Method Statement for Plate Heat Exchanger Installation

method-statement-plate-heat-exchanger-installation

The Method Statement for Plate Heat Exchanger Installation defines the guidelines and methodology to be followed while performing construction by complying with project specifications and safety requirements.

Scope

The step covers the detailed procedure for the installation of Plate Heat Exchanger (PHE) for the chilled water system that includes the technical requirement set forth for the installation methodology. This procedure defines the method used to ensure the installation has been carried out as per approved shop drawings in line with the project specification.

References

Project Specifications
Approved IFC Drawings
Approved Shop Drawings
Manufacturer’s Installation Procedure
Approved Material Submittal

Abbreviation

QC – Quality Control
HSE – Health, Safety, and Environment
ITP – Inspection & Test Plan
MST – Method Statement
PPE – Personal Protective Equipment
MSDS – Material Safety Data Sheets
RA – Risk Assessment
QCP – Quality Control Procedure
PQP – Project Quality Plan
INR – Inspection Request
QA/QC – Quality Assurance/ Quality Control
PHE – Plate Heat Exchanger

Responsibilities

General

The Project Manager will be responsible to manage, execute complete and handover the MEP construction activities within approved budgets and resources in compliance with project requirements as specified in Project Specifications. He will be overall in charge of implementing the Method Statement for Plate Heat Exchanger Installation in accordance with QA/QC and HSE requirements.

The Construction Manager will be responsible for managing MEP construction activities and will lead and communicate site supervision, subcontractors, and vendors to assist them in working on the project schedule with conformance to the QA/QC and HSE requirements at the site.

HSE Manager will be responsible for plan, coordinate, and implement issues and directives within the organization. He ensures safe environmental working conditions for all MEP employees.

QA/QC Manager will be responsible for supporting the project MEP team in implementing and maintaining Quality Management System for the project through PQP, ITP, Method Statement for Plate Heat Exchanger Installation, and Procedures in compliance with Project specifications, Codes, and Standards.

HSE Officer will ensure enforcement of safety procedures in accordance with the approved HSE Plan. He will be closely monitoring the site engineer’s strict implementation of the Method Statement for Plate Heat Exchanger Installation and Risk Assessment, the use of proper tools and equipment to maintain safety, certifications of equipment and their adherence to safety regulations, reporting of any unsafe work or stopping work that does not comply with HSE procedures.

The Site Engineer will be responsible for carrying out all construction-related activities as per contract specifications, drawings/documents, codes, standards, and in-line with HSE and QA/QC requirements.

The QA/QC Engineer will be responsible for conducting inspections as per PQP.

The Supervisor/Foreman will be responsible for coordinating all works and workers related to the job.

The Electrician / other tradesmen will be responsible for assisting his superiors during all construction work-related activities. And work shall be in line with HSE and QA/QC requirements.

The Store In-charge receives and inspects all incoming materials and reconciles with documents; processes and distributes documentation; reports, documents, and tracks damages and discrepancies.

The Safety Officer will be clearly visible, vigilant, respond quickly and correctly during the crisis, observing and reporting, checking and monitoring, maintain order among workers, and offer safety warnings and tips.

Handling, Storage/Preservation, and Transportation of Materials

All documents must be available with the supplied Plate Heat Exchanger (PHE) i.e. shipping document, packing list, delivery note, catalogs, installation, and operation manual, test certificates, etc.

Each shipment must be blocked and securely fastened to avoid damages during transportation.

Transportation of PHE shall be in full compliance with the manufacturer’s instruction.

  • The unit needs to be transported in an upright condition with little or no tilting to avoid misalignment of plates. This is because the plates are suspended (hanging) on the carrying bar.
  • The Plate Heat Exchanger (PHE) and accessories will be protected for shipping as per the manufacturer’s recommendation.
  • The material will be delivered at the site in undamaged condition, in manufacturer’s packaging, with identifying labels intact and legible.
  • The Plate Heat Exchanger (PHE) is supplied from the factory in proper packing in which should remain until they have been installed.
  • All documents such as a delivery note, certificates and etc. shall be presented to the personnel in charge of main storage for verification.
  • Unloading at the site must be controlled by the site team following the manufacturer’s instructions.
  • The lifting equipment rating must under no circumstances be exceeded.
  • All lifting equipment must be rated for the purpose and checked for damage before any attempts are made to lift the materials.
  • Ensure that the material is stored in the shaded area to protect it from exposure to direct sunlight.
  • The storage area shall be cleaned and is at an appropriate height from the ground level. Separate areas in the storage zone must be marked for different materials.
  • Delivered PHE is ready to be put into service upon arrival. In any case that the area is not yet ready for installation, the manufacturer’s recommendation regarding preservation/storage for longer periods of time (one month or more) shall be followed. Certain precautions should be made to avoid unnecessary damage to the PHE (refer to Manufacturer’s Installation Detail-Storage/Preservation).

