Main Contract 5

Development of Salalah Airport

METHOD STATEMENT FOR INSTALLATION OF DX SPILT UNITS

MCOS (MECHI 09
ACONEX NUMBER: SA-BEN-OSMC-MST-1011
Rev.No

Date

Description

Prepared

28/04/2012

Submittal for Approval

Nachiappan

Checked
QA/QC
R.Menon

Pra

Development of Muscat International and Salalah Airport Project

Contractor Documentation Response to Engineers Conmments

L & T - Galfar Consortium
Contract

MC-5

Contractor

L& T Galfar Consortium

Package

Development of Salalah
Airport
LTG-TRANSMIT-009063

Ref.No.

LTG-TR--0O9063

Contractors
Submission No.
Doc.No.1 Drawing List
SA-BEN-05MC-MST
-1026

Title
Method Statement for

Date

Prepared
N/S
Name

Checked
RM
Sign

Comments to Rev. 2
Ref No.

Comments from Engineer

Date Received by
Contractor
Date Responded by
Contractor
25.04.2012

Contractor's Response

Name

SK
Sign

Name

PROGRAM NAME
MTC - Midfield Terminal Complex Construction

Contents

Page No

1.0 Scope

2.0 Purpose

3.0 References

4.0 Definitions

5.0 Responsibilities

6.0 Resources

7.0 Procedure

8.0 Quality Assurance

11

9.0 Health and Safety

11

10.0 Environment

13

11.0 Attachments

13

1.0 SCOPE
This method statement is applicable for the installation of OX Split Units with refrigerant
piping under MC-5 ACMV scope of work under LTG contract during the entire execution
work.
2.0 PURPOSE
The purpose of this method statement is to define construction sequence contractor intends
to perform in relation to the Installation of OX split unit.
3.0 REFERENCES
General Contract Requirement SA-000-H-11155_ T06_GCR_15.12.2010.
General specification SA-000-M-11507 T01 Mechanical HVAC / refrigeration
Approved Material submittal.
Relevant approved IFC drawings.
Inspection and Test Plan ITP: SA-BEN-05MC-PLN-1012.
HSE Management Plan SA-L TG-05AP-PLN-0003-Rev.2
HSE guide lines for supervisory staff (SA-L TG-SC-PRO-0006).
4.0 DEFINITIONS
Engineer - HILL International LLc
LTG - Larsen & Toubro Galfar Consortium
QCI - QA/QC Inspector
HSE - Health, Safety & Environment
ITP - Inspection and Test Plan
IFC -Issued for Construction
HEMP - Hazard and Effect Management Process
ACMV - Air Conditioning & Mechanical Ventilation
OAMC - Oman Airport Management Company
HVAC - Heating Ventilation & Air Conditioning
UPVC - Un plasticized Polyvinyl Chloride
PVC - Polyvinyl Chloride
MAS - Material Approval Submittal
IR -Inspection Request
QA / QC - Quality Assurance / Quality Control

 PPE - Personal Protective Equipment

TBT - Tool Box Talk
OLS - Over Load Safety
5.0 RESPONSIBILITIES
Construction Manager:
Shall be responsible for control of operation and ensure that the works
are carried as per the Specifications, Drawings and Method Statements. Shall ensure the
Specification, Drawings, Method Statements are available on site and is communicated down to
Site Engineer.
Project Engineer:
Shall coordinate with Construction Managers and Site Engineers and ensure
all the project activities are performed according to the scheduled program, HSE procedures and
Quality procedures.
Site Engineer:
Shall be responsible to ensure site Construction activities are being executed as
per approved Method Statements and Specifications. Coordinate with surveyor to ensure
"Reference points" are complying as per the IFC Drawings. Storage and handling of materials are
as per approved methodology/ General engineering practice. He shall prepare IR and forward it to
QA/QC inspector.
QAlQC Inspector (QCI):
Shall be aware of the daily construction program. Shall attend all
inspection points, record the results of the inspection on the appropriate forms and obtain
the approval signatures. He shall arrange for IR verification from L TG/Engineer, compile
and maintain all inspection records under his control and report to QNQC Engineer.
Identify non- conformances, if any, during the process and report it to the concerned
construction personnel for corrective actions.

