

KE01-00-000-AK-H-PR-0601-000

HSE Plan

KE01-A1-000-RK-Q-QC-0001-000

Contract Quality Plan

SniP RoK 4.02-05-2001

Building Regulations: Heating, Ventilation and Air Conditioning

ASHRAE

American Society of Heating, Refrigeration and Air Conditioning Engineers (1997 Handbook Fundamentals, 2000 HVAC Systems and Equipment)

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 6 of 18

Chartered Institute of Building Services Engineers (Publication B3: Ductwork) Heating and Ventilating Contractors Association (United Kingdom); publications including the following: NFPA 90A/90B National Fire Protection Association UL Underwriters Laboratories CIBSE

4.0

DEFINITIONS AND ABBREVIATIONS Company Contractor HSE PPE TRIC TBT

5.0

AGIP KCO RENCO-KAT Health, Safety & Environment Personal Protective Equipment. Toolbox Talk Risk Identification Card Toolbox Talk

ROLES AND RESPONSIBILITIES Project Manager : Has ultimate responsibility of compliance of work to, relevant methodologies,

standards, specifications listed, while assuring adequate organization

resources to conduct the work. QA/QC Manager : Responsible for controlling and directing the activities complying with the quality requirements given in the references. He reports to the Project Manager. HSE Manager: Responsible for the maintaining of the HSE Plan and management system. He reports to the Project Manager. Construction Manager: Shall plan the work schedule and coordinate with project manager for the methodology and resources required to conduct the work. And he ensures that Project safety Procedures are being implemented. Site QC Inspector: Shall perform first line inspections and follow it with developing and implementing Inspection Requests in accordance with Construction priorities. Accompany Agip KCO Inspectors to carry out routine Inspections when requested. Supervisor: shall be responsible for Inspection of the HVAC system to ensure quality and confirm compliance with project documents and specifications. Timely delivery of the material to site and ensure the work is progressing according to the schedule. Provide technical directions and monitor "checkout test" associated with pre-commissioning. Evaluate shipping damage to HVAC materials and recommend corrective action. He reports to construction manager. Shall ensure that the work crew under his supervision shall work according to safety standards. Foreman: He is directly in charge of the crew, equipments and material being used to conduct the work. He shall ensure that all work performed under his supervision shall be performed according to approved project HSE procedures.

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 7 of 18

6.0

HSE 

All work shall be carried out in accordance to AGIP KCO and Renco-KAT safety regulations & policies.



Team coordination shall be implemented by the work supervisor.



All personnel related to work shall wear PPE.



Valid certification of all lifting equipment will be verified prior to operation.



All personnel involved in HVAC installation shall be competent enough and well conversant with the works to be carried out.



When working at height, safety harness with double lanyard shall be fixed with approved safety life line, and man lift/scaffolding shall be used.



Scaffolding shall be erected/approved/dismantled under supervision of scaffolding supervisor.



If lifelines are used, it will be designed to withstand a load of 2275 Kg per person attached to the line.



Only two persons may be attached to a lifeline at any time. After implementation, a lifeline needs to be inspected on a regular basis.



AKCO HSE must be notified if a lifeline is going to be used.



All man lifts / trucks / cranes to be inspected & approved for use on site.



All lifting equipments /tackle to be inspected & certified prior to use and shall adhere to AKCO color coding procedure

7.0



TRIC & TBT to be conducted prior to start of work.



Continuous HSE coverage to be available.

METHODOLOGY 

To verify whether duct is free of the air leak - smoke test, light test or leakage test as per code ASHRAE can be used.



By SMACNA “HVAC Duct Construction Standards” - testing of low pressure ducts for leakage is untested (see attachment 3). Because ducts are low pressure can be used light test to verify connection of the elements duct, prior start insulation. The points of leakage if found any shall be sealed with approved sealing material.

Follow following sequence: 

Duct prepared – all openings to be closed;



To be provided temporary earthing protection for duct;

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 8 of 18



To provide the light – inside the duct, access door dampers cab be used;



Source of the light inside the duct – can be simple lamp 100-200W, portable with protection



Mechanic, flexible cable (30m-50m) and possibility to switch ON/OFF;



The lights inside the room where testing to be carried out shall be switched off at the time of test.



Scaffolding will be provided to access the ducts



Total darkness shall be maintained at test area during the test.



Check at every joint – the light from outside shall not be visible.



If any defects found, the point shall be marked and then rectified/sealed after finishing the test

8.0



After rectification, the test to be repeated;



Test to be done for each section of the duct (supply and return duct);

QUALITY ASSURANCE AND CONTROL PROCEDURE Request for Inspection (RFI) shall be submitted to QA/QC section prior to commencing the installation work as per ITP KE01-A1-000-RK-Q-QC-0010-000. The supervisor in coordination with the QA/QC inspector shall inspect all the necessary requirements prior to carrying out light test, thus ensuring the readiness of the work.

9.0



Check all Applicable Documents & Specifications available & are approved.



Inspection of Tools and Equipment.



Check all arrangements done for carrying out light test.

ATTACHMENTS 1 Request for Inspection 2 Risk Assessment 3 Attachment from SMACNA (HVAC DUCT CONSTRUCTION STANDARDS)

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 9 of 18

ATTACHMENT 1 REQUEST FOR INSPECTION

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 10 of 18

REQUEST FOR INSPECTION ЗАПРОС НА ПРОВЕДЕНИЕ ИНСПЕКЦИИ Client: AGIP KCO

Contractor:

Заказчик: АДЖИП ККО

Подрядчик:

Project: KASHAGAN DEVELOPMENT EXPERIMENTAL PROGRAM Проект: Проект разработки восточного месторождения Кашагана

Discipline:

RFI No.

