CRAC Unit Installation and Commissioning Method Statement

Method Statement for CRAC Unit Installation, Testing & Commissioning | Data Center HVAC Guide📚

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📘 INTRODUCTION (CRAC Unit Installation, Testing & Commissioning)

✔️ A Computer Room Air Conditioner (CRAC) is a precision cooling system designed to maintain strict temperature, humidity, and air quality requirements in data centers, server rooms, and critical IT environments.
✔️ Proper installation and commissioning of CRAC units are essential to ensure system reliability, equipment protection, and uninterrupted operations.

CRAC Unit Installation and Commissioning Method Statement in HVAC

CRAC Unit Installation & Commissioning Method Statement

✔️ This Method Statement for CRAC Unit Installation, Testing & Commissioning defines the systematic approach, safety requirements, quality controls, and responsibilities involved in executing CRAC works in compliance with project specifications, approved drawings, international standards, and HSE requirements.

CRAC Unit Installation and Commissioning Method Statement

Method Statement for CRAC Unit Installation and Commissioning

✔️This document serves as a practical guide for engineers, supervisors, QA/QC personnel, and safety teams involved in CRAC projects.

1️⃣ SCOPE AND PURPOSE

This method statement is made to enumerate the general activities to be performed in Mechanical system works for CRAC Project.

It covers the procedure to be implemented for handling, installation and inspection of CRAC unit installation works.

This method statement explains the plan and safe execution method at a various stage of the CRAC unit installation works, in accordance with project specification and as per the latest approved drawings that are related with CRAC and unit installation works.

CRAC Unit Installation

Reference Documents

CRAC Project:

Typical inspection and test plan for CRAC unit installation works.
Inspection checklist.

General Requirements

All CRAC installation works, materials, fittings, and accessories used for the project shall comply with ASHRAE, ISO, IEC, and NFPA standards, as well as the approved project specifications.

2️⃣ ROLES AND RESPONSIBILITIES

Site Manager👷🏻‍♂️

Site Manager shall provide his site teams with appropriate resources to ensure that works are done in accordance with the project quality, HSE requirements and shall be responsible for the overall site work management.

Site Manager

Construction Manager👷🏻‍♂️

Construction Manager shall be responsible for the overall implementation and monitoring of all construction activities for the project.
He is responsible for the development and maintenance of the construction procedures.

Construction Manager

Ensure construction direction to the construction team, and implementation of safety and security plan.
Maintain a full control of materials throughout the construction.

QA/QC Manager👷🏻‍♂️

QA/QC Manager shall ensure that all works are in accordance with the approved drawings, project specifications, applicable international standards, and established quality control procedures.

QA and QC Manager

He must ensure that Inspection and Test plan are observed and must review Method Statement for CRAC installation works.

QA/QC Inspector👷🏻‍♂️

QA/QC Inspector shall be responsible for the necessary inspection and witness of the testing to be carried out for all the related activities on the CRAC unit installation works.
He shall monitor all related CRAC unit installation works activities and ensures that work execution complies with the project specifications, codes, standards and other relevant project documents whenever required.

QA and QC Inspector

He shall also prepare quality control records and documents for final inspection and acceptance by the concerned consultant/client department in accordance with project specifications and applicable standards.

Mechanical Engineer and Supervisor👷🏻‍♀️⚙️👷🏻‍♂️

Mechanical Engineer and supervisor shall be directly involved in planning and execution of all related CRAC unit installation works activities at site.
Prior to the start of the work, he shall prepare Safety Action Plan that must be implemented and observed during CRAC and CRAH unit installation works activities.

Mechanical Engineer and Supervisor

He shall ensure that Mechanical foremen comply with the requirements of the procedure and other relevant project specification, drawings, other reference codes and standards applied to the project site.
He is responsible for the schedule control and tracing of all relevant planning, assists to summarize various construction requirement for CRAC unit installation work sand resolve the problems arising from the drawing discrepancy with the contract engineer.