HSE Advisor:
Shall advise the line staff & workers on HSE matters; organize I conduct
HSE training , facilitate implementation of HSE requirements, monitor compliance and
report performance and non-performance.
Supervisor:
Shall coordinate with the Site Engineer and shall be responsible for individual
activity. Ensures that all recommended PPE are used by the workers and supervisors.
Ensure that risk control measures are known to workers by arranging daily tool box meetings.

.
6.0 RESOURCES
6.1 Materials
DX Split units consisting of Indoor unit and air-cooled outdoor unit
~ Hi-wall mounted type OX-split units
~ Cassette type OX split units
Inter connecting refrigerant pipes, valves & accessories
Cabling
Vibration isolator pads
Anchor fasteners & Threaded rods
Spring mount hangers

6.2 Manpower
The manpower to be used for the installation includes, but not limited to:
Construction Manager
Project Engineer
Site Engineer
Supervisior
QA/QC inspector
QA/QC Incharge
HSE Advisor
Foreman
Pipe Fitter
Asst Pipe fitter
Rigger
Helper

Equipment and instruments

Equipments

The equipments to be used for the installation includes, but not limited to:
Mobile crane
Mobile scaffold
Drilling Machine
Flaring Tool kit
Copper tube bending Machine
Nitrogen Gas cylinder
Calibrated pressure gauges
Pipe fitter tool box
Vacuum pump
Refrigerant cylinder
Spanners
Fire Extinguisher & Fire Blankets
Electrical Extension Board with Cables
Instrument
Plumb, Spirit level, Chalk line
Torque wrench

7.0 PROCEDURE
7.1 Material Receipt
Verification of quantity as per delivery note, the packing list and country of origin, shall be done
by stores personnel and respective information's shall be conveyed to project engineer.
The project engineer along with OC shall be responsible for checking materials hall received at
the site stores for manufacturer details, MTC as per delivery note and approved Material
Submittal.
Upon verification , Materials are offered through an IR for inspection by OA/OC Engineer to LTG /
CL-JV as per ITP.
Materials received at site shall be verified by supervisor against the delivery note and material
request.

7.2 Material Handling

7.2.1 The weight of the indoor units is max. 30 kg and hence unloading shall be done
manually with sufficient manpower.
7.2.2 Lift manually / Use of Hydraulic Pallet trolley (if required) , inside the building for
shifting the indoor units

7.2.3 The unit shall be handled with care to prevent it from damages, do not drop or
drag it on hard / rough surfaces. .
7.2.4 Where Chain Pulley blocks are more appropriate, suitable capacity of the tested &
certified Chain Pulley blocks shall be used.
7.3 Material Storage
7.3.1 The OX Cooling Units, Copper pipe, pipe fittings and refrigerant pipe insulation
shall be stored over wooden sleeper and valves on pallets.
7.3.2 Materials should be kept covered if stored in open area.
7.4 Preparatory Works
7.4.1 DX Split Units to be installed in accordance with HVAC / Refrigeration, General
specifications SA-000-M-11507 T01, approved shop drawing and manufacturers
recommendation.
7.4.2 All equipment, material shall be received at site as per IFC drawings and site
requirements.
7.4.3 The equipments shall be cleaned before installation using a blower, if found dirty.
7.4.4 Install UPVC sleeves at all pipe openings through walls, partitions and slabs as
per shop drawing.
7.4.5 Indoor/ Outdoor units and its matching pair shall be checked as per drawing and
manufacturer recommendation.
7.4.6 It shall be ensured that the drain connection is available nearest to the indoor unit
condensate drain outlet.
7.4.7 HSE risks involved are assessed as per attached HEMP with current site
conditions.
7.4.8 Approved interface management procedure to be followed wherever coordination
with other works and services are required.
7.5 Installation of Wall mounted indoor units
7.5.1 The indoor units shall be shifted as per clause 7.2.2 to the respective area.
7.5.2 It shall be ensured that the correct unit is shifted to the place of installation.
7.5.3 It shall be ensured that the unit location / orientation / marking are done on
the wall surface for installing the unit as per the approved shop drawings.
7.5.4 The back plate panel of the indoor unit shall be removed and it shall be
placed on the wall for marking the position of hole.
7.5.5 Holes shall be drilled and the fischer shall be fixed accordingly to the hole
size of the back plate panel.
7.5.6 The back plate panel shall be fixed and screwed properly.

