METHOD STATEMENT FOR INSTALLATION, TESTING AND COMMISSIONING OF UNDER GROUND & ABOVE GROUND PVC PIPE SYSTEM
PROJECT
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CLIENT MAIN CONTRACTOR : PMC
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CONSULTANT
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TABLE OF CONTENTS
1. SCOPE ……………………………………………………………………..………………… 3 2. REFERENCES ……………………………………………………………….. ……………..3 2.1. Contract documents 2.2. Contractor submittals 3. DEFINITIONS/ABBREVIATIONS ……………………………………………………3 3.1. Definitions 3.2. Abbreviations 4. QUALITY CONTROL ……………………………………………………………….….. 4 5. EQUIPMENTS/TOOLS/MANPOWER/MATERIALS ………………………..4 5.1. Material used 5.2. Tools & equipment 6. WORK SEQUENCE AND METHODOLOGY ……………………………………..6 6.1. Piping system 6.2. Installation of fire fighting equipment and accessories 6.3. Installation of pumps 6.4. Flushing/Cleaning of piping and equipment 6.5. Installation of fire detection system and accessories 7. HEALTH
AND ………………………………………………………………...13
SAFETY
1. SCOPE This procedure covers installation, testing and commissioning of Under Ground & above Ground PVC pipe system. 2. REFERENCES 2.1. Contract documents 1. Project Specification
2. Contract Drawings 3. Bill of Quantity 2.2. Contractors Submittal 4. Project Quality and Safety Plan 5. Material approvals 6. Shop Drawings 7. Related method Statements
3. DEFINITIONS / ABBREVIATIONS 3.1. Definition 1. Project - Kaluthara Resourt & Spa, 2. Client - Miner International 3. Consultant - Wijitha Perera Associates(Pvt)Ltd 4. PMC 5. Contractor - Access Project 6. MEP Design Build contractor –Yonsan Engineering Pte Ltd 3.2. Abbreviations 1. RFC - Request for Clarifications 2. RFI - Request for Inspection 3. MA - Material Application 4. MEP - Mechanical Electrical Plumbing 5. MET - Method Statement 6. MIR - Material Inspection Request 7. PPE -Personal Protective Equipment 8. PTW -Permit To Work ( Working at Height or enclosed spaces) 9. RA -Hazard Identification and Risk Assessment 10. SPD - Shop Drawing 4. QUALITY CONTROL 1. Quality of installation and materials at site will be ensured by our project team consisting of a Project Manager, Project Engineers, QA / QC Officer and the site Supervisor. All will be according to the Specification, Applicable standards and /or industry norms. 5. EQUIPMENTS/ TOOLS / MANPOWER/MATERIALS 5.1. Materials used 1. All materials to be used are as per the approved material submittals. 5.2. Tools & equipment The following Tools and Equipment will be used for this Installation: 1. Hand tools 2. Drill Machines 3. Measuring equipment 4. Hack saw
5. High pressure PVC Glue 6. Pipe Wrenches & Spanners, etc. 6. WORK SEQUENCE AND METHODOLOGY 6.1.
Piping system
6.1.1 Storage and handling 1. The pipes will be stacked in the site store on a flat surface. Fittings will be separately packed and stored as per the sizes required for the project. All open ends of pipes will be covered to protect from foreign matter, dirt/debris. 6.1.2 General Piping Installation Guidelines 1. Pipe work shall be installed in accordance with the piping general arrangements and their supporting drawings, specifications and schedules. 2. Installation of pipe work shall be carried out under conditions satisfactory to the consultant. 3. All work performed and completed will meet the approval of the consultant. 4. Scheduling of work to carry out the installation of pipe work shall be agreed and to the satisfaction of the main contractor and shall be cocoordinated with the work schedules of other trades and disciplines involved in the overall construction. 6.1.3 Installation of pipes( PVC Type 600) 1. Mark the pipe path by using white chalks/marker pen as per approved coordination drawings. 2. Run all piping as direct as possible, avoiding unnecessary offsets and conceal piping in finished rooms. 3. Make tees, bends, reducers,…etc connections with standard fittings for full size branches. 4. All piping will be rigidly supported by a combination network comprised of pipe hangers and rigid support brackets. Pipe hangers are used to support the “dead load” of the pipe system. Pipe hangers will be spaced according to the relevant standard / Specification clause and Hanger rod sizes and numbers will comply with the requirement of the respective standard / Specification clause or Manufacture’s recommendations. 5. Hanging, bracing, and restraint of fire protection system piping must be performed in maintain as per the spacing given below.