Material Inspection

The material will be delivered at the site in undamaged condition, in the manufacturer’s original container or packaging, with identifying labels intact and legible.

Delivery of Plate Heat Exchangers (PHE) and accessories will be checked /inspected by QA/QC Engineer to ensure all items on the delivery note are correct prior to signing. Any shortage or damaged items should be recorded on the delivery note and damage materials will store separately with an identification tag or shall be removed from the site.

Each material item shall be allotted a distinct and separate reference number and mentioned on the material requisition. Make sure that material is approved/examined by the Consultant and QA/QC and associated documents/test certificates are approved.

The QA/QC Engineer/Store in charge shall ensure that all approved supplies be delivered to the site as per the approved material submittal; with the manufacturer’s seals, labels, or other proof of origin intact. These labels and seals shall not be removed until the material is required for use and shall be retained for inspection by the QA/QC Engineer and Consultant.

Materials, which do not conform to the given specification/approved material submittal, shall be rejected. Any discrepancies or damages will be notified and reported for further action.

Upon delivery of materials at site stores, inspection will be raised by QA/QC Engineer for consultant’s approval.

The QAQC Engineer shall initiate material inspection for all incoming material. The material shall be inspected against reference documents and as per approved material submittal. Moreover, the physical condition of the material shall be checked. Afterward, an INR shall be raised by QA/QC Engineer to Consultant and inspection will be carried out by Consultant.

Resources

a. Tools and Equipment

The job will be carried out by manual means. The following are the types of Tools identified for works:
Standard Mechanical tools
Drilling Machine
Hammering machine
Open and box type wrench /spanners set
Measuring Tape/ Level bar
Forklift/ Crane
Hydraulic Jack Trolley
Note:
All testing equipment and measuring tools to be used shall have a valid calibration certificate prior to usage.
Equipment and machines shall be 3rd party verified with valid certificates.
Operator’s competency certificates shall be checked and maintained as quality and HSE records.
The contractor’s HSE inspection for all light and heavy equipment prior to site acceptance shall be carried out.
HSE inspection sticker shall be posted on the windshield to indicate that the equipment passed inspection.

b. Materials

Material includes but not limited to the following:
a. Plate Heat Exchangers
b. Valves and accessories.
c. The material shall be used after being approved by Approved Material Submittals.
d. All material to be used shall conform to the project specification and authorities regulations
(where required).

c. List of Manpower

Construction Manager
Site Engineer
QA/QC Engineer
HSE Officer
Supervisor
Foreman
Installers
Surveyor
Helpers
Trailer Driver
Exchanger
Mobile Crane/Crane Operator
Forklift Operator

Methodology

a. Pre-Installation/General Requirement

The meeting shall be scheduled prior to the beginning of the work and before any sub-contractor starts on the project.

• Prior to the commencement of any construction works, the area and access will be inspected to confirm that they are in a suitable condition for construction work to commence. Prepare a working permit (if any) and submit it to any designated safety officer.
• All relevant documentation (approved shop drawing, coordination drawing, approved method statement, Approved material submittal, approved ITP, checklist) and material applicable to a particular section of work will be checked before commencement of work.
Mechanical Site Engineer will instruct the supervisor to in-charge who in return will relay to the tradesmen regarding the execution of the work and will distribute all necessarily approved construction shop drawings and coordinated layout plan.
• Check if the concrete foundation/ plinth is as per approved shop drawing layout plans, section, and details with regards to its exact size to accommodate the plate heat exchanger as inspected and approved by the consultant. Verify from civil work if surface preparation and its inspection are approved as clearance in mounting the plate heat exchanger into the concrete foundation/plinth. Before mounting the plate heat exchanger, area and access will be
inspected to confirm that they are in a suitable condition.
• The site mechanical Engineer/supervisor should also check the tools and equipment available which should be compliant with the contract requirement and are in good and safe working condition.
• Ensure that only approved materials are required to carry out the work shall be available.
• Plate heat exchanger (PHE) selection shall be as per approved material submittal, project specification & approved equipment schedule.
• Plate Heat Exchanger (PHE) identifications: Manufacturer’s nameplate, trademark, and model, serial number, capacities, maximum working pressure shall be fixed at each piece of equipment.
• The in-charge Mechanical Engineer, supervisor, and foreman should verify that the assigned person must have sufficient knowledge of the procedure for the installation, operating instruction, and necessary fundamental information. Review training and qualification records for those individuals who will do the task to determine whether they are skilled enough to follow the procedure before the work is carried out.
• The installer will receive a set of installation drawing from the factory with tag number and hoisting shall be executed as per the manufacturer’s recommendation.
• All safety regulations must be observed at the installation site.
• Ensure clearance is issued by the architectural/civil team prior to mounting the Plate Heat Exchanger (PHE) in the concrete foundation.