7.5.7 Custom made mobile scaffolding shall be arranged for stage wise lifting and
installing the indoor unit.
7.5.8 Indoor unit shall be installed on the slot of the back plate panel (refer
manufacturer's installation manual for further details).
7.5.9 The tray inside the unit shall be inclined and the unit shall be properly

installed at drain point position, so that the proper slope is maintained for the
condensate drain.
7.5.10 The Condensate Drain Pipe installation shall be concealed in the walls as
per IFC Drawing.
7.5.11 The Condensate Drain Pipe outlet in near Drain Point/ Floor Gully
7.5.12 It shall be ensured that the condensate drain connections are made with
adequate slope running trap
7.5.13 The slope of drain piping shall be checked by pouring water.
7.6 Installation of Ceiling mounted indoor units (cassette type OX-split unit)
7.6.1 Steps from 7.5.1 to 7.5.3 shall be followed.
7.6.2 Anchor bolts shall be fixed with threaded rods as per the indoor unit
mounting holes on the ceiling and shall be tightened firmly as per the
manufacturer recommendations.
7.6.3 Custom made scaffolding shall be arranged for stage wise lifting and
installing the indoor unit.
7.6.4 The slope of the drain tray shall be checked in the direction of the drain pipe
connection.
7.6.5 Water shall be filled in the drain tray and it shall be ensured that the water is
drained out completely.
7.6.6 The drain piping shall be connected with U trap as per the approved shop
drawings.
7.6.7 It shall be ensured that the provision for cleaning of U trap shall be provided.
7.6.8 U-trap shall be provided near the indoor unit in liquid line, to ensure oil return at
part loads.
7.6.9 Oil traps shall be fitted to vertical suction risers where outdoor unit is above
indoor unit. A trap shall be fitted at the starting of the vertical riser and then at
5m (maximum) intervals. If the outdoor unit is installed below or at same
level of the indoor unit no trap is required in such installation.
7.7 Installation of Ground I Roof mounted Outdoor units
7.7.1 Prior to installation, outdoor units shall be inspected for any damage during
shipping / storage.
7.7.2 The foundation provided for mounting the outdoor unit shall be checked for
conformance to the required dimensions as per shop drawings/ equipment layout
details.
7.7.3 The surface level of the plinth / foundation shall be flat and uniform. It shall
be checked by using water tube, spirit level, right angle and plumb.

7.7.4 The location of outdoor units shall be marked over the foundation as per the
approved shop drawings.
7.7.5 It shall be ensure that the correct unit is shifted to the place of installation.
7.7.6 The outdoor units shall be manually shifted and positioned with sufficient
manpower to the foundation directly.

7.7.7 Shift and position the roof / Terrace mounted outdoor units, by using mobile
crane of required capacity, to the foundation directly.
7.7.8 The units shall be carefully placed into the position.
7.7.9 The outdoor unit (condenser unit) shall be installed on the plinth as per the
manufacturer recommendations / installation manual.
7.7.10 The anchor bolts shall be fixed as per the outdoor unit mounting holes and
the anti vibration pads shall be placed in between the unit base and the plinth
firmly as per the manufacturer recommendations and the unit base shall be
tightened against the foundation.
7.7.11 Refrigerant piping connections shall be done as per IFC drawing.
7.7.12 Suction and discharge shut off valves shall be provided in the pipe line at the
unit as per the installation manual.
7.7.13 Electrical & control cable connections to the units shall be done as per the
manufacturer recommendations.
7.7.14 The base frame to earth connections shall be done.
7.8 Installation of Copper piping
7.8.1 Copper pipes sizes (based on unit capacity) shall be as per the approved
Material Submittal/Manufacturer recommendations.
7.8:2

Piping support system shall be as per shop drawing / Installation Manual.