№ контракта.

№ ЗНИ

Location/Местонахождение:

Date: Дата:

Karabatan/ Карабатан

Hold Point  Witness Point 

ITP No. :

Дисциплина:

Contract No.

№ ППТ:

ITP activity code: Код деятельности ППТ:

Description of inspection: Описание инспекции:

INSPECTION DATE

INSPECTION TIME

ДАТА ИНСПЕКЦИИ

LOCATION/AREA

ВРЕМЯ ИНСПЕКЦИИ

МЕСТОНАХОЖДЕНИЕ

Ref. DOCs / DWGs

Ссылка на Документы/ Чертежи

The above mentioned work activity has been final inspected and accepted. Вышеуказанная работа была проинспектирована и принята.

RENCO-KAT/ CONSTRUCTION Ренко-КАТ/ СТРОИТЕЛЬНЫЙ ОТДЕЛ

RENCO-KAT/ QA/QC

RENCO-KAT / OTHER

Ренко-КАТ / ОТДЕЛ КОНТРОЛЯ КАЧЕСТВА

Ренко-КАТ / ДРУГИЕ

Name Имя

Name Имя

Name Имя

Date Дата

Date Дата

Date Дата

Signature Подпись

Signature Подпись

Signature Подпись

Validated by AKCO / CONSTRUCTION Date & Time:

Name:

Signature:

Received by AKCO / QA-QC Date & Time:

Name:

Signature:

RFI Acceptance & Inspection Result ACCEPTED

REJECTED A) Work is not ready at the inspection time.

See AKCO comments attached

B) Result of inspection is not acceptable. RFI shall be issued. C) See AKCO comments attached.

AKCO / QA-QC Name

Date & Time

Signature

New

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 11 of 18

REQUEST FOR INSPECTION ЗАПРОС НА ПРОВЕДЕНИЕ ИНСПЕКЦИИ PART “B” Client: AGIP KCO Заказчик: АДЖИП ККО

Contractor: Подрядчик:

Project: Kashagan East Field Development Project Проект: Проект разработки восточного месторождения Кашагана

Contract No.

RFI No.

№ контракта.

№ ЗНИ

Location/Местонахождение:

Date:

Karabatan/ Карабатан

Дата:

Comments:

……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ……………………………………………………………………………………………………………… ………………………………………………………………………………………………………………

AKCO / QA-QC Name

Date & Time

Signature

RENCO-KAT / QA-QC Name

Date & Time

Signature

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 12 of 18

ATTACHMENT 2 RISK ASSESMENT ФОРМА ОЦЕНКИ РИСКА

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 13 of 18

RENCO Risk Assessment Worksheet TASK/ACTIVITY

PROJECT/LOCATION

GENERAL HAZARD TYPE

REPORT NO

HVAC DUCT SYSTEM AIR LEAK TEST (LIGHT TEST)

KEPSIS/KARABATAN

EQUIPMENT

RA-027

RISK ASSESSMENT (NO CONTROLL) S.N

JOB STEP

TARGET

UNDESIRABLE EVENTS

CONTROL MEASURES SEVE RITY

LIKELIH OOD

RISK

  P A 1.

Slips , Trips & Falls due to poor house keeping in work area

3

B

3B

 

Preparation and set up

P A

Back pain and body injuries due to improper manual handling

1

C

IC

  

RISK ASSESSMENT (WITH CONTROLL) SEVER LIKE ITY LIHO OD

Proper PPE Make sure that have a correct foot wear to suit the ground condition Job site must be kept clean and free of obstruction in working areas Walk slowly if there are slippery or uneven conditions

3

Proper PPE Proper Training on manual handling Prefer to mechanical means of manual handling

1

3B

IB

OVER ALL RISK

M

L

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct system (Light Test) Rev. C01, November 2008 Page 14 of 18 RISK ASSESSMENT (NO CONTROLL) S.N

JOB STEP

TARGET

UNDESIRABLE EVENTS

CONTROL MEASURES SEVE RITY

LIKELIH OOD

RISK



2.

Working at height

P A

Falling from height Falling objects

 4

C

4C    

3.

Scaffolding use

P A

Dropping tools and objects, dropping of the crew, Scaffolding collapse, overturn

2

2

M   

4.

Electric Shock

P A

Electric shock due to cable damage, equipment and switch damages

2

2

M

 

Wear full body harness (double lanyard with shock absorbers) and 100% tie-off on heights. Adequate access and egress arrangements and suitable working platforms at the place of work RA/Safety training awareness Necessary barricades and indication at the ground level Always follow safe work practices Scaffolding shall be assembled by certified worked and supervised according to the specific procedure Toe- boards need to be used Egress/Ingress points always need to be assigned Always temporary power lines needs to be attached to scaffolding or working platform by a certified electrician Illumination shall be arranged and tested during day light There shall be qualified electrician on site with quick access to location.

RISK ASSESSMENT (WITH CONTROLL) SEVER LIKE ITY LIHO OD

OVER ALL RISK

3

3B

M

1

1

M

1

1

M

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ATTACHMENT 3 ATTACHMENT FROM SMACNA

RENCO-KAT CONSTRUCTION&ENGINEERING KE01-A1-000-RK-M-TT-0002-000 KEP SIS Method Statement for Air Leak Test for HVAC Duct System (Light Test) Rev.C01,November 2008 Page 16 of 18

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