Foreman👨🏻‍🔧

Foreman shall be responsible for the direct execution of all related CRAC unit installation works according to the work plan.
Also, he has to provide instructions to the workers. He shall confirm the proper condition of all ill a construction tools and equipment to be used at site.

Foreman

He shall also ensure workers to prepare proper PPES, good housekeeping compliance.
Safety rules and regulations.

Safety Manager and Supervisor👷🏼‍♂️

Safety manager / supervisor shall review safety action plan that must be implemented and observed in relation with CRAC unit installation works during the construction.

Safety Manager and Supervisor

He shall review the applications for work permits if required by safety department.

3️⃣ REQUIRED TOOLS, MATERIALS AND EQUIPMENTS

Tools

Standard mechanical tools,
Level,
Movable platform or Ladder,
Electric Cord Reel,
Flash Light & Hand Light,

REQUIRED TOOLS

Industrial Vacuum Cleaner,
Engine welding machine (400A),
Electric Drill machine with Drill bits,
Hack Saw & Blade, any others if required.

Instruments

Measuring Tape (5m long),
Insulation Tester,
Multi meter,
Steel Ruler,
Inspection Mirror, any Others if required.

Required Instruments

4️⃣ METHOD STATEMENT – WORK PROCEDURE

Handling procedure for materials:

All material handling, transportation shall be performed in a safe manner as to avoid any damage by mishandling & mechanical forces and also avoid exposure to moisture, dust, oil and lubricant while storing of CRAC unit.
Each & every delivered item shall be inspected to ensure compliance to specification data sheet and free from damages.
It is the responsibility of the Contractor to transport and deliver the CRAC and CRAH units from the laydown area to the CRAC project site.
The haul road levelling, compaction shall be done by civil contract and make sure that all is ok before transportation.
Prior to installation of CRAH and CRAC unit in the locations.
Concerned Supervisor and QC inspector shall be inspected the site conditions for the installation of CRAC unit and verify its correct location with site conditions prior to start the works.
After transporting the CRAC unit wooden box.

✔️Open the wooden box.

✔️Inspect the Distribution CRAH and CRAC unit.

✔️All confirm by the concerned supervisor and Engineer it is ok.

Handling procedure for materials

Pre-installation check

Make sure the area has been cleaned and enough access to install the CRAH and CRAC unit.

Make sure the CRAIL and CRAC unit identification and location as per drawing before installations the panel.

Arrange air-conditioning systems to maintain the room temperature in accordance with approved project specifications and applicable standards.

5️⃣ METHOD OF INSTALLATION

METHOD OF INSTALLATION-1

The Contractor shall obtain the necessary work permits prior to commencement of the job and ensure adequate provisions for working at height. The following steps shall be followed during installation.
Check and ensure that all site conditions and working practices are observed strictly and to obtain the work permit.
Ensure that the level and elevation details while installing the steel support frame for CRAH and CRAC unit.
Ensure the CRAH and CRAC unit shall be provided with the circuit directory sheet that showing list of breakers with circuit detail.
Mobilize the adequate qualified man power with required tools to the work site as per detailed schedule of activities.
Install the steel support / bracket with correct dimensions on the location of CRAH and CRAC unit as per the approved IEC drawings.
Install the CRAII and CRAC unit to its location as per the approved IFC drawings and accessories shall be mounted/ installed after installation of the same.
Tighten the bolts after the problem alignment of CRAH and CRAC unit.
Laying and brazing pipes as per the best and shortest possible routing in the building along with cable for the outdoor unit
Adding insulation (K-flex) to the external pipes from indoor to outdoor were ever possible.
Fixing the pipes to the ceiling, ground, walls were ever needed using steel U channels and C clamps, depending on the route of the pipe Testing the pipes for leaks using high pressure Nitrogen alter closing the ends of the pipes.
Installing Isolator Switch on the wall near the Indoor unit and cables from the main panel to the switch, and from switch to the unit (main panel usually inside the room).
Connecting water supply and water drain lines (PVC pipes) to the units (both tabs should be available inside the room),
Terminating the outdoor power supply from both sides,
Vacuuming the pipes using Vacuum pump to remove air and moisture from the pipes.
After adding primary charge, the unit (including the compressor) can be started to complete the Freon charge and balance the pressures,
Checking the settings of the controller and adjusting any needed,
Checking the settings of the outdoor speed controller,
Taking readings of the unit and filling start up report.