7.8.3 It shall be ensured that the proper pipe bending machines and Flaring tools
are used for the piping installations.
7.8.4 Refrigerant pipe routing shall be as per the approved shop drawings in
coordination with other services.
7.8.5 The pipe with insulation (Refer M.ethod Statement for Thermal Insulation of
refrigerant Piping Doc No:- SA-BEN-05MC-MST-1012) shall be carried out
through walls, floor and roof slab and pipe sleeve (Refer Procedure for
sealing of floor and wall opening for duct & pipe Doc No:- SA-BEN-05MCPRO-1005) through them shall be projected minimum
50mm as per
Procedure on either side of the walls, floor and roof slab.
7.8.6 The length and elevation of the piping connection from indoor unit to outdoor
unit shall be measured.
7.8.7 Bend in the copper pipe where required shall be done with copper bending
machine and it shall be ensured by visual examination that there is no
pinching in the copper pipes. Soft tempered copper piping can be applied
where bending occurs.
7.8.8 Burr shall be removed and the edge of the copper pipe shall be smoothly
finished using a file.
7.8.9 The copper pipe joints shall be flanged or flared.
7.8.10 Flaring tools shall be used at the edge of the copper pipes to flare without
crack / damage to avoid leakage in the system.

7.8.11 Flaring nut shall be used for connecting the copper piping into the system.
7.8.12 It shall be ensured that all the flare connections shall be firmly tight and
Teflon tape shall be used to make sure that there is no leak at the
connections.
7.9 Nitrogen leak testing, vacuuming and Refrigerant charging

7.9.1 The completion of the refrigerant pipe installation shall be verified by reviewing the
corresponding documents.
7.9.2 Pressure gauge shall be connected on one end of the pipeline with a pressure
relief valve.
7.9.3 The other end of the pipe line shall be connected to the nitrogen cylinders through
the regulating valve.
7.9.4 The line shall be purged with the nitrogen to a pressure of 300 psi and shall be
kept under the pressure for duration of 2 hrs.
7.9.5 Soap solution shall be applied on all the joints and shall be visually inspected for
leakage.
7.9.6 If leakage is observed in any of the joints, the joint shall be repaired using the
same procedure as that of the original joint and the line shall be retested.
7.9.7 After completion of the leak testing, the line shall be vacuumed to a pressure of
760mm of Hg using a vacuum pump.
7.9.8 The entire line shall be kept under vacuum for duration of 30 minutes.
7.9.9 After the completion of the vacuuming process the line shall be charged with the
refrigerant as per the manufacturer recommendation.
7.9.10 After checking completion of installation, Site Engineer shall coordinate with
QA/QC Engineer for conducting inspection, raising IR and verification by LTG /
Engineer.
7.9.11 IR should be submitted 48 hours prior to Engineer inspection. Approval of this IR
shall be taken as a clearance for the testing and pre-commissioning of the system
Quality Assurance
8.1 Inspection and Test plan (ITP) SA-BEN-05MC-PLN-1 012 shall be referred.
8.2 Availability of latest "Issued for Construction" (IFC) drawings and Specifications
shall be checked.
8.3 Materials used shall be as per approved Material Approval Submittals (MAS)
8.4 Hold Points shall be followed as per ITP.
8.5 Works Execution, Inspection and Tests shall be monitored, witnessed and
recorded as per the Inspection and Test Plan
9.0 Health & Safety
All employees involved in the activity shall undergo LTG site HSE induction course prior to
deployment to the work site.
Site activities shall be carried out in a safe manner according to the approved "Project
Health Safety & Environment plan".

