“Yatırımcı” CAPITOL VISTA “Proje Yönetim”

Doc N° Rev
Location Ankara, Türkiye
”Mekanik XXX 0
Yüklenici” Capitol Vista
Project Page 1 of 15
Office Project

TESTING & COMMISSIONING

METHOD STATEMENT

For

BOOSTER PUMP

Rev. Description Prepared by Checked Approved Date

0 Issued for Approval 01-05-2013
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 TABLE OF CONTENT
PAGE No’s
1 Scope 04
2 Reference Documents 04
3 Health, Safety, and Environment 04
4 Key Personnel 04
5 Sequence of Operation 04
6 Method And Sequence of Work. 05
7 Testing and Commissioning Equipment – Certification 07
8 Attachment 07
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 Booster pump for domestic water systems are properly installed and shall
perform as designed and as per requirement.

2. Reference:
2.1 The Project Specification
 221123 Domestic Water Pumps
 221116 Domentic Water Piping
 221119 Domestic Water Piping Specialties
 220500 Common Work Results for Plumbing
 220513 Common Motor Requirements for Plumbing Equipment
 220519 Meters and Gages for Plumbing Piping
 220529 Hangers and Supports for Plumbing Piping and Equipment
 220523 General Duty Valves for Plumbing Piping
 220548 Vibration and Seismic Controls for Plumbing Piping and Equipment
 220700 Plumbing Insulation
 232500 Water Treatment
 230593 TAB
 234100 Filters
2.2 Material Transmittal
2.3 National Standards (CIBSE & ASRHAE)
2.4 NFPA 70, Article 100
2.5 UL 778
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. Method statements and assist inspection.
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 Contractor Safety Officer will assist in all issues related to the HSE.
5. Sequence of Operation
5.1 The pump#1 is intended to maintain pressure in the system at XXX Bar for potable or XXX
Bar for non-potable water system to prevent unnecessary cycling of the other two pumps.
Small pressure losses in the line are compensated for by the pump#1, which starts to run when
system pressure has dropped to XXX Bar for potable and XXX Bar for non-potable and stops
when pressure is restored to XXX Bar for potable and XXX Bar for non-potable.
5.2 A more significant pressure drop in the system would trigger a series of events intended to
restore system pressure.
5.2.1 The pump#1 runs. If it fails to restore line pressure and instead pressure goes down to
XXX Bar for potable and XXX Bar for non-potable, the pump#2 in the operational
order runs.
5.2.2 If the pump#2 fails to raise system pressure, it shall reach full speed and the pump#3
starts, they will run until pressure is restored at XXX Bar for potable and XXX Bar for
non-potable or all three pumps are running.
5.2.3 When and if pressure is restored to XXX Bar for potable and XXX Bar for non-
potable, all pumps that are running shall stop.
5.2.4 If the pumps are unable to restore pressure, they will continue running until low water
at the level switches is reached or the pumps are manually switched off.
5.3 Once the system is off, a cyclic changeover function shall alternate the main pumps’
operational order.
5.4 If pressure in the system goes above operational (XXX Bar for potable and XXX Bar for non-
potable water system) the cushion tank accommodates the excess pressure.
6. Method and Sequence of Work:
Start- up and Commissioning of Booster Pump units will be carried out by Manufacturer/ Specialist
supplier. All check sheets and signed reports from the manufacturer shall be collected and attached.
We will assist their commissioning engineer as required. 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 or responsible contractor and to be attached on
commissioning checklist.

