The purpose of this method statement is to define the sequence and methodology for installation of heat pump.
Method statement gives details of how the work will be carried out and what health and safety issues and controls are involved.
Content of this method statement also reflects the findings of the relevant health and safety risk assessment.
PLANT AND EQUIPMENT REQUIREMENTS
- Tool Box
- Measuring tape
- Drill machines
- Adjustable wrench
- Torque ratchet
- Screw driver
- Laser indicator
- Marker / Chalk line
- Spirit level
- Grinding machine
- Teflon Tape
Roles and Responsibilities
Project Manager
Will have the overall responsibility of the project for execution, quality and safety. Also, he will maintain the planning progress and coordination of works with main contractor.
The Project Manager lead the health and safety process, constantly monitoring the project environment and performance.
Taking action to correct discrepancies reported as a result of safety surveys and inspections.
Project Engineer
Is responsible to carry out the work as per the Method statement, specification and approved drawings.
Project Engineer will plan and determine the resources required to cover open work front.
PE will ensure all necessary permits are made available.
Project Engineer shall be available at site full time for the execution of works as per schedule and specification.
He will report to project MEP manager.
Project Engineer is responsible to ensure execution team implement HSE rules and risk assessments control measures.
Site Engineers
Will be responsible for the day-to-day activities on site, for materials, drawings, testing and commissioning and allocation of Departmental resources to work on Site.
The Site Engineer will report to the project engineer / manager.
Site engineers will play leading role in the Health and Safety process, constantly monitoring the project environment and performance, providing the force and resources necessary for project compliance with agreed safety procedures and standards.
They will be responsible for the Health and Safety aspects on site as per the Main Contractor and Client requirements as documented within QHSE plans.
MEP Coordinator
Will advise on any impact on services caused by Architectural changes.
Coordinate main contractor’s work plan with MEP team.
Will assist internally QS and Planning department for update MEP system progress.
Ensuring that services provisions clearance is provided in time for structure.
Will oversee MEP service installation under civil contractor scope of works.
Ensure that MEP site instruction/NCR are closed out.
Ensure that Company HSE policies are implemented at site in coordination with HSE department.
QA/QC Engineer
Will be overseeing the quality requirements and quality control measures for the Project in coordination with the Senior Project Engineers as outlined in the Project Quality Plan.
He will be responsible for the Health and Safety aspects on site as per the SHEQ plan.
Shall ensure all materials used & method used are in accordance with project specification and are approved by the Engineer.
Shall ensure ITP requirements are met and QA/QC procedures are followed.
Plumbing Supervisor/Foreman
Will be directly responsible for the day-to-day job on site, for coordinating work with the technicians or any other staff assigned to their area.
Instructing personnel in SHEQ requirements and practices applicable to the Work that they will be performing through instruction and on-site guidance, this will be on a daily basis before any new task is started.
Ensuring that all required safety equipment is requested and made available to personnel carrying out the work on site.
Reviewing SHEQ considerations for all job tasks and recognizing potential risks before starting.
Discussing and solving any areas of concern with the relevant SHEQ personnel.
Ensuring that Risk/impact assessments are carried out by the relevant engineers/ SHEQ personnel prior to the execution of specific tasks.
Plumbers
Execution of work according to the approved shop drawings and co-ordination drawings.
Execution of work in good quality and accurate as per the instructions of the foreman of approved shop drawings and co-ordination drawings.
He is responsible for accurate measurements and height levels.
Using safe working practices as per safety regulations.
Keeping the working area clean.
Helpers
Bringing tools and materials to the Plumber.
Helping the Plumber, in marking and fixing boxes.
Using safe working practices as per safety regulations.
Keeping the working area clean.
Closing pipes after inspection
HSE Manager & Officer
Develop and assist site management in implementing this method of statement and risk assessment.
Have the ultimate authority to issue stop work order on site if any imminent danger is not being rectified immediately to his satisfaction.
Advise construction team on safe systems of work and safest method of working.
Ensure that safe systems of work are defined and documented, and that hazard analysis and risk control methods have been incorporated during the preparation.
Focus on the elimination of unsafe acts, and rectify unsafe conditions quickly.
PHSEM shall provide assistance to PM in achieving and maintaining best possible HSE performance throughout the activity.
PREINSTALLATION ACTIVITIES
Pre Ordering
Workshop Drawings and Material Submittal must be prepared and approved.
Ordering
Follow Supplier standard procedures for ordering of pumps and relevant materials.
Factory Manufacture
As per Supplier/ Manufacturer instructions and their own procedures.
Transportation to Site
Materials will be transported to the site by the supplier or subcontractor in accordance with the manufacturer’s recommendations so as to avoid damage or deterioration.