9.1 Training (Workers & Supervisors)

The following HSE training shall be delivered to the crew but not limited to:
Material handling (Mechanical & Manual)
Rigging awareness.

 Use of hand tools / power tools

Fire fighting
Scaffolding Safety
Working at Heights
Chemical Handling / MSDS Awareness
Working with MEWP
Awareness on Emergency response procedure.
9.2 Risk assessment and control - through HEMP
9.2.1 HSE hazards involved in the activities, pertaining to this job has been assessed
through Hazards & Effects Management Process (HEMP) for each and every
activity and the outcome is recorded. (Refer attachment)
9.2.2 The contents in HEMP register shall be disseminated within the crew by the shift
. supervisor / foreman through toolbox talk.
9.2.3 Any new hazards identified other than in the HEMP with reference to site
conditions shall be assessed and control measures shall be taken by the Site
Engineer / Supervisor prior to commencement of any activity.
9.2.4 Following control measures generally apply to all hazards that shall be adopted as
a proactive measure in addition to the specific controls identified in the HEMP Register:
Correct use and maintenance of tools and equipment.
Deployment of competent personnel for the task
Conduct of toolbox talk prior to work commencement
Provision of adequate warning signs, traffic signage barricading, etc.
Good house keeping
Adequate and effective supervision
Use of necessary PPE
Provision of welfare facility
9.3 Additional Personal Protective Equipment (PPEs)
Hand gloves, ear plug & goggles to be used while doing drilling / grinding.
Heavy duty hand gloves to be used for manual handling, handling of materials.
9.4 First Aid I Medical Facility I Emergency Response
Availability of first aiders, with ready access to first aid boxes kept at site shall be ensured
at worksite
Medical facility for the crew when in need, shall be utilizing the clinic / hospital identified for
the purpose.
Ambulance shall be available for attending medical emergencies.
Following are the steps to be taken in case of response to emergencies
~ In case of any emergency, stop the job at site and look at the situation quickly &
carefully assess what help is required.
~ Call LTG emergency number: 93216576 for help.

~ Follow LTG emergency procedures

10.0 Environment
10.1 Environmental Issues
Environmental issues arising from the activities covered in this method statement are
mainly
Oil & Fuel leakage
High noise
Waste generation
Chemical Spillage
10.2 Mitigation Measures
Provision of drip tray / spill kits / Removal of Equipment / vehicle from site
Use of ear plugs while drilling / grinding
Collection and disposal of waste at the designated area
Handling of Chemicals as per MSDS
11.0 Attachments
HEMP
Inspection Test Plan
Inspection Check list

SALALAH AIRPORT PROJECT MAIN CONTRACT 5

METHOD STATEMENT

ATTACHMENT
HEMP

MSS/0497/M/M001

HSE HAZARDS AND EFFECTS MANAGEMENT

PROCESS
(HEMP)

RANKING RISK

LITY PROBABI

Ref: SA-LTG-05MC-MST-1012

ENCE CONSEQU

Activity: Installation of: DX,Spllt

Units & 'Hi Wan Units.

CONTROL MEASURES

RESI
DUAL

RECOVERY MEASURES

MSS/0497/M/M001

HSE HAZARDS AND EFFECTS MANAGEMENT

PROCESS
RANKING RISK

LITY PROBABI

Ref: SA-LTG-05MC-MST-1012

ENCE CONSEQU

(HEMP)
Activity: Installation of: DX,Spllt
Units & 'Hi Wan Units.

CONTROL MEASURES

RESI
DUAL

RECOVERY

MEASURES

MSS/0497/M/M001

HSE HAZARDS AND EFFECTS MANAGEMENT

PROCESS
RANKING RISK

LITY PROBABI

Ref: SA-LTG-05MC-MST-1012

ENCE CONSEQU

(HEMP)
Activity: Installation of: DX,Spllt
Units & 'Hi Wan Units.