PIPE SIZE (Diameter in MAXIMUM SPACING (Millimeters) mm) Horizontal Vertical Installation Installation
25mm 32mm 40mm 50mm 65mm 80mm 100mm 150mm
2000 2000 2000 2000 2000 2500 2500 2500
mm mm mm mm mm mm mm mm
3000 3000 3000 3000 3000 3000 3000 3000
mm mm mm mm mm mm mm mm
6. Level the brackets by using split level, water level etc. 7. Place the pipe on the brackets and insert the “U” bolts and tight it firmly.
8. Where supports are supporting pipelines or equipment subjected to vibration or noise, rubber vibration isolation blocks should be provided and be so installed as to prevent the transmission of vibration or noise to the environment. 6.1.4 Threaded Joints 1. Threaded piping will be made with Teflon tape or with a suitable pipe sealing compound (jute and mastic combination) applied on male threads only. Ends of pipe will be reamed out before being made up into fittings. 2. Joints in threaded steel pipe will conform to the British Standard BS 21. All burrs will be removed, pipe ends will be reamed or filed out size of bore, and all chips will be removed. 6.1.5. Pipe Fabrications and Installation 2. Make piping layout and installation in the most advantageous manner possible with respect to headroom, valve access, opening and equipment clearance, and clearance for other work, particular attention will be given to piping in the vicinity of equipment. Preserve the equipment parts for maintenance. 3. Cut all pipes accurately to measurement determined at the site. After cutting the pipe, ream it and remove all burrs. 4. Install piping neatly, free from unnecessary traps and pockets. Work into place without springing or forcing. Use fittings to make all changes in direction. Make all connections to equipment using flanged joints or unions. Make reducing connections with reducing fittings only. 5. Remove dirt, scale and other foreign matter from inside piping before tying in sections, fitting, valves or equipment.
6.1.6.. Offsets and Fittings 1. Carefully investigate the structural and finish conditions affecting the work and take such steps as may be required to meet such conditions. 2.
Install all piping close to walls, ceilings and columns so piping will occupy the minimum
3.
space. Proper space will be provided for covering and removal of pipe, special clearance, and for offsets and fittings.
4. Pipe work will be installed not closer than 200 mm to electrical conduits, lighting, and power cables. Pipes will be spaced in ducts, ceilings, voids and plant areas, such as adequate access is permitted to any pipe for maintenance or removal without disturbance to the remaining pipe work and other services. 5. Couplers, unions and fittings will be screwed up to the reduced depth of the thread, such that no more three-turns are showing when pulled up tight. 6. All pipes, valves and fittings and connected equipment will be thoroughly cleaned of rust, sand and dust, scale and other foreign matter before erection and before any initial fill water for hydraulic testing. 7. Prior to hydraulic testing, all pipe work systems including valves, strainers and fittings will be washed thoroughly. Such washing of the piping systems will be carefully carried out where there are isolation valves or equipment are employing. 8. Any stoppage due to foreign matter or air lock which is found to impede the flow of fluid will be removed, either before or after the systems are in operation. 9. Fittings will be of the eccentric pattern to ensure proper drainage and the elimination of air pockets wherever necessary. Increases or decreases in pipe diameters required to suit fittings, tee-offs and equipment connections will be formed using taper pieces, flanged as Required with taper reduction located about axis of the pipe to facilitate proper flow and to allow proper venting and draining of the pipes. The angle of the taper of such fabricated taper pieces will not be greater than twenty (20 ▫) degree. 6.1.7. Painting ( Applicable BI sch 40 Pipes where it exposed )
1. All pipes will be cleaned inside and outside for removal of dust and debris before painting. 2. Apply two coat of epoxy anticorrosive paints on BI pipe surface. 3. Finally apply approved quality Post Office Red paint on the pipes after hydraulic test and in the final stages.
