“Yatırımcı” CAPITOL VISTA “Proje Yönetim”

Doc N° Rev
Location Ankara, Türkiye
”Mekanik XXX 0
Yüklenici” Capitol Vista
Project Page 1 of 14
Office Project

TESTING & COMMISSIONING

METHOD STATEMENT

For

“CIRCULATION PUMP”

Rev. Description Prepared by Checked Approved Date

0 Issued for Approval 01-05-2013
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 TABLE OF AMENDMENTS

This sheet must be completed in detail, after this document has been approved. Details must include revision
number, description and indication of which pages and paragraphs have been revised, date of revision approval
and approval indication.

R
E DESCRIPTION DATE APPROVED BY
V

0 Issue for Review and Approval by the Client, Client’s

Representative and Construction Manager.

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 TABLE OF CONTENTS

PAGE

1. Scope.................................................................................................................................4
2. Reference Documents......................................................................................................4
3. Key Personnel.................................................................................................................. 4
4. Health, Safety & Environment........................................................................................4
5. Method & Sequence of the Works .................................................................................5
5.1 Pre-Commissioning.............................................................................................5
5.2 Commissioning....................................................................................................6
5.3 Performance Test................................................................................................6
5.4 Temporary Works during Commissioning Stages............................................6
6. Testing and Commissioning Equipment – Certification...............................................6
7. Attachments......................................................................................................................7
7.1 Circulation Pump Pre-Commissioning Checklist ............................................8
7.2 Circulation Pump Punch List ............................................................................9
7.3 Circulation Pump Commissioning Checklist .................................................10
7.4 Circulation Pump Equipment Schedule..........................................................12
7.5 Material Approvals...........................................................................................13
7.6 Schematic Diagrams..........................................................................................14
1. Scope:
1. 1 The systems will be Pre-commissioned and Commissioned in accordance with the approved
method of statement.
1. 2 Ensure that all permanent wiring has been tested for insulation resistance and continuity prior
to connection.
1. 3 Ensure that earthing/grounding arrangements are intact and that leakage currents can be
effectively discharged.
1. 4 Ensure that the Circulation pump for hot and cold domestic water systems are properly
installed and shall perform as designed and as per requirement.
2. Reference:
2.1 The Project Specification
2.1.1 232123 Hydronic Pumps
2.1.2 232113 Hydronic Piping
2.1.3 230523 General Duty Valves
2.1.4 230500 Common Work Results
2.1.5 230513 Common Motor Requirements
2.1.6 230519 Meters and Gages
2.1.7 230529 Hangers and Supports
2.1.8 230548 Vibration and Seismic
2.1.9 230593 TAB
2.1.10 230700 Insulation
2.1.11 234100 Filters
2.2 Material Transmittal
2.3 NFPA 70, Article 100
2.4 UL 778
2.5 National Standards (CIBSE & ASRHAE)
2.6 Information for Construction Drawings (IFC)
3. Health, Safety, and Environment:
3.1 “AECOM” will operate a strict safety policy. “AECOM” recognizes the importance of
safety on site and will strictly adhere to the safety requirements for working.
3.2 A team of experienced and well qualified safety officers will be assigned to implement and
control the Health Safety & Environment Plan on site.
4. Key Personnel:
4.1 The Contractor’s T&C for Mechanical/Electrical Group has the overall responsibility for the
implementation of this Method of Statement.
4.2 The Contractor’s T&C MEP Coordinator will ensure that the resources are available to carry-
out the works as per approved drawings, method of statement, and work as scheduled.
4.3 The Contractor’s Site Engineer/Supervisor is responsible to ensure that the work has been
carried out as per approved drawings and method statements and shall assist in carrying out
inspection procedures.
4.4 The Contractor’s commissioning technician/s is responsible to ensure that they are abiding
the method of statement to achieve the required data as per equipment schedule and project
specification.
4.5 The Manufacturer/Specialist Supplier’s representative shall start up and commission the
circulation pumps, including controls and operational sequences, in accordance to this