METHOD OF INSTALLATION-2

6️⃣ INSPECTION AND TEST

Work performed as per IEC DWG and relevant specification shall be monitored. witnessed and recorded by QC inspector in accordance with Inspection & Test Plan.

A Ready for Inspection (RFI) shall be issued to the Consultant/Client QC Inspector at least 24 hours in advance to verify readiness for testing or completion of installation in accordance with IFC drawings and applicable standards.

INSPECTION AND TEST

Relevant appropriate inspection & checklist form will be filled as observed by QC inspector.

Maintaining Inspection record.

7️⃣ SAFETY REQUIREMENTS & JOB SAFETY ANALYSIS

General

All personnel involved in the activities shall wear complete Personal Protective Equipment's (PPE) in accordance with the Safe work Requirements.

Conduct job safety tool box.

Work permit for CRAC and CRAH unit installation works shall be obtained prior to start the works.

SAFETY REQUIREMENTS

Place barricade and warning sign boards in applicable location restricted equipment's entering the work area.

Check adequacy and availability of all tools and equipment for erection und installation activities, before commencement of the erection activity.

The Safety officer shall verify that all the necessary and applicable documents, related to the safest operation, are in possession before commencing the job.

Tools & Equipment's

welding gloves & Shields,
harness,
working gloves,
face shield,
Electrical grinder,
PPE and tool box w/hand tools.

Safety Tools and Equipment's

Risk Involvement

Electric shock,
fire,
injury (Body, eye, finger, foot etc.),
slips and falling load etc.

Risk Involvement

Recommendation & Responsibility

Need to study MOS and DWG prior to starting the job by the concerned supervisor and foreman

Check all PPE, tool and protection devices by the supervisor and confirm to workers realization at the time of work commencement.

Ensure Electrical earth connection for the work shall be secured by the safety officer and nearest close to the working location.

Fire extinguisher and firewatcher is located close to the equipment

Housekeeping is a mandatory during and after work completion.

Housekeeping

Proper PPE and protection devices, such as face shield, gloves, full body harness etc. to used, shall be inspected by the concerned supervisor & foreman prior to starting the works.

Prohibit attending any person who is not authorized for this work.

Barricade and warning sign board shall be located at the work place to prevent entering any unauthorized persons.

Any incident occurred during the work, supervisor and safety officer shall be reported to his superior by mobile phone and official report to be accordingly.

Job Safety Analysis

PPE tools & equipment in this CRAC and CRAH unit system shall be inspected prior to starting work to prevent any incident.

The concerned supervisor has fully understand job procedure and work sequence.

Ensure to explain all workers to understand safety point such as electric shock, fire, injury and etc. during execution of the works.

Job Safety Analysis

Housekeeping is a mandatory during works and after works.

Prohibit loitering and other person who is not working at the working place

The hot work area should have proper barricading, fire extinguisher, fire blanket etc, along with fire watcher.

🧐Conclusion

The successful installation, testing, and commissioning of CRAC units play a vital role in ensuring reliable and continuous cooling for critical environments such as data centers and server rooms.
By strictly following this method statement, project teams can achieve safe execution, high-quality installation, and optimal system performance.
Adherence to approved drawings, inspection procedures, safety protocols, and commissioning requirements ensures compliance with project specifications and enhances long-term system reliability.⚙️
This method statement serves as a comprehensive reference for engineers, supervisors, QA/QC personnel, and safety teams involved in CRAC HVAC works.❄️