6.1.8. Underground steel pipe works (Applicable BI sch 40 Pipes ) 1. Once the pipe fabrication is over all pipes will be cleaned inside and outside for removal of dust and debris before laying them in the trenches. 2. Underground portion of pipes will be tightly wrapped with bitumen tape with 20mm overlapping until the pipe surface is full wrapped and seal against atmosphere. 3. Finally full wrapped pipes are laid in the trenches for flanged connection with HDPE pipes. 6.2 Installation of Fire fighting Equipment and Accessories 1. Check cabinets are approved size and dimension. Inspect for signs of damage. 2. Locate exact location of these Cabinets as per approved shop drawings and with careful measure of elevation and plumb. 3. Fix cabinet using recommended (anchor bolts) bolts. Proceed with installation of accessories, valve, landing valves, etc. taking in consideration of approval for these devices. a. Installation of hose reel Make the required size holes by using drill machine and insert the Set Anchor bolts on to it. Depth of the bore will not exceed 50mm and bore size would be 10mm Lock the top anchor bolts as per the manufactures recommendations. Insert the Hose Reel’s mounting base in to the set anchor bolts and tight the four nuts to fix the Reel firmly. Installed the 1” Union in to Hose Reel and attached it to Pipe line at Fire Hose Reel cabinet.
b. Installation of landing valves Make sure the materials are approved quality and free from foreign materials. Physically inspect for cracks and damages. Installed threaded type 65mm flange to the riser pipes. Place the approved quality rubber packing to it. Place the De-pressuring plate between the two flanges and tight the four screws for secure joint. Outlet height of the Landing valve should be within the 750mm ~1000mm from the finished floor level. Rotate the lever and check for opening and closing of the shut off lever. c. Installation of Breaching Inlet Locate Breaching inlet cabinet and its accessories as shown on the shop drawing near the appropriate location of the property for Fire brigade to inject water in to the system in case of emergency. d. Installation of Pillar hydrant Make sure that the materials are approved quality and free from foreign materials, damagers.
Install the Rubber packing sheet on to mounting flange of the Pillar hydrant and place the pillar hydrant on the Flange.
Insert six Nuts and bolts to mounting base of the hydrant point and tight it firmly.
Check the vertical alignment of the hydrant point by using split level.
Outlet height of the pillar hydrant point should be within the 750mm ~1000mm from the finished floor level.
6.3 Installation of Pumps
Mark the Pump’s mounting places on the pump plinth by using marker pen.
Drill the marked points by using Hilti drill machine and insert & lock the anchor bolts.
Place the Fire Pumps on the Pump plinth and Insert the rubber anti vibration mounting pads between the plinths and pump base.
Check the levels of the pumps (horizontal & vertical) by using split level. Correct the levels if there is any oblique.
Insert the correct size bolts in to pumps base and tight it firmly by checking the levels of the pumps.
After mounting of pump, install the valves and accessories of suction and delivery as per the approved shop drawings.
Please refer the method statements of joining of pipes, installation of valves for more information.
Lay the power cables from the Pump control panel by using the cable tray. Please refer method statement of installation of cable tray and installation of cables for more info.
Check all the connections, terminations ect prior to do the testing.
Rotate the motor fan manually and check for smooth rotation
Obtain the services of the pump supplier and check the alignment of the pump.
6.4 Flushing: Cleaning of Piping and Equipment 1. After piping is erected, all piping systems including main header line and branch line will be cleaned to remove all mill, welding scale, oil, corrosion, and other construction debris. 2. System will be flush cleaned and filled ready for service immediately after cleaning. 3. Do not operate pumps or equipment until debris has been removed from the respective system has been flushed out. 4. Flush the piping system until all debris is removed and clean water comes out. 5. Automatic devices which can become clogged during the cleaning process will be disconnected and will not be connected permanently until the cleaning process is complete.
6.5 Installation of Fire detection system and accessories a. Conduiting works Prior to commence the installation, check all materials are of approved brand, Size and free from defects such as corrosion, dents,..etc
Site supervisor will study and counter check the proposed locations of the conduit as shown on the approved shop drawing. Ensure proper coordination with the Main Contractor and other trades to optimize the space allocation.
Site supervisor will arrange the length of conduit required for installation at site and instruct the workers to prepare these conduits.
Installation will be carried out in a planned & timely fashion so as not to delay works by other trades.
Technicians will mark the point locations and conduit path by using permanent marker as shown in the approved shop drawing with assistance of supervisor and double check the dimensions for any corrections.
Prior to do the installation, make sure that the conduit path coordinates and elevation has been checked and verify by the coordinator/consultant.