b. Installation Procedure of Plate Heat Exchangers

• Plate Heat Exchanger (PHE) shall be installed as per Material Submittal approval, manufacturer/supplier instruction, project specification requirements, and approved shop drawings.
• It is very important that enough space around the plate heat exchanger is kept free for servicing of the unit.
• Shift the Plate Heat Exchanger (PHE) from the store to the area of installation as per the manufacturer’s recommendation.
• Never lift the plate heat Exchanger (PHE) by the connections or the stud around them.
• Strap should be used when lifting the plate heat exchanger.
• After laying down on the foundation, the plate heat exchanger should be leveled and aligned.
• For Applicable accessories all should be installed as per approved detail drawings.
• Valves shall be installed as per the approved shop drawing details and project specification.
• Support shall be followed as per the approved shop drawing details and project specification.
• When connecting the piping system to the heat exchanger, make sure that no stress or strain is imposed, by the pipe system, on the heat exchanger.
• Make sure that pipe works, connected to the heat exchanger are secured against pressure peaks/surges and temperature shocks.
• Ensure flange type, bolts and nuts are matching.
• For proper venting the vent should be fitted on the highest point on both sides of the heat exchanger.
• For the detailed installation procedure, refer to “Manufacturer’s Installation Procedure”.

c. Post Installation

• Final sealing of all joints shall be done after successful commissioning of the units and in full compliance with the manufacturer’s recommendations and project specifications.
• Ensure all equipment and piping used shall be protected against sudden and extreme variation of temperature and pressure.

d. Inspection

• After completion of the work, The Site Engineer & Supervisor who perform an activity are required to raise an INR with complete attachment & information regarding the scope of the inspection, including necessary drawings highlighted to show the scope of the inspection. He shall systematically check and inspect their work. The inspection shall be performed according to the approved typical Inspection Checklist and Inspection and Test Plans (ITP).
• After the Site Engineer & Supervisor completed their inspection and testing, INR shall be submitted to QA/QC Department who shall check and process the documents to have completed work inspected by Supervision Consultant for their approval.
• Start-up and commissioning is to be performed by a Third Party Specialist approved by the consultant and the related method statement is to be submitted separately.
Note: INR must be processed and submitted to Supervision Consultant 24 hours before the actual inspection and/or witnessing.

Health and Safety Analysis

a. Risk Assessment

Refer Risk Assessment/Job Hazard analysis sheets.

b. Environmental Impact Assessment

This activity doesn’t have a feasible impact on the environment. Waste management will be done by the Waste Management certified company.

c. Protective and Safety Equipment

All workers involved shall be equipped with adequate PPE as state below:
• Safety Helmet with Company Logo
• Safety Boots, Safety Goggles, Hand Gloves
• High Visibility Vest
• Welding specific PPE (Welding Vest, Mask, Gloves, Visor)
• Twin-Tail Harness, Max 1m long (when working on height). All special PPE (Harness) is considered as a last resort when we cannot engineer, administratively eliminate, or guard against hazards.

d. Information to Personnel

Safety Induction
Job Training
Superintendents
Notices/Memos
Toolbox Talks
Briefings before starting work

e. Permit Requirements

Vehicle Permit for equipment
Working permit
Night Work
Driving permit

Quality Assurance and Quality Control

a. Quality Assurance Requirements

The contractor shall provide the required documents for the Consultant’s approval prior to initiating the execution of this activity as per project specification requirements.

• The quality control requirement shall include related QCP’s, ITP’s and other related documents as applicable. Refer to Inspection Test Plan.

• Applicable codes and standards for materials are: Project specifications.

b. Quality Assurance Process

The contractor shall notify the engineer prior to the start of the activity and comments from the site instruction will be complied with as per contract.

c. Follow up and Evaluation

• Follow-up on quality performance shall be carried out through an in-house monitoring system such as progress reporting to the planning department, daily, weekly and monthly reports generated by the planning department to closely monitor site performance in general and reflect on quality performance in specific.
• All the above shall be conducted in close coordination with the quality department to monitor any deviations from the normal quality requirement and induce corrective actions whenever required to eliminate non-conformance or quality deviations.
• All remedial actions to be taken, if any, shall take into account the official schedule which is to be used as a guideline for performance and most importantly under the close supervision of the quality control department.

Records of Method Statement for Plate Heat Exchanger Installation

• Checklists (CL)
• Inspection Request (INR)
• Inspection and Test Plan (ITP)

See the video – Plate Heat Exchanger Applications and Working Principle HVAC Heat Transfer

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