Method Statement For Installation Installatio n of Refrigerant Piping
MS/485/AC-09
PR!"C#$ A% MAFRA& 'IA%(SIS 'IA%(SIS C")#"R C ")#"R
Page$ * of +
Method Statement For Installation of Refrigerant Piping
Prepared by:
Reviewed by:
Approved by:
Revision: 01
Project Engineer / QA/QC Engineer
Construction Manager
Project Manager
Date:!"0#"011
Method Statement For Installation of Refrigerant Piping
MS/485/AC-09
PR!"C#$ A% MAFRA& 'IA%(SIS C")#"R
Page$ , of +
I)#R'C#I)
$%is is a brie& out'ine o& (ua'ity syste) to be i)p'e)ented* +t contains a wor, )et%odo'ogy and procedure- w%ic% is app'icab'e wit% t%e speci&ic wor,* $%is )anua' a'so provides an appropriate re&erence to a'' procure)ent- &abrication and construction activities and identi&ies (ua'ity re'ated )atter*
PRPS"
$%is Met%od .tate)ent is designed to give guidance &or t%e Installation of Refrigerant Piping constructions*
C)'I#I)
$o insta'' t%e +nsta''ation o& Re&rigerant Piping )eeting a'' re(uire)ents &or t%e overa'' activities de'ivering good wor,)ans%ip and up to t%e 'eve' acceptab'e standard*
R"F"R")C"S
Spe.ifi.ation Referen.e as follos .ection 1110- Page --2 o& 11 .ection 113#- Pages to 10 o& 10 'raing Referen.es as follos
.%op drawing re& As per 45AC Drawings +6C drawing re& As per 45AC Drawings
Material S1mittal Referen.e
$./A.C/A1#/MEP"M$/AC"17- Rev 0 MA#"RIA% 2A)'%I)3 A)' S#RA3" A# SI#"
18 A'' )ateria's s%a'' be care&u''y o&&"'oaded at site using necessary )anpower in suc% a way t%at no da)age is caused to pipe* 8 Materia' wi'' be inspected at o&& 'oading point &or any p%ysica' da)age and co)p'eteness- M+R s%a'' be sub)itted to consu'tant &or veri&ication / approva'* #%S A)' "&IPM")#
Method Statement For Installation of Refrigerant Piping
MS/485/AC-09
PR!"C#$ A% MAFRA& 'IA%(SIS C")#"R
Dri'' Mac%ine*
4i'ti Mac%ine*
4and too's*
9raing set*
.pirit ;eve'*
6'aring set*
$ube cutter*
5accu) pu)p*
Cutting ,ni&e*
$ube bender*
Page$ of +
R6 I)S#RC#I)S
$%e insta''ation wor,s wi'' be carried out strict'y in accordance wit% t%is docu)ents / speci&ications / approved )ateria' sub)itta'* PRC"'R" *7 3")"RA% R"&IR"M")#
MA$ER+A;: Copper pipes- Copper &itting- C'a)p support- $%readed rod- y"Acety'ene cy'inder wit% co)p'ete set- 9raing rod and copper pipe insu'ation* ,7 PIPI)3 I)S#A%%A#I)S
18 +nsta'' piping as s%ort and direct as possib'e- wit% a )ini)u) nu)ber o& joints- e'bows and &ittings as reco))ended by e(uip)ent supp'ier piping 'ayout* 8 Pipe s%a'' be cut accurate'y to )easure)ents estab'is%ed at t%e construction site and s%a'' be wor,ed into p'ace wit%out springing or &orcing* #8 +nsta'' piping wit% ade(uate c'earance between pipe and adjacent wa''s and %angers or between pipes &or insu'ation insta''ation* ?se s'eeves t%roug% &'oors- wa''s- or cei'ings- sied to per)it insta''ation o& &u'' t%ic,ness insu'ation* 8 +nsta''ation )ust be as rapid as possib'e so t%at signi&icant (uantities o& )oisture- air or ot%er i)purities %ave 'itt'e c%ance o& co''ecting in t%e syste)*
Method Statement For Installation of Refrigerant Piping
MS/485/AC-09
PR!"C#$ A% MAFRA& 'IA%(SIS C")#"R
Page$ 4 of +
8 Pipe s%a'' be provided wit% capping or p'ugged ends w%en s%ipped and as erected- to prevent conta)inating t%e syste)* 28 Pipe )ust be cut wit% a tube cutter- rea)ed and burrs re)oved* !8 9ot% inside o& &ittings and outside o& tubing s%a'' be we'' c'eaned wit% an abrasive c'ot% or stain'ess stee' wire brus% be&ore braing* 38 A'' braed joints s%a'' be c'eaned to re)ove residua' &'u>* 78