6.1 Pre-Commissioning
6.1.1 Pump & Motor should be properly mounted, making sure that the base of the unit is
permanently supported.
6.1.2 Proper piping (outlet & inlet), correct foundations and motor mounts must be
implemented to minimize external stress on all piping.
6.1.3 Ensure that all flexible connections are secure.
6.1.4 Lubrication should be observed or implemented as per manufacturer’s
recommendation.
6.1.5 Ensure sufficient feed water supply. Booster should be thoroughly purged of air before
start-up.
6.1.6 Ensure that the piping system pressure leak test, attached on pre-commissioning
checklist.
6.1.7 Ensure that the pump motor power requirements are connected to a suitable electrical
supply.
6.1.8 Ensure that the pump motor is earth or bonded to earthing system.
6.1.9 Pump control panel is properly commissioned by supplier or installer contractor.
 6.1.10 Cables, terminal connections, trunking lines or conduits, cable trays are as per
approved materials and installation.
6.1.11 Ensure that complete installation and start up checks is according to manufacturer’s
written instruction.
6.1.12 Clean strainer on suction piping.
6.1.13 Verify that each pump is free to rotate by hand. If pump is bound or drags, do not
operate until cause of trouble is determined and corrected.
6.2 Commissioning
6.2.1 Ensure that the entire pre-commissioning checklists are completely done.
6.2.2 Prime the pump by opening suction/discharge valve and prepare pump for operation.
6.2.3 Turn on the power of the pump in AUTO Mode.
6.2.4 Verify that the pump is running in the correct rotation.
6.2.5 Check the charge on the connected cushion tank. It should be the same as the
operating pressure: XXX Bar for the potable water system and XXX Bar for non-
potable. Recharge or bleed off air if necessary.
6.2.6 Close slowly the discharge valve and record the cut off pressure of the pump#1.
6.2.7 Open the discharge valve slowly and then record the cut in pressure of the pump#1.
6.2.8 With the pump running, check the motor current and volts.
6.2.9 For all pumps, check dry protection level.
6.2.10 Install a temporary bypass line with an isolation valve from the discharge header into
the water storage tank (potable or non-potable tank) to which the booster pump set
under commissioning is connected at the suction side. Isolate the discharge header
from the domestic water system.
6.2.11 Check the operational order of the pumps.
6.2.9.1 Switch the booster pump set panel on automatic mode.
6.2.9.2 Open the valve on the bypass line. This would simulate a drop in the system
pressure and the pump#1 should start.
6.2.9.3 Note the pressure at the point in which the pump#1 starts.
6.2.9.4 Because the discharge line is not feeding into the system, a further drop in
pressure should happen. This would start the pump#2.
6.2.9.5 A further drop in system pressure is expected. However, if that does not
happen, switch off the pump#2 at the isolator switch. This should lower the
pressure and the pump#3 shall start. Note the pressure at the point when
each main pump starts.
6.2.9.6 Note the order of activation of the pumps.
6.2.9.7 Slowly close the valve on the bypass line. This should raise system pressure
and stop all running pumps.
6.2.9.8 Note the pressure at the point when each pump stops.
6.2.12 Repeat 6.2.10 until cyclic changeover function is found to be working properly.
6.3 Performance Test
The objectives of the performance test follow:
6.3.1 To ensure that the Booster pumps are operating automatically as required for system
application.
6.3.2 To ensure that the Booster pumps for Potable and Non-Potable Water Systems are
performing according to the design data and specification.
6.3.3 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.
6.4 Temporary Works during Commissioning Stages
6.4.1 Necessary Permits shall be obtained prior to works.
6.4.2 Location of work to be secured through the use of barricade tapes. Unauthorized
personnel to be excluded from works location.
7. Testing and Commissioning Equipment – Certification
The following equipment / tools are to be use during testing and commissioning works:
Items Equipment Nos. Purpose Certificates
1 Multi Tester 1 For Testing of Volts To be provided during
and Current commissioning stages
2 Hand Tools (set) 1 Use for related works N/A
3 Pressure Gauge 2 Use for checking the To be provided during
pressure. commissioning stages
8. Attachment:
8.1 Booster Pump Pre-Commissioning Checklist
8.2 Booster Pump Pre-Commissioning Punch list
8.3 Booster Pump Commissioning Checklist
8.4 Booster Pump Performance Test Checklist
8.5 Booster Pump Equipment Schedule and Pump Performance Curve
8.6 Riser Diagram – Domestic Water
8.7 Material Transmittal Approval
8. Attachments
 8.1 Booster Pump Pre-Commissioning Checklist
Contact Ref.
Client
Plant Ref.
Location/ Area Serving
Tick “Yes” if Acceptable; Provide comment if unacceptable Yes No Comment
General
Installation is as per manufacturer’s instructions
Manufacturers recommended spare parts are provided
Equipment label permanently affixed
Pump turns freely
Pump foundation is level within manufacturer’s tolerances
Pumps in place and properly supported
Isolation valves and piping specialties installed
Flexible connections check and secure.
Shaft seal is leak free
Pump detail checked against the drawings and all devices gages and
appurtenances are in place
Electrical and Controls
Power isolator is located within site of the unit it controls and labeled
Pump motor connected to a suitable electrical supply
All electric cable and terminal connections tight
Grounding installed for components and unit
Safeties installed and operational
Starter overload breakers installed and correct size
All control devices and wiring complete
Control system interlocks connected and functional
Operation of Control switch checked in all positions
Installation per manufacturer’s instructions

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Name &Surname        
Position Name        
Dat            
e
Signature          
 8.2 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        
 8.3 Booster Pump Commissioning Checklist
Contact Ref.
Client
Plant Ref.
Location/ Area Serving
Tick “Yes” if Acceptable; Provide comment if unacceptable Yes No Comment
General
The Control switch properly activates and deactivates the unit
Pump rotation verified correct
No unusual noise or vibration
No leaking apparent around fittings
Record cut in and cut off pressure of all pumps.
Specified sequences of operation and operating schedules have been
implemented with all variations documented.
Specified point-to-point checks have been completed and documentation
record submitted for this system.
Check cushion tank pre-charge. It should be the same as operational
pressure ( XXX Bar for potable and XXX Bar for non-potable water
system). Bleed or recharge as required.
Install a temporary bypass line with valve from discharge header to non-
potable or potable water tank, whichever system is being tested.
Sequence of operation
Check that the pump#1 cuts in at XXX Bar for potable water system or
XXX for non-potable
Cut-out ____ Bar
Confirm that the pump#2 cuts in at XXX Bar for potable water system or
XXX for non-potable
Cut-in ____ Bar
Check that the pumps cut in when the previous main pump has reached
full speed and line pressure is not restored at XXX Bar for potable water
system or XXX for non-potable
Note order of operation of the pumps
Repeat until cyclic changeover function is found to be working properly

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Name &Surname        
Position Name        
Dat            
e
Signature          
 8.4 Booster Pump Performance Test Checklist
Contract Ref
Client
Plant Reference
Location/Area serving
Manufacturer Model No. Serial No. Type
PUMPS

Pump 1

Pump 2
Pump 3
Design Actual
Cut in (bar) Cut off (bar) Cut in (bar) Cut off (bar)
PUMP

Pump 1 XXX / XXX * XXX / XXX *

PERFORMANCE

Pump 2 XXX / XXX * XXX / XXX *

Pump 3 XXX / XXX * XXX / XXX *
Voltage Current Speed Power Voltage Current Speed Power
(volts) (amps) (rpm) (kW) (volts) (amps) (rpm) (kW)
MOTOR

Pump 1
Pump 2
Pump 3
*The figure to the left of the slash (/) is for potable water system and that at the right is for non-potable water system.
Remarks:

      1 2 3 4
Name &Surname        
Position Name        
Dat            
e
Signature          
8.5 Booster Pump Schedule and Performance Curve
8.6 Riser Diagram – Domestic Water
8.7 Material Transmittal Approval