CONTROL MEASURES

RESI
DUAL

RECOVERY

MEASURES

MSS/0497/M/M001

HSE HAZARDS AND EFFECTS MANAGEMENT

PROCESS
RISK RANKING

PROBABILITY

HAZARD EFFECT

(A,B,C,D,E)

SIGNIFICANT
SAFETY
HAZARD

(0,1,2,3,4,5)

Ref: SA-LTG-05MC-MST-1012

CONSEQUENCE

(HEMP)
Activity: Installation of: DX,Spllt
Units & 'Hi Wan Units.

CONTROL MEASURES

RESI
DUAL
RISK

RECOVERY

MEASURES

MSS/0497/M/M001

HSE HAZARDS AND EFFECTS MANAGEMENT

PROCESS
(HEMP)
Activity: Installation of: DX,Spllt
Units & 'Hi Wan Units.
Ref: SA-LTG-05MC-MST-1012

CONTROL MEASURES

RECOVERY

MEASURES

(A,B,C,D,E)

RISK RANKING

PROBABILITY

CONSEQUENCE

HAZARD
EFFECT

(0,1,2,3,4,5)

SIGNIFICANT
SAFETY
HAZARD
RESI
DUAL
RISK

MSS/0497/M/M001

HSE HAZARDS AND EFFECTS MANAGEMENT

PROCESS
RISK RANKING

PROBABILITY

HAZARD
EFFECT

(A,B,C,D,E)

SIGNIFICANT
SAFETY
HAZARD

(0,1,2,3,4,5)

Ref: SA-LTG-05MC-MST-1012

CONSEQUENCE

(HEMP)
Activity: Installation of: DX,Spllt
Units & 'Hi Wan Units.

CONTROL MEASURES

RESI
DUAL
RISK

RECOVERY

MEASURES

MSS/0497/M/M001

HSE HAZARDS AND EFFECTS MANAGEMENT

PROCESS

Environment

RISK RANKING

PROBABILITY

RESI
DUAL
RISK

NA
NA

Prepared by
PRABHAKAR.N
HSE Manager

Revision

RECOVERY

MEASURES

NA

(0,1,2,3,4,5)

HAZARD EFFECT

CONTROL MEASURES

(A,B,C,D,E)

SIGNIFICANT
SAFETY
HAZARD

NA
NA

Ref: SA-LTG-05MC-MST-1012

CONSEQUENCE

(HEMP)
Activity: Installation of: DX,Spllt
Units & 'Hi Wan Units.

Date

Hemp ref:

NA

22.04.2012

SA-BEN-05MC-MST -1011

SALALAH AIRPORT PROJECT MAIN CONTRACT 5

METHOD STATEMENT

ATTACHMENT
INSPECTION & TEST PLAN

MC-S, DEVELOPMENT OF SALALAH

AIRPORT
ITP-INSPECTION AND TEST PLAN-SABEN-OSMC-PLN-OO11
Contract No: Main Contract MC-5
Discipline:

SI.
No.

Activity
Description

Installation of Air Handling Units

Reference : Method Statement

Characteristics
to be Checked

Metho
d of
check

Quant
um of
check

Referenc
e
document

Acceptanc
e norm

Forma
t of
record

Responsibility
BE
C

LTG

CLJV

SALALAH AIRPORT PROJECT MAIN CONTRACT 5

METHOD STATEMENT

ATTACHMENT
INSPECTION CHECKLIST

FORMS INDEX
LIST OF ATTACHED FORMS

S.NO

SL
N
O

REFERENCE

Checks

REV
NO

DOC.NO

REV
NO

Require
d

DESCRIPTION

Inspection
(QA/QC-BEC)

Inspection
(QA/QC-BEC)

Signatur
e

Signatur
e

Date

Dat
e

Remark
s

Write N/A if not applicable

Comments:

Organization
Name

Signature
Date

BEC

LTG

CL-JV