Re)ove interna' and e>terna' burrs wit% a de"burring too'- as app'icab'e*
7 RAI)3
$%e tube wi'' be cut to desired 'engt% wit% a s(uare cut- pre&erab'y in a s(uare"end sawing vise* $%e cutting w%ee' o& t%e type speci&ica''y designed &or cutting copper tube wi'' a'so be used to do a satis&actory job* $%e tube wi'' be t%e e>act 'engt% needed- so t%at t%e tube wi'' enter t%e cup o& t%e &itting a'' t%e way to t%e s%ou'der o& t%e cup* Re)ove a'' s'ivers and burrs 'e&t &ro) cutting t%e tube- by rea)ing and &i'ing- bot% inside and outside*
$o )a,e a proper braing joint- t%e c'earance between t%e so'der cup and t%e tube wi'' be appro>i)ate'y 0*001@ to 0*010@ 0*0)) to 0*))8* Maintaining a good &it on parts to be braed insures:
Ease o& App'ication B e>cessive'y wide to'erances tend to brea, capi''ary &orce and- as a resu't t%e a''oy wi'' eit%er &ai' to &'ow t%roug%out t%e joint or )ay &'us% out o& t%e joint*
Corrosion Resistance B t%ere is a'so a direct re'ation between t%e corrosion resistance o& a joint and t%e c'earance between )e)bers* $%e sur&aces to be joined wi'' be c'ean and &ree &ro) oi'- grease and %eavy o>ides* $%e end o& t%e tube need be c'eaned on'y &or a distance s'ig%t'y )ore t%an it is to enter t%e cup* .pecia' wire brus%es designed to c'ean tube ends )ay be used- but t%ey s%ou'd be care&u''y used so t%at an e>cessive a)ount o& )eta' wi'' not be re)oved &ro) t%e tube* 6ine sand c'ot% or e)ery c'ot% wi'' a'so be used wit% t%e sa)e precautions*
Method Statement For Installation of Refrigerant Piping
MS/485/AC-09
PR!"C#$ A% MAFRA& 'IA%(SIS C")#"R
Page$ 5 of +
$%e cup o& t%e &itting wi'' be c'eaned by )et%ods si)i'ar to t%ose used &or t%e tube end- and care s%ou'd be observed in re)oving residues o& t%e c'eaning )ediu)* 9raing a''oys wi'' not &'ow over or bond to o>ides and oi'y or greasy sur&aces tend to repe' &'u>es- 'eaving bare spots w%ic% wi'' o>idie- resu'ting in voids and inc'usions* .o )a,e sure above is )entioned de&iciencies wi'' be overco)e by good wor,)ans%ip*
6'u> wi'' be app'ied to t%e tube and so'der cup sparing'y and in a &air'y t%in consistency* Avoid &'u> on areas not c'eaned* Particu'ar'y avoid getting e>cess &'u> into t%e inside o& t%e tube itse'&*
+))ediate'y a&ter &'u>ing- t%e parts to be braed wi'' be asse)b'ed* +& &'u>ed parts are a''owed to stand- t%e water in t%e &'u> wi'' evaporate- and dried &'u> is 'iab'e to &'a,e o&&- e>posing t%e )eta' sur&aces to o>idation &ro) t%e %eat* Asse)b'e t%e joint by inserting t%e tube into t%e cup%ard against t%e stop* $%e asse)b'y wi'' be &ir)'y supported so t%at it wi'' re)ain in a'ign)ent during t%e braing operation*
9raing wi'' be started by app'ying %eat to t%e parts to be joined* $%e pre&erred )et%od is by t%e o>yacety'ene &'a)e* A s'ig%t'y reducing &'a)e wi'' be used- wit% a s'ig%t &eat%er on t%e inner b'ue cone t%e outer portion o& t%e &'a)e- pa'e green* 4eat t%e tube &irst- beginning at about one inc% &ro) t%e edge o& t%e &itting* .weep t%e &'a)es around t%e tube in s%ort stro,es up and down at rig%t ang'es to t%e run o& t%e tube* +t is very i)portant t%at t%e &'a)e be in continuous )otion and wi'' not be a''owed to re)ain on any one point to avoid burning t%roug% t%e tube* enera''yt%e &'u> )ay be used as a guide as to %ow 'ong to %eat t%e tube- continuing %eating a&ter t%e &'u> starts to bubb'e or wor,- and unti' t%e &'u> beco)es (uiet and transparent- 'i,e c'ear water* $%e &'u> wi'' pass t%roug% &our stages:
