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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:

CONTRACTORS
JOB NO:

2007-0757
DOCUMENT TITLE:

HOLDS

N/A

SHEET NO.

1 OF 17

CONTRACTORS 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



Client: AGIP KCO

Contractor:

Project:
KASHAGAN DEVELOPMENT EXPERIMENTAL PROGRAM
:

Discipline:

RFI No.

Location/:

Date:
:

Karabatan/

Hold Point

Witness Point

ITP No. :

Contract No.

ITP activity code:


:

Description of inspection:
:

INSPECTION DATE

INSPECTION TIME

LOCATION/AREA

Ref. DOCs / DWGs

The above mentioned work activity has been final inspected and accepted.
.

RENCO-KAT/ CONSTRUCTION
-/

RENCO-KAT/ QA/QC

RENCO-KAT / OTHER

- /

- /

Name

Name

Name

Date

Date

Date

Signature

Signature

Signature

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



PART B
Client: AGIP KCO
:

Contractor:
:

Project: Kashagan East Field Development Project


:

Contract No.

RFI No.

Location/:

Date:

Karabatan/

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

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

3B

Preparation and
set up

P
A

Back pain and body injuries due to


improper manual handling

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

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

3B

IB

OVER
ALL
RISK

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

4C

3.

Scaffolding use

P
A

Dropping tools and objects,


dropping of the crew, Scaffolding
collapse, overturn

4.

Electric Shock

P
A

Electric shock due to cable


damage, equipment and switch
damages

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

3B

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 15 of 18

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

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 17 of 18

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 18 of 18