PVC conduits run in the concrete slab will be tightened to the rebar using binding wires in order to protect conduits and to keep their location unchanged.
All PVC conduit joints will be glued and socketed and only standard fittings will be used for joining.
When the conduits run in wall they will be fully concealed by chasing the wall to the required depth and conduits will be kept fully attached to wall using wire nails.
Conduits cutting will always done by using hacksaw blades.
Remove the unwanted materials/chips from the joining area before joining of conduits, bends, junction boxes,…etc.
Install bends, junction boxes etc in to the conduit using PVC solvent cement and make sure the joint is properly fixed.
Place the conduits as per approved shop drawings and bracket the conduit by using Saddles in 2m intervals where exposed conduiting is required.
Use Flexible conduits in where the rigid conduits not possible to install.
Place surface mounted back boxes where it is required.
Conduit path should be parallel to the walls, beams and need to be installed in timely and proper manner.
Conduits in wall will be laid only vertically and horizontally.
Physical separation between conduits from high voltage supply lines (parallel) shall not be less than 300mm.
b. Fire alarm cabling Installation should be carried out accordance with the guidelines below Conduits paths should be cleared by using a draw wire prior to installation of cables. The cable shall be kept clear of other services and piping.
Scaffoldings and Ladders to be used during installation shall be erected properly to ensure that safety of people working on it.
When multiple cable runs occur, the cable shall be installed in such ways that crossover of cables are avoided. The cables shall be supported at proper spacing.
The cable pulling shall be subjected to Consultant’s prior approval.
Cables shall not be bent during installation.
Clear all boxes from cement stains and other foreign materials
All cables shall run from point to point without joints. All cable installation shall be on pre-laid conduits, cable trays or cable ladders.
Prepare wires for pulling. Make sure that the wires are properly marked for their circuit number designation.
The termination of all cables shall be performed by a senior technician.
Drawing of cables should be done smoothly and excessive force should not be applied to pull the cables
Once cable is cut for the purpose of making termination, the work involved shall be completed without interruption. If for any reason that the work cannot be completed, the cable ends shall be sealed immediately with PVC tape.
The cable shall be marked at each end and at access points by a label indicating the cable size and circuits. Each group of cables shall be indicated by separate cable tag.
Each cable shall be provided with a means of identification fixed adjacent to the termination at each end. It shall be in the form of a plastic label securely fixed to the sealing box or tied to the cable and provide details of the cable size, function and cable reference number.
The cores of all mains cable shall be individually identified at termination by means of colors. Where the core insulation is not itself colored, bonds of self-adhesive PVC tape in the appropriate color shall be affixed to each core over the insulation.
Conduct insulation, resistance test, earth continuity test.
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HEALTH AND SAFETY 1. Work shall strictly follow as per the Manufacturer’s/ Client’s / Consultant’s Health & Safety recommendations for handling and use of the materials. Ensure all involved personnel shall be aware of the same.
1 Mark the pipe Mark the pipe for depth of penetration into the heater bush and fitting (see table). The mark must remain visible under heating and joining.
2 Heat pipe & fitting Push the pipewithout and the moving fitting into the heating tools. Once pipe and fitting are ooling time sleeve and pipe hot (after the correct time), pull out pipe and fitting very slowly. mm minutes 3 Joint pipe & fitting 20 10 Joint the pipe & the fitting and push 25 10 the pipe until it reaches the mark (that has to stay outside). 32 10 During the jointing time the welded 40 15 part of pipe and fitting must remain fix, without any rotation. 50 15 During the cooling time, the welded 63 20 part of pipe and fitting can be adjusted until cold. 75 25 90 30 4 Fusion inspection 35 Fusion inspection. The outer fusion seam must be inspected. The seam must 110 be present all around the pipe. Summary Value table Pipe Diameter( mm) 20 25 32 40 50 63 75 90 110
Minimum wall thickness (mm) 3, 4 4, 2 5, 4 6, 7 8, 4 10, 5 12, 5 15, 0 18, 4
Insert depth (mm) 14 16 18 20 23 26 28 31 33
Heating Jointing Cooling time (sec) time (sec) trime (sec) 6 7 8 12 18 25 30 40 50
4 4 6 6 6 8 8 10 10
2 3 4 4 5 6 8 8 8
