Hot Water Calorifier Testing and Commissioning Method Statement

This method statement is applicable for the testing and commissioning of hot water calorifier or water heater for any kind of building or projects.

Arrange below tools before start of the work:

• Electrical Toolbox
• Box spanner set
• Pipe wrench

Pre Commissioning Requirements

Before commencing the testing and commissioning of calorifier the following shall be carried out:

Make sure that the installation of hot water calorifier has been carried out by trained technicians in accordance with the approved shop drawing by the engineers.

Check and make sure that the electrical connection is done / tested and approved by the electrical engineer.

Make sure that the tank is completely filled with water and any trapped air has been bled off.

Ensure that temperature and pressure relief valves are installed and the related piping is connected to the nearest drain point.

While filling the tank with water the nearest hot water tap should be open to make sure that air  is releasing from the tank, watch the water flow from this tap until continuous flow of water  is achieved which means the tank is fully purged from air.

Make sure that the cold water supply feeding the tank will be kept open even the calorifier tank is full to be always on the safe side that heating elements and always immersed into water.

The temperature and pressure release valve shall be opened manually and keep discharging the water until continuous water flow without pebbles is observed.

Open the electrical control panel and set the thermostat to the set temperature(82°C)

Carefully check the tank, pipe and fittings for any sign of water leak. Immediately repair as needed. Open the access door to the immersion heating elements and check for leaks at the element mounting flanges if any leak is detected, tighten the screw in element.

Calorifier Start Up Method

Turn on the power supply from the main control panel.

As the water heater starts heating check the contactors for “buzzing” or “Chattering” during operation, if noise is detected, turn off the main power, open the control panel and clean the contact points of the magnetic contactor.

Remove any dust, dirt or foreign matter that may have found its way into the contactor or other electrical components in the control panel.

Now turn on the power again and allow the water heater to heat for approximately thirty minutes.

Turn off the main electrical power to the water heater / calorifier.

Open the electrical control panel door and feel each wire connection and fuse clip for excessive heating/ temperature. If any connection is found to be excessively hot, check all factory settings and connections, including internal wiring connections and the field made power connections for tightness.

After completing above requirements close the control panel and turn on the power supply for the water heater.

Temperature control and contactor operation should be checked by allowing the water heater to come up to the setting temperature and shut off automatically.

The water heater is now ready for continuous normal operation.

Inspection: Inspection requests shall be raised to the consultant and to be conducted in presence of main contractor.

HEALTH, SAFETY AND ENVIRONMENTAL REQUIREMENTS

Site general safety procedures will be followed. In case of emergency the Safety Officer will stop the work; he will put into action the emergency arrangements and report to assembly points as indicated during Site Induction Course.

Fire Precautions: There is no significant fire risk associated with this activity but general fire prevention measures will be taken as per project HSE plan.

Communication: Communication from work areas to site office shall be via mobile phone by the senior foremen. In emergency situations the users of hand-held 2-way radios to be notified if deemed that this can speed up notification of relevant personnel and/or the Site Clinic.

Hazards / Risks: Relevant risk assessments to be prepared for the use of below items/materials:

• Hand Tools
• Ladder and Stepladders
• Disposals of Waste Materials

Environmental Considerations: After the finalization of the works the working area should be cleaned from any scrap materials related to the performed work.

Working places will be cleaned from the scarp 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.

Health and Safety Hazards

Implementation of Health & Safety mechanisms and checks as per contract agreement.

The responsible Safety Officer for each building will conduct routine safety inspections.

Good housekeeping must be maintained throughout the execution of work.

The work location must be gas free and precautions must be taken to prevent ignition of flammable materials.

Only qualified personnel will be deployed to perform the water heater testing and commissioning work.

All personnel protection equipment’s (PPE) shall be worn during the work, the generally used PPE are Coverall, Safety shoes, Hard Hat, Safety glasses, dust mask and Hand gloves.

Material Safety Data Sheets for the materials used shall be followed.

Safety Lighting: Safety lights will be used in case of power failure ensuring the good illumination of the working area for safe evacuation of the site people.

Task Lighting: Adequate lighting will be provided ensuring the good illumination of the working area. Task lighting will be connected to the nearest site distribution board which is RCD protected.

ATTACHMENTS

• • Inspection Checklists
  • Inspection and Testing Plan
  • HSE Risk Assessment
  • Technical Data sheet (TDS)
  • Material Safety Data Sheets (MSDS)