Pre Installation Steps
A pre-start meeting prior to the commencement of the works will take place with the Site Engineer, H&S Officer, QC Engineer, and Supervisor/Foreman in charge to address the following:
Ensure specific training provided to workers for the installation as per manufacturer requirement.
Ensure that the area is clean and has been surveyed as per approved drawings and safe to carry out the work.
Safety permit to be obtained.
Ensure that all materials to be use are as per approved Material Submittal and Project Specification.
All materials delivered to site shall be inspected and approved by the consultant by using the Material Inspection Requisition (MIR).
Ensure MIR to be approved prior to installation of heat pump. 
Ensure that latest approved shop drawing for this installation is present, and all personnel are working of the same drawing.
Ensure that adequate numbers of tradesmen with proper tools are present.
Ensure that all related civil works are properly coordinated with main contractor and with other services to avoid conflict for future installation.
Ensure approved material is available at the site.
All related document such as shop drawing, approved method statement shall be available at site during installation
Pre inspections hall be done to check any possible clashes with other services.
MATERIAL MANAGEMENT
Materials shall be approved prior to procurement. A material approval schedule shall be maintained by the Project QA/QC Engineers.
Incoming materials shall be inspected for conformance by the Project QA/QC Engineer.
Obtain MIR approval prior to site installation of heat pumps.
The Project MEP Consultant or Main Contractor’s QA/QC Engineer shall be invited to inspect materials for conformance prior to installation.
Relevant certificates of conformance shall be presented at the time of inspection with the MEP Consultant as applicable.
All material inspections shall be recorded on the MIR log (Material Inspection Request). All major items shall be inspected for each
Material requirements shall be as per shop drawings.
Handling
Necessary precautions shall be taken for unloading, shift and storing.
For shifting pumps use mechanical lifting. Protected slings and padded supports to be provided.
Incoming material shall be checked by the QA/QC weather it meets the latest approved material submittal.
Storage:
The heat pumps should be kept on a flat surface or on level ground free from stones and sharp objects with supports at the bottom.
Pump shall not be in direct contact with ground.
It should be covered by polyethylene plastic protection while storing.
Heat pumps will be stored based on manufacture recommendations.
Only approved material shall be stored at
Placement of heat pump on the plinth shall be done as per manufacturer installation instructions and detail drawings.
Inspection of Materials in Store
Upon receipt of materials on site these will be inspected by the Store man and Site Engineer or representative, to ensure correctness of materials and quantities.
A Material Inspection Request (MIR) shall be issued and all materials will be inspected and verified by the Engineer that they are correct.
Obtain MIR approval prior to site installation.
Heat Pump Installation Procedure
Check the required Configuration as per below:
DUCTED CONFIGURATION
Minimum frost-free room (T > 1 °C).
Heat pump operation between -5oC and 43o
Set the “Installation type” parameter to “Individual duct (Ext./Ext.)”
Recommended location: habitable space (heat loss from the water heater is not lost), close to external Avoid placing the water heater and/or ducts close to bedrooms, to reduce noise levels.
Observe maximum duct lengths. Use insulated rigid or semi-rigid Install air inlet and outlet grilles to prevent foreign bodies from entering. Caution: air inlet and outlet grilles with manual obstruction are prohibited.
Leave a space of 500 mm in front of the electrical equipment and 300 mm in front of the hydraulic equipment, so that the water heater is accessible for periodic maintenance.
Air Inlet from the room and Air Outlet to the outside of the room.
SEMI-DUCTED CONFIGURATION (FRESH AIR WITHOUT & EXHAUST AIR WITH DUCT)
Unheated room with a temperature above 5 o c, isolated from heated rooms in the house.
Heat pump operation between 5 oc and 43 °C.
Set the “Installation type” parameter to “Semi-ducted (lnt./Ext.)”
Recommended location: = buried or semi-buried, room with temperature above ·10 oC all year round.
The negative pressure created in the room by the discharge of outside air causes air to enter through the joinery (doors and windows). Install an air inlet (0 160 mm) to the outside to avoid drawing air from the heated space. In winter, the air entering through the air inlet can cool the room.
Aeraulic connection
To guarantee correct connection always use 160 mm diameter ducts, as per approved drawings and installation and connection details. Detailed diagram shall be available on site during installation works.
It is also possible to use the jig available on the water heater packaging to drill the walls and the duct adapters
To position the duct,
1) Unscrew the grille locking screws
2) Unclip the grilles
3) Fit the duct adapters (if necessary)
This operation should be performed by a qualified person with the power off (only when using ducts, otherwise do not remove the grilles.
For connection to ducts, the control system must be configured accordingly.
