AHI Carrier Fzc

A Carrier Joint Venture Company

B1 (22-24) SAIF Zone – P O Box 122341 Sharjah - U A E

Tel: +971 6 5045700 Fax: +971 6 5572278
Email: [email protected]

Method Statement
Brief Description of work: Supply, Testing and Commissioning of Toshiba SMMSe VRF Airconditioning
systems.

Introduction.

This document is intended to provide an outline to the work flow and standard installation process from
installation to commissioning phase.

The general procedure and sequence for installation of airconditioning units is mentioned below which may
change as per the actual site conditions and scope of work.

AHI Carrier technical support engineer will provide the installation training for Toshiba VRF systems to the
contractor / installer’s site engineer and technician team. Work progress and routine site coordination with
client team will be handled by the contractor/ installer site engineer. AHI Carrier engineer will randomly visit
the site for installation and quality inspection and advice on points wherever rectifications are required to be
done for satisfactory performance of system.

The site engineer from Installer / contractors side will ensure that health and safety norms shall be followed
during project execution stages.

Protective Gear

When an air conditioner is to be transported, installed, maintained, repaired or removed installer team will
use below mentioned protective gears for different activities to follow safety norms.

Work Undertaken Protective gear to wear

All type of work Protective gloves and safety working clothing
Electrical related work Gloves and heat insulating shoes and proper clothing to provide
protection from electrical shocks
Piping work Protective gloves and safety working clothing, Safety shoes, Eyewear,
Fire blanket & extinguisher, Oxy Acetylene Cyliner regulators and back
flash arrester
Work at height - 50cm or more Helmets and safety belts , eyewear, shoes,
Transportation of heavy objects Safety shoes with protective toe cap

A Limited Liability Company, registered with the Sharjah Airport International Free Zone.
Certificate of Incorporation No. 3574. Share Capital: USD 80,304.
Tools:-
1. Manifold gauge for R410A
2. Charging hose
3. Refrigerant Charging cylinder.
4. Vaccum pumps with counter flow preventive adapter.
5. Flaring tool.
6. Mechanical benders.
7. Torque wrench.
8. Screw driver sets.
9. Electronic Micron gauge.
10. Digital Weighing scale.
11. Tube cutter set.
12. Brazing set with necessary arrangement.

Material:-
As per Toshiba recommendations
1. Cu pipes for R410A refrigerant systems.
2. Insulation.
3. Drain pipe.
4. Control and Power cables with necessary lugs/ thimbles.

Storage:-
The units and installation material like cu tube, insulation will be properly handled and in case of storage,
will be ensured to be kept properly covered in store to avoid damages to same.
Protection covering (cap/tape) will be used during storage and installation of cu piping in order to prevent
water / moisture, contamination or dust to avoid entry.

Basic principles work method for cu piping work

Cu piping installation actual lengths will be ensured within range as per Toshiba selection details and
installation process will be done as per recommendations of Toshiba as mentioned below.

1. Clean
a. Acetone Cleaning
b. Nitrogen Purging
To ensure cu piping inner surface is clean and dirt, dust, foreign particles free.
2. Tight
a. Flaring
b. Bending
c. Brazing with nitrogen displacement.
d. Pressure testing
To ensure the piping is intact and safe to handle the system working pressure.
3. Dry
a. Vaccum Testing
To ensure the system is free from moisture and for satisfactory performance of the SMMSe system.

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 Work flow

Prior to installation

Determination of extent of work ................................... ………..Identify the scope of work

Drafting of drawings ..................................................... …….….Draft- Refrigerant piping line diagrams.
- Control & power wiring line diagrams.
Installation

Pipe pre-install engineering………………………………………Ensure the sleeve/insert in civil works as per requirement.

Installing indoor unit………………………….………………….…Make sure the unit model is correct and at location.

Refrigerant piping …...……………………..…….Keep the refrigerant pipes dry, clean and sealed. While
brazing of cu pipes, ensure nitrogen displacement.
Condensate drain piping .............................................. ………..Downward inclination. Ensure Slope Min.1:100

Air duct work ............................................................. …… …Ensure sufficient flow rate and designed size & lengths.

Thermal & Accoustic insulation……………………………………Ensure no gap between the thermal insulation materials

Control wiring…………………………………………………..… Select & install proper control wire as per specifications.

Outdoor unit installation.………………………………….Ensure and install units horizontally as per recommendations to

avoid short-circuit ventilation and ensure sufficient with vibration
isolators.Ensure sufficient space around units as per guidelines.

Air tightness test. ......................................................... Check whether the air pressure remains at 4.15Mpa (R410a) after
correction is made within 24 hours
Vacuum drying…………………………………………....Use vacuum pump with vacuum degree of less than -775mmHg
and check Vaccum reading of 5 Torr or min for 1 hr hold.

Refrigerant charging .................................................... Record the amount of refrigerant to be recharged on the outdoor
unit and document it as per liquid line lengths.
Electric power wiring……………………………… Select and install proper power wire and isolators as per
specifications.

Pre commissioning check………………………………………….…Check the readiness of system.

Test Run and commissioning ...................................... …………..To check and record the system parameters.

Delivering operation instructions .................................. …………...Provide operation training to facility team.

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Quality Control
AHI Carrier Engineer - Technical support, will randomly visit the site for inspection to confirm that the
Toshiba recommended installation standards are followed and advice on points wherever rectifications/
improvements are required to be done for satisfactory performance of system.

Pre commissioning Check – Toshiba SMMSe VRF System

The following items will be checked by installer engineer at site prior to planning commissioning of system
1. Workshop drawings:
To cross check and compare the length and route of cu piping and cabling actual installed with necessary
cu pipe lengths and unit details like sr.no. & model no. mentioned on same.
2. Refrigerant Cu piping:
Refrigerant pipe sizes, y joints positions, cu pipe insulation work should be checked and ensured work is
completed along with insulation patchwork.
3. Pressure Test and Vaccum Drying Reports:
The Pressure testing and Vaccum drying should be completed as per work method ANNEXURE I&II.
4. Additional refrigerant quantity calculation format and system info:
The additional refrigerant quantity and system details with necessary information should be provided to
cross check and record as per work method ANNEXURE III & IV.
5. Drain Pipe:
Condensate drain piping must be completed with insulation and proper slope.
6. Control wiring:
Continuity test for control wiring should be done after installation and wiring should be completed till unit
terminal connections. Use lugs/thimbles at termination.
7. Power Supply wiring:
The Power supply to equipments with correct rating isolators and cable sizes and earthing should be
ready. Use lugs/thimbles at termination.
8. Additional refrigerant charge and Weighing scale:
Add. Refrigerant quantity should be arranged and available at site before commissioning.

Testing and Commissioning of Toshiba SMMSe VRF systems

1. Additional refrigerant charging

2. Field settings and Turn Power On for units
2. Indoor Unit Address settings
3. Field setting
4. Test Run and Normal operation
5. Recording of data
6. Handover

AHI Carrier Engineer - Service, will provide support for testing and commissioning of Toshiba SMMSe VRF
systems.