METHOD STATEMENT FOR PLUMBING WORKS

METHOD STATEMENT FOR PLUMBING WORKS

CONTENTS

  1. INTRODUCTION
  • PURPOSE
  • SCOPE
  • REFERENCES
  • DEFINITIONS
  • ORGANIZATION CHART
  • DUTIES AND RESPONSIBILITIES
  • METHOD STATEMENT FOR EQUIPMENT INSTALLATION
  • METHOD STATEMENT FOR PLUMBING INSTALLATION
  1. METHOD STATEMENT FOR PLUMBING SYSTEM TEST
  1. QUALITY CONTROL
  1. SAFETY PLAN
  1. INTRODUCTION

This method