Hydraulic connection
The use of a recirculation system on the cold-water inlet is prohibited: such an installation causes water desertification in the tank and leads to the heat pump and electric heater having to work harder.
The cold-water inlet has been marked with a blue flange, the hot water outlet with a red one. They have a gas thread with a diam. 20/27 (3/4″). For regions with water having a high mineral content (Water hardness – Th > 20 of), water treatment is recommended. With a water softener, the hardness of the water must remain above 8°f. The water softener does not give rise to a waiver of our warranty, provided that it is authorized in the relevant country and set up in accordance with good engineering practices, and regularly checked and serviced. The hardness criteria must respect that defined by DTU 60.1.
Before creating the hydraulic connection, check that the network pipes are clean. The installation must include a new safety unit set at 0.7 MPa (7 bar) (not provided), compliant with standard EN 1487 and connected directly to the water heater’s cold water branch connection.
No components (stop valve, pressure reducer, hose etc.) must be positioned between the safety unit and the water heater cold water branch connection.
Water may flow from the discharge pipe of the pressure relief valve device; the discharge pipe must be kept vented. Irrespective of the installation type, it must include a shut-off valve on the cold-water supply, upstream of the safety unit.
The drain of the safety unit must be connected to the wastewater to allow free flow, via a siphon. It must be installed in a frost-free environment. The safety unit must be activated regularly (1 to 2 times per month). The installation must include a pressure reducer if the supply pressure is greater than 0.5 MPa (5 bar). The pressure reducer should be installed on the general distribution flow (upstream of the safety unit). A pressure of 0.3 to 0.4 MPa (3 to 4 bar) is recommended.
Do not connect the hot water union directly to the copper pipes. It must be equipped with a dielectric union (supplied with the appliance). In the event of corrosion to the threads of the hot water union not equipped with this protection, our warranty is invalid.
Do not connect the recirculation branch connection directly to the copper pipes. It must be equipped with a dielectric union (not supplied with the appliance). In the event of corrosion to the threads of recirculation branch connections not equipped with this protection, our warranty is invalid.
To limit heat loss, the entire recirculation loop must be insulated. Use a circulation pump with a flow rate of between 0.5 and 4 1/min Program the circulation pump and choose very short time slots for this purpose.
If the recirculation branch connection is not used, a “plug + seal” assembly must be connected to this branch connection (supplied with the appliance).
Protect against overpressure due to expansion of the water when heating with a 3 bar- 3 MPa valve, or an open expansion tank (at atmospheric pressure) or a closed diaphragm expansion tank. The working pressure of the circuit must not exceed 3 bar- 0.3 MPa and its temperature must not exceed 85 oC When connecting to solar sensors, a glycol mixture must be used to protect against frost and corrosion: “TYFOCOR L” type. In the case of an installation with a stop valve at the inlet and outlet of the exchanger, never close the two valves at the same time to avoid any risk of the exchanger bursting.
Preparing the circuit for any installation (new or renovation), the pipes of the water network must be thoroughly cleaned. The aim of this pre-set-up cleaning is to eliminate any germs or residue that could lead to the buildup of In new installations in particular, residues of grease, rusty metal or copper micro deposits must be removed. Cleaning the system before it is commissioned helps to improve efficiency, reduce energy consumption and combat scaling and corrosion. This operation requires the intervention of a professional (water treatment).
Operating the heat pump generates condensation. Condensed water is drained off via the pipe shown With the product stopped, fill the siphon with water up to the arrow, through the condensate drain pipe.
Please note: this operation is not required for an ambient installation. In the case of a ducted product, the filled siphon can be used to check that the ductwork is correct on the intake side.
Do not add a siphon downstream of the one already fitted to the product; the waste water outlet must be unobstructed. Risk of condensate overflowing the heat pump.
With the fan running, compare the water level with the color bar.
Electrical Connections
Refer to the electrical connection diagram on the inside cover of the unit.
The water heater must only be electrically connected once it is filled with water.
Water heater requires an uninterrupted power source.
The water heater can only be connected to and operated via a single-phase 230 V AC. Connect the water heater using a rigid conductor cable with a 1.5 mm2 cross-section.
Electrical installation must include:
An all-pole 16 A circuit breaker with a minimum opening gap of 3 mm,
Protection by a 30-mA residual current device.
If the power cable is damaged, it must be replaced by the manufacturer, its customer service or a professional with similar qualification to prevent any hazards.
Never provide direct power supply to the heating element.
In no case should the safety thermostat on the electric heating element be repaired outside factories. Failure to comply with this clause will void the warranty.
The appliance must be installed in accordance with the national rules regarding electrical installations.