A* At 16 100C8 t%e water boi's o&&*
9* At 2006 #1*2C8 t%e &'u> beco)es w%ite and s'ig%t'y pu&&y and starts to wor,*
Method Statement For Installation of Refrigerant Piping
MS/485/AC-09
Page$ : of +
PR!"C#$ A% MAFRA& 'IA%(SIS C")#"R
C* At 3006 2*!C8 it 'ays against t%e sur&ace and %as a )i',y appearance*
D* At 11006 7#*#C8 it is co)p'ete'y c'ear and active and %as t%e appearance o& water*
on t%e &itting beco)es (uiet* Avoid e>cessive %eating o& cast &ittings* F%en t%e &'u> appears 'i(uid and transparent on bot% t%e tube and t%e &itting- start sweeping t%e &'a)e bac, and &ort% a'ong t%e a>is o& t%e joint to )aintain %eat on t%e parts to be joinedespecia''y toward t%e base o& t%e cup o& t%e &itting* $%e &'a)e wi'' be ,ept )oving to avoid burning t%e tube or t%e &itting*
App'y t%e braing wire or rod at a point w%ere t%e tube enters t%e soc,et o& t%e &itting* $%e te)perature o& t%e joint s%ou'd be %ot enoug% to )e't t%e braing a''oy* Geep t%e &'a)e away &ro) t%e rod or wire as it is &ed into t%e joint* Geep bot% t%e &itting and t%e tube %eated by )oving t%e &'a)e bac, and &ort% &ro) one to t%e ot%er as t%e a''oy is drawn into t%e joint* F%en t%e proper te)perature is reac%ed- t%e a''oy wi'' &'ow readi'y into t%e space between t%e tube outer wa'' and t%e &itting soc,et- drawn in by t%e natura' &orce o& capi''ary attraction* F%en t%e joint is &i''ed- a continuous &i''et o& braing a''oy wi'' be visib'e co)p'ete'y around t%e joint* .top &eeding as soon as t%e joint is &i''ed*
47 C%AMPS ; SPPR#S
A'' piping s%a'' be rigid'y supported &ro) t%e bui'ding structure &ro) t%e bui'ding structure by )eans o& rubber 'ined supports* ?nistrut %angers s%a'' be used w%ere pipes run side by side* 4anger spacing s%a'' be &o''ows: 4orionta': Copper piping
#/3H and under JH t%roug% KH
Ma
I 2I
Method Statement For Installation of Refrigerant Piping
MS/485/AC-09
Page$ + of +
PR!"C#$ A% MAFRA& 'IA%(SIS C")#"R
H and 'arger
10I
5ertica': Copper piping s%a'' be supported at 10 &eet interva's )a>i)u)* Pipe &i>ing brac,ets- C'ips- etc* )ust be pitc%ed to suit t%e pipe dia)eter and 'oad &ro) c o)ponents )ounted in t%e 'ine* 57 %"A6 #"S#I)3 F R"FRI3"RA)# PIPI)3 S(S#"M=
$%e testing )edia s%a'' be dry nitrogen* $EM s%a'' per&or) t%e 'ea, test be&ore insu'ationevacuating and c%arging* +so'ate t%e co)pressor &ro) t%e 'ea, test by &ir)'y c'osing t%e suction and disc%arge va'ves* Do not atte)pt to repair any 'ea, w%i'e t%e syste) is pressuried* +& any 'ea, are &ound- re'ieve t%e rest pressure and per&or) repairs* :7 #"S# A)' A%A)C"
$%e entire re&rigerant syste)- inc'uding a'' contro' syste) s%a'' be tested and ba'anced be&ore operation* SAF"#(
1* A'' insta''ation wor, wi'' be underta,en in accordance wit% $EM sa&ety p'an* * A'' site personne' s%a'' be provided wit% t%e necessary persona' protective )easures suc% as %ead gear- sa&ety boots- sa&ety be'ts L gogg'es and s%a'' be worn on site* #* A'' site wor, activities wi'' be ,ept in a c'ean and tidy condition* 2S" 6""PI)3
A&ter co)p'etion o& insta''ation wor,s- t%e area invo'ved wi'' be c'ear and c'ean &ro) e>cess )ateria's* >>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>
