| Document No. | [ENTER DOCUMENT NUMBER] | Revision | 00 |
| Project Location | [ENTER PROJECT LOCATION] | Project Name | [ENTER PROJECT NAME] |
| Project No. | [ENTER PROJECT NUMBER] | Prepared By | [NAME / DESIGNATION] |
| Date | [DD/MM/YYYY] | Reviewed By | [NAME / DESIGNATION] |
| Approved By | [NAME / DESIGNATION] | Client / Owner | [ENTER CLIENT / OWNER NAME] |
| Main Contractor | [ENTER MAIN CONTRACTOR NAME] | Sub-Contractor | [ENTER SUB-CONTRACTOR NAME] |
| Applicable Standards | ASHRAE 90.1 / ISO 9001:2015 / ISO 45001:2018 / [PROJECT SPECIFICATIONS REFERENCE] | ||
This Method Statement establishes the documented procedure for the precommissioning and commissioning of water-cooled and/or air-cooled chillers, including associated auxiliary systems, instrumentation, and controls, in strict accordance with the manufacturer's recommendations, project specifications, and applicable international standards. It governs all preparatory, inspection, start-up, testing, and handover activities undertaken by [ENTER COMPANY / CONTRACTOR NAME] on the project [ENTER PROJECT NAME].
The purpose of this document is to define the sequence of activities, safety controls, quality hold points, and responsibilities required to safely and successfully execute chiller commissioning works whilst maintaining compliance with ISO 9001:2015 (Quality), ISO 45001:2018 (Health & Safety), and ISO 14001:2015 (Environment), as well as the regulatory requirements of [LOCAL AUTHORITY / REGULATORY BODY NAME].
This document shall be read in conjunction with the approved construction drawings, equipment manufacturer's Installation, Operation and Maintenance (IOM) manuals, project specifications, Risk Assessment reference [ENTER RA REFERENCE], and the project Inspection and Test Plan (ITP) reference [ENTER ITP REFERENCE]. Any conflict between this document and project specifications shall be immediately reported to the [PROJECT ENGINEER / CLIENT REPRESENTATIVE] for resolution prior to proceeding.
This Method Statement covers the following activities associated with the precommissioning and commissioning of chiller plant and associated systems:
- Receipt, inspection, and off-loading of chiller units and associated auxiliary equipment upon delivery to site.
- Pre-commissioning checks: verification of mechanical installation, refrigerant piping connections, condenser water and chilled water pipework connections, electrical connections, and control wiring.
- Verification of all associated isolation valves, strainers, balancing valves, and expansion vessels against approved shop drawings.
- Leak testing of refrigerant circuits in accordance with EN 378 / ASHRAE 15 requirements.
- Verification of factory refrigerant charge or site charging, as applicable.
- Electrical supply verification, meggering of motor windings, and earth continuity testing.
- Initial start-up, commissioning, and running-in of chiller units under part-load and full-load conditions.
- Verification of chiller controls, BAS/BMS integration, safeties, and alarm functions.
- Commissioning of pumps, cooling towers, and condenser water systems in interface with chiller operation.
- Performance testing, including capacity verification, COP measurement (where required), and logging of operating parameters.
- Documentation of commissioning results on chiller commissioning data sheets and submission to the QA/QC Inspector and Client.
- Witnessing by [CLIENT / CONSULTANT REPRESENTATIVE] at designated hold points as specified in the ITP.
- Final handover, O&M documentation compilation, and training of facility management personnel (if specified).
| Role / Designation | Responsibilities |
|---|---|
| Site Engineer / Commissioning Engineer | Overall technical oversight of precommissioning and commissioning activities; preparation and sign-off of commissioning data sheets; coordination with manufacturers' representatives; liaison with QA/QC Inspector and Client; ensuring work is executed in accordance with this Method Statement, drawings, and specifications. |
| Site Foreman / Chiller Commissioning Supervisor | Direct supervision of commissioning technicians and operatives on site; enforcement of safe systems of work; delivery of daily toolbox talks; control of access to energised plant areas; verification of pre-start checklist completion; ensuring calibrated test equipment is used and logged. |
| HSE Officer | Conducting site HSE inductions; daily site inspections; enforcing PPE compliance; reviewing and communicating the Risk Assessment; issuing Permit to Work (PTW) where required; investigation of incidents and near misses; ensuring emergency procedures are understood by all personnel. |
| QA/QC Inspector | Witnessing designated hold points and witness points per the approved ITP; signing off inspection records and commissioning data sheets; reviewing non-conformances and issuing NCRs; maintaining documentation registers for all commissioning submittals. |
| Manufacturer's Representative (if applicable) | Providing technical guidance on chiller start-up sequence; confirming factory settings and control parameters; witnessing and certifying initial start-up and performance runs; issuing manufacturer commissioning certificate. |
Additional roles may be added as required per [PROJECT / COMPANY ORGANISATIONAL CHART REFERENCE].