Electrical Connection Diagram
Post-Startup Operation
After completing the startup program settings, the polychromatic display will animate, indicating the heating process.
The heat pump will operate continuously until the programmed set point temperature is achieved.
Pressing the OK button on the display will show the current water temperature.
Once the set point temperature is reached
The heat pump switches off automatically.
Polychromatic display indicates maximum level.
Use calibrated digital thermometers at the hot water draw-off point to verify the actual water temperature at the hot water outlet.
Compare measured values in the hot water with the control panel display.
The temperature difference between the hot water outlet and the control panel depends primarily on heat loss along the hot water pipe.
For uninsulated pipes, this difference is more and influenced by the pipe length, ambient temperature, and heat loss along the run.
When the pipe is insulated, the temperature difference is reduced and depends on the insulation properties as well as the pipe length to the outlet.
Ensure the system reaches the programmed set point temperature.
If any issue occurs, contact the manufacturer’s service centre.
Change the Operation Program
Click the three horizontal line button in HMI Display to change the mode of the operation.
User can select Away Mode, Boost Mode, Change the setting temperature, monitor the energy consumption etc.
If any issue occurs, contact the manufacturer’s service centre.
Heating Time Performance Test
Fill the unit with water and after set up the unit setting measure the time taken to reach the set point temperature.
Heating time depends on the ambient temperature, cold water inlet temperature, HPWH set point temperature, capacity of HPWH and mode of the operation of HPWH.
Once the HPWH reaches the set point temperature, measure the total time for heating.
Record the total time and final water temperature.
If any issue occurs, contact the manufacturer’s service centre.
Drain Pipe and Flow Verification
Inspect all drain pipe connections for tightness and proper sealing.
Operate the safety valve to confirm smooth discharge flow, free from blockages.
Condensation Pipe Verification
Verify that the condensation pipe connected to unit to siphon.
Verify that the siphon filled with water up to the manufacturer mark.
Verify that condensation pipe connected to siphon to drain pipe.
Inlet and Outlet Air Ducts Verification
Verify that the installed duct type complies with manufacturer recommendations.
Confirm that the duct type with insulation as per manufacturer specifications.
Ensure there is no condensation along the duct route from Heat Pump Inlet/Outlet.
If condensation occurs, check the insulation quality with the duct manufacturer.
Vibration Monitoring
Observe the unit during compressor and fan operation.
Confirm vibrations are minimal and within acceptable limits.
If abnormal vibration is detected, contact the manufacturer’s service centre.
Noise Verification
Measure operational noise levels using a sound level meter (if available), or by observation.
Ensure noise is steady and within acceptable limits, with no abnormal sounds (e.g., rattling, knocking, humming).
If abnormal noise is detected, contact the manufacturer’s service centre.
Final Confirmation
Re-check all control panel settings.
Ensure the system is stable, and consistently maintains the required set point temperature.
Document all results in the commissioning report.
Obtain consultant/engineer sign-off to complete verification
QUALITY CONTROL INSPECTION
All request for inspection shall be raised by QA/QC at minimum 24 hours prior to inspection.
In process works shall be monitored for quality of workmanship and installation against approved construction drawings by the relevant QA/QC Engineer, Supervisor and Project Manager.
All works shall be inspected for quality of workmanship and conformance to specification prior to offering for Engineers inspection.
Ensure that all the pre-commissioning checks are carried out successfully.
Ensure no damaged on the ducts
HEALTH, SAFETY & ENVIRONMENT RISK CONTROLS
Site general safety procedures will be followed. In case of Emergency arrangements and report to assembly points as indicated during the Site Induction Course.
Fire Precaution:
General fire prevention measures will be taken as per the Main contractor’s site Fire & Emergency plan.
Fire prevention and protection as per standard client procedures.
Communication:
Senior Foreman will communicate from work areas to Site Office via mobile
Safety Lighting:
Safety Lights will be used in case of power failure ensuring good illumination of the area for evacuation
Task Lighting
Adequate lighting will be provided to ensure the good illumination of the working area
Task Lighting will be connected to the nearest site distribution board which will be RCD protected.
House Keeping
All work places will be cleared of all scrap materials derived from their work, ensuring clean and healthy work environment as well as to maintain free access and egress in the event of emergency
TRAINING
Tradesman performing the described work will be experienced technicians. If deemed necessary specific team/ individuals will undergo further training and awareness programs for this activity by the Production/ Quality Assurance Departments.
Toolbox talks will provide general training and awareness for each activity and also in Health & Safety matters and precautions (including the use of hazardous materials e. solvents)
ATTACHMENTS
- Schedule of proposed materials
- Inspection and Testing Plan
- Checklist
- Risk Assessment