Method Statement, using the attached checklists. All check sheets and signed reports from the
 manufacturer shall be collected and attached. The Contractor’s T&C team shall provide
assistance and coordinate the works.
4.6 The Contractor Safety Officer will assist in all issues related to the HSE.
5. Method and Sequence of Work:
Start-up and Commissioning of Circulation Pump units shall be carried out by manufacturer/
specialist supplier. This shall be done in three phases. First, tests will be conducted by supplier and
witnessed/assisted by the contractor. When all tests conducted have passed, the second phase is for
the contractor CA to inspect and accept test and submit test data and set date for the third phase of the
exercise where the contractor, in the presence of all relevant parties, shall demonstrate to the client
the operation of the equipment.
We will assist their commissioning engineer as required, whenever necessary. The main objective is
to minimize the risk of injury and damage to personnel and equipment. Electrical test on control panel
shall be implemented and signed off by supplier/responsible contractor.
5.1 Pre-Commissioning
For all items, note any discrepancy on the punch list forms and rectify before commissioning.
5.1.1 Electrical Checks:
Pre-commissioning of the electrical installation and connection should be carried out
in accordance with the following standards as per Project Specification and approved
manufacturer’s electrical layout.
5.1.2 Motors:
5.1.2.1 Check and verify if power, control alarm and earthling are properly installed
and as per project requirement.
5.1.2.2 Check and verify the rated voltage, current, speed and power as marked on
the pump nameplate. Ensure that the motor is suitable for the electrical
supply on which it will be used. Record the operating voltage and amperage
of the pumps and compare with the nameplate and thermal overload ratings.
5.1.2.3 Electrical connection should be carried out as per manufacturer’s layout or
approved drawings.
5.1.2.4 Electrical terminals and connections are properly protected.
5.1.2.5 Motor should be properly mounted. Make sure that the base of the unit is
properly supported.
5.1.3 Controls:
5.1.3.1 All terminal connection properly torqued as per specs or from
manufacturer’s recommendation.
5.1.3.2 Disconnect switch functional and tested.
5.1.3.3 Starters, fuses, and overload relays are of the correct size and complying
with project specifications.
5.1.3.4 Auxiliary accessories, i.e., indicating and pilot lamp, push button, and
selector switches are functional and with no sign of damage.
5.1.3.5 Incoming and outgoing power supply cables are of the correct size and
tested.
5.1.3.6 Alarm, protective devices and emergency stop functional and tested.
5.1.3.7 Both manual and automatic control tested.
5.1.4 Pump & Piping:
5.1.4.1 Check piping connection for tightness.
 5.2 Commissioning
5.2.1 Turn ON the power of the control panel.
5.2.2 Prime the pumps. Ensure that no pump shall run “dry”.
5.2.3 Open all isolation valves.
5.2.4 Start the pump and check for correct rotation.
5.2.5 With the pump running, check pump flow and motor current and volts.
5.2.6 Compare to design and rated values.
5.2.7 Switch all pumps to automatic setting and check that they work properly.
5.3 Performance Test
5.3.1 The objectives of performance test are:
5.3.1.1 To ensure that the circulation pumps are operating automatically as required
for system application.
5.3.1.2 To ensure that the circulation pumps are perform according to the design
data and specification.
5.3.1.3 A representative from each trade shall be available during the performance
test as well as one representative minimum from the owner, engineer, and
general contractor. The trades involved shall include as a minimum
Mechanical, electrical, controls, and commissioning agent.
5.3.2 Procedure:
5.3.2.1 Perform a close-head test on pumps. Check that the pressure corresponds to
zero-flow on the pump curve.
5.3.2.2 Perform head test at intermediate flow. Check that these pressures
correspond to pump curve values.
5.4 Temporary Works during Commissioning Stage
5.4.1 Necessary Permits shall be obtained prior to works.
5.4.2 Location of work to be secured through the use of barricade taped. Unauthorized
personnel to be excluded from works location.
6. Testing and Commissioning Equipment – Certification
The following equipment / tools are to be use during testing and commissioning works:
Item Equipment Nos. Purpose Certificates
1 Multi Tester 1 For Testing of Volts and To be provided during
Current commissioning stage
2 Hand Tools (set) 1 Use for related works N/A
3 Pressure Gauge 2 Use for checking To be provided during
Differential pressure. commissioning stage
7. Attachment:
7.1 Circulation Pump Pre-Commissioning Checklist
7.2 Circulation Pump Punch List
7.3 Circulation Pump Start Up Commissioning Checklist
7.4 Circulation Pump Performance Checklist
7.5 Circulation Pump Equipment Schedule
7.6 Material Approvals
7.7 Schematic Diagrams
 7. Attachments