- Calibrated digital manifold gauge set (compatible with relevant refrigerant type, e.g. R-134a, R-410A, R-1234ze)
- Refrigerant leak detector (electronic, calibrated and certificated)
- Vacuum pump (dual-stage, minimum 7 CFM capacity) with micron gauge
- Refrigerant recovery/charging unit and certified refrigerant cylinders
- Calibrated clamp-on power analyser / multi-function power meter
- Digital insulation resistance tester (Megger), rated minimum 1000V DC
- Calibrated earth continuity / loop impedance tester
- Calibrated digital thermometer with surface, immersion, and ambient probes (resolution ±0.1°C)
- Calibrated differential pressure gauge / manometer
- Ultrasonic flow meter (clamp-on type) for chilled water and condenser water flow measurement
- Torque wrench set (metric and imperial)
- Digital tachometer / stroboscope for pump and fan speed verification
- Vibration analyser / data logger
- Network/BAS laptop with relevant commissioning software and BMS interface cables
- Personal gas monitor / refrigerant detector (for enclosed plant room use)
- Nitrogen pressure cylinder with regulator (for leak testing)
- Standard hand tools: adjustable spanners, screwdrivers, Allen key set, pipe wrenches
- Personal Protective Equipment (refer to Section 8)
- Calibration certificates for all test instruments — valid and in date at time of use
- Chiller unit(s) — approved manufacturer and model as per approved material submittal
- Refrigerant (type as specified: [e.g. R-134a / R-410A / R-1234ze]) — virgin grade, certified cylinders with SDS
- Compressor oil / lubricant (manufacturer-specified grade)
- Flexible anti-vibration connections (chilled water and condenser water, EPDM or approved equal)
- Shut-off and balancing valves, strainers, and expansion vessels (as specified)
- Water treatment chemicals (inhibited glycol solution or biocide as specified) with SDS
- Chilled water and condenser water system flushing chemicals (as per approved chemical treatment programme)
- Electrical terminal lugs, cable glands, and conduit fittings (project-specified type and rating)
- Pipe insulation lagging (where required for commissioning completion, project-specified specification)
- Consumables: thread seal tape, jointing compounds, consumable fittings
- Commissioning data sheets and record forms (as per approved ITP)
Where chiller skid assembly or prefabricated pipework spools are prepared off-site or in a designated fabrication area, all works shall be carried out in accordance with the project specifications and manufacturer requirements. Completed sub-assemblies shall be tagged, inspected, and documented prior to transfer to the installation area. Refrigerant-containing components shall not be fabricated or modified without manufacturer authorisation.
Upon delivery, each chiller unit and associated ancillary equipment shall be subject to the following:
- Verification of delivery documents, packing list, and approved material submittal against actual delivered items.
- Visual inspection for damage, dents, corrosion, or transit damage to refrigerant piping, control panels, and structural frames.
- Verification that factory refrigerant holding charge (nitrogen or refrigerant) is intact via pressure gauge reading. Any loss of holding charge shall be reported immediately to the manufacturer.
- Inspection of all ancillary items: sensors, controls, valves, and documentation packs (IOM manuals, wiring diagrams, commissioning guides).
- All non-conforming or damaged items shall be tagged, segregated, and documented on a Non-Conformance Report (NCR). No damaged equipment shall be installed without written resolution from [ENGINEER / CLIENT].
- Delivery inspection records shall be signed by the Site Engineer and submitted to the QA/QC Inspector.
- Chiller units shall be lifted using manufacturer-approved lifting points only. Lifting lugs, spreader beams, and slings shall be rated and certified for the equipment load.
- A Lifting Plan and Risk Assessment shall be prepared and approved prior to any crane or forklift lifting operation.
- Equipment shall be stored on a level, dry surface, protected from direct weather and contaminants. Factory packaging shall be retained until immediate installation.
- Control panels and electrical components shall be stored in a weatherproof, temperature-controlled environment in accordance with manufacturer requirements.
- Refrigerant cylinders shall be stored upright, secured against falling, segregated from ignition sources, clearly labelled, and maintained with current SDS on site.
- All stored items shall be clearly identified and tagged. Damaged or quarantined items shall be physically separated from serviceable stock.
All works shall comply with the project HSE Plan, the applicable regulations of [LOCAL HSE AUTHORITY / REGULATORY BODY NAME], and the requirements listed below:
- Toolbox Talk (TBT): A site-specific TBT shall be conducted before commencement of each working day and before any new commissioning phase begins. Attendance records shall be signed and retained. TBT topics shall address the specific activities of that day, including refrigerant handling, electrical work, and confined space entry.
- Mandatory PPE: Safety helmet; safety footwear (steel-toe, anti-static); high-visibility vest; safety glasses (chemical splash rated during refrigerant handling); nitrile or neoprene chemical-resistant gloves (for refrigerant and chemical handling); insulated electrical gloves (rated for working voltage); hearing protection where noise levels exceed 85 dB(A); face shield (during refrigerant charging / leak testing); respiratory protection (where refrigerant concentration risk exists in enclosed plant rooms).
- Working at Height: Where access to elevated components (cooling tower roof, rooftop chillers) is required, a Working at Height permit shall be issued. All fall protection equipment (harness, lanyard, anchor point) shall comply with BS EN 363 and OSHA 29 CFR 1926.502. Scaffolding or MEWP to be inspected and certified prior to use.
- Electrical Safety: LOTO (Lockout/Tagout) procedure shall be strictly enforced on all electrical isolation prior to any electrical work. Only competent, authorised electricians shall perform electrical connections. Live testing, where unavoidable, requires a two-person team and appropriate insulated PPE.
- Refrigerant Handling: Only certified refrigerant handling operatives (F-Gas certified or equivalent) shall charge, recover, or handle refrigerant. Recovery equipment shall be used for all refrigerant removal. Intentional venting of refrigerant to atmosphere is prohibited. SDS for each refrigerant type shall be available on site.
- Chemical / Substance Handling: All water treatment chemicals, refrigerants, and compressor oils shall be handled in accordance with their current SDS. COSHH/chemical risk assessment to be completed and communicated prior to use. Appropriate PPE, spill containment, and disposal procedures shall be in place.
- Confined Space: Where commissioning activities are conducted in enclosed or restricted plant rooms with inadequate ventilation, a Confined Space Entry permit shall be required. Atmospheric testing (oxygen, refrigerant concentration) shall be performed prior to and during entry.
- Manual Handling: Mechanical aids (trolleys, chain blocks, engine hoists) shall be used for lifting heavy components. Manual lifts exceeding [SPECIFY WEIGHT LIMIT PER LOCAL REGULATION] kg shall not be conducted without mechanical assistance. Manual handling technique training shall be confirmed for all operatives.
- Waste Management: All waste refrigerant shall be recovered and disposed of by a licensed contractor in accordance with local regulations and the project Environmental Management Plan. Chemical containers shall be disposed of as hazardous waste. General waste and recyclables shall be segregated on site.
- Emergency Procedures: Emergency muster point: [ENTER MUSTER POINT LOCATION]. First aid kit and eyewash station shall be available in the chiller plant room. Emergency services contact: [ENTER LOCAL EMERGENCY NUMBER]. In the event of refrigerant release, evacuate plant room, eliminate ignition sources, ventilate space, and contact HSE Officer immediately.