Contact Ref.
Client
Plant Ref.
Location/ Area Serving
Item Y/N/NA Comment
General
Installation is as per manufacturer’s instructions
Manufacturers recommended spare parts are provided
Equipment label permanently affixed
Pumps in place and properly supported
Isolation valves and piping specialties installed
Shaft seal is leak free
Pump detail checked against the drawings and all devices, gauges and
other appurtenances are in place
Insulation installed per requirements
Electrical and Controls
Power isolator is located within site of the unit it controls and labeled
All electric connections are tight
Grounding installed for components and unit
Safeties installed and operational
Starter overload breakers installed and of correct size
All control devices and wiring complete
Control system interlocks connected and functional
Installation per manufacturer’s instructions

7.1 Circulation Pump Pre-Commissioning Checklist

      1 2 3 4
Name &Surname        
Position Name        
Dat            
e
Signature          
 7.2 Circulation Pump Pre-commissioning Punch List Form

"Project"

Punch List
 
System /   Document
 
Equipment No.
Buiding /  
Location

Inspection Description of Action Completed Comment

No Location Category
Date Defect Time Date / Result
               
               
               
               
               
               
                 
                 
                 
               

SUB- 3RD PARTY GENERAL OWNER'S

 
CONTRACTOR INSPECTOR CONTRACTOR REPRESENTATIVE
Company name        
Name&Surname        
Position Name        
Date        
Signature        
 Contact Ref.
Client Date
Plant Ref. Job Ref
Location/ Area Served Sheet
Pump Motor
Manufacturer Manufacturer
Type/Make Frame Size
Size/Model Serial No.
Serial No. Power kW
Ordered Duty Electrical Supply Volts/Ph/Hz
Impeller size (dia) Motor Current (FLA) Amps
Speed RPM
STARTUP INSPECTION
Item Y/N/NA Notes
Pump rotation verified correct
Check valve operation tested    
Mechanical

No leaking apparent around fittings    

Vibration and noise level at start-up
   
acceptable.
Start up prerequisite form by manufacturer
   
rep.(checklist attached)
Operation of HOA switch checked out in all
   
positions
Electrical

Electrical interlocks functional    

Motor Amps - Rated    
Motor Volts - Rated    
STARTUP DATA
Item Rated Actual
Voltage
Amps
DEFICIENCY CORRECTED

7.3 Circulation Pump Commissioning Checklist

      1 2 3 4
Name &Surname        
Position Name        
Dat            
e
Signature          
 7.4 Circulation Pump Performance Test Checklist
Contract   Ref
Client
Plant Reference
Location / area served
Equipment Tag
Manufacturer
PUMP DATA

Model No.
Serial No.
Type
Output (kW)
Drive
No Flow Intermediate Flow
PERFORMANCE
Design Test Design Test
Flow Rate 0 m³/h 0 m³/h m³/h m³/h
PUMP
Pump Head m m m m
Voltage volts volts volts volts
MOTOR Current Amps Amps Amps Amps
Power kW kW kW kW
Equipment Tag
Manufacturer
PUMP DATA

Model No.
Serial No.
Type
Output (kW)
Drive
No Flow No Flow
PERFORMANCE
Design Test Design Test
Flow Rate 0 m³/h 0 m³/h 0 m³/h 0 m³/h
PUMP
Pump Head m m m m
Voltage volts volts volts volts
MOTOR Current Amps Amps Amps Amps
Power kW kW kW kW
Instruments used / Comments:

      1 2 3 4
Name &Surname        
Position Name        
Dat            
e
Signature          
7.5 Circulation Pump Schedule
7.6 Material l Approval
7.7 Schematic Diagrams