Risk Assessment Reference: [ENTER RA DOCUMENT REFERENCE NUMBER]
All inspection and test activities shall be conducted in accordance with the project Inspection and Test Plan (ITP). Each hold point and witness point shall be signed off by the designated QA/QC Inspector before subsequent activities are permitted to proceed.
| # | Inspection Activity | Reference Document | Acceptance Criteria |
|---|---|---|---|
| 1 | Material Delivery & Receipt Inspection — chiller unit, ancillaries, and documentation | Approved Material Submittal; IOM Manual; Packing List | No physical damage; holding charge intact; correct model/specification per submittal |
| 2 | Mechanical Installation Check — levelness, anti-vibration mounts, pipework connections | Approved Construction Drawings; IOM Manual | Level within ±2mm/m; connections per drawing; all shipping brackets removed |
| 3 | Refrigerant Leak Test (nitrogen or electronic) on all field connections and service points | EN 378 / ASHRAE 15; IOM Manual | Zero pressure loss over 24 hours (nitrogen test); no detectable leaks (electronic detector) |
| 4 | Vacuum Test — deep vacuum to ≤500 microns and standing vacuum (blank-off) test | IOM Manual; ASHRAE 15 | Micron level achieved ≤500 microns; standing vacuum stable (no moisture or leak) |
| 5 | Electrical Inspection — wiring terminations, circuit breaker ratings, phase rotation, earth continuity | Approved Single-Line Diagram; IOM Manual; IEC 60364 | Connections per wiring schedule; correct phase rotation confirmed; earth continuity <1Ω |
| 6 | Insulation Resistance (Megger) Test — compressor motor windings | IOM Manual; IEC 60034 | Minimum ≥1 MΩ (or per manufacturer specification); results recorded and signed |
| 7 | Water Flow Verification — chilled water and condenser water flow rates | Approved Hydraulic Design Drawings; IOM Manual | Flow rates within manufacturer's specified range (min/max); results recorded |
| 8 | Initial Start-Up & Safety Controls Test — all protective devices and interlocks | IOM Manual; Project Commissioning Data Sheet | All safeties trip at correct setpoints; chiller shuts down and alarms annunciate correctly |
| 9 | Full-Load Performance Run — operating parameters recorded and compared to design | Design Specifications; IOM Manual; Commissioning Data Sheet | LCHWT achieved within ±0.5°C of setpoint; capacity within ±5% of design (or per spec) |
| 10 | BMS/BAS Integration Verification — control signals, alarms, setpoints, and data points | Approved Controls & BAS Points Schedule; Project Specification | All data points confirmed operational at BMS workstation; alarms and controls functional |
ITP Reference: [ENTER ITP DOCUMENT REFERENCE NUMBER]
- ISO 9001:2015 — Quality Management Systems
- ISO 14001:2015 — Environmental Management Systems
- ISO 45001:2018 — Occupational Health & Safety Management Systems
- ASHRAE Standard 15 — Safety Standard for Refrigeration Systems
- ASHRAE Standard 90.1 — Energy Standard for Buildings
- EN 378 — Refrigerating Systems and Heat Pumps — Safety and Environmental Requirements
- IEC 60364 — Low-Voltage Electrical Installations
- IEC 60034 — Rotating Electrical Machines
- IOSH Managing Safely — Risk Assessment and Method Statement Principles
- BS EN 363 — Personal Fall Protection Equipment
- OSHA 29 CFR 1926.502 — Fall Protection Systems Criteria
- ISO 16025 — Standards for Height Safety Equipment
- Approved Material Submittals — [ENTER REFERENCE]
- Approved Shop / Construction Drawings — [ENTER DRAWING REGISTER REFERENCE]
- Project Specifications — Section [ENTER RELEVANT SECTION NO., e.g. 23 60 00 — Central Cooling Equipment]
- Project HSE Plan — Ref: [ENTER REFERENCE]
- Inspection & Test Plan (ITP) — Ref: [ENTER REFERENCE]
- Risk Assessment — Ref: [ENTER REFERENCE]
- Chiller Manufacturer's IOM Manual — [ENTER MANUFACTURER AND DOCUMENT REFERENCE]
| Rev. | Date | Description of Change | Approved By |
|---|---|---|---|
| 00 | [DD/MM/YYYY] | Initial Issue | [NAME / DESIGNATION] |
| 01 | [DD/MM/YYYY] | [DESCRIBE REVISION] | [NAME / DESIGNATION] |
| Prepared By | Reviewed By | Approved By | Client / Owner Representative |
|---|---|---|---|
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Name: [ENTER NAME] Designation: [ENTER DESIGNATION] Signature & Date
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Name: [ENTER NAME] Designation: [ENTER DESIGNATION] Signature & Date
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Name: [ENTER NAME] Designation: [ENTER DESIGNATION] Signature & Date
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Name: [ENTER NAME] Designation: [ENTER DESIGNATION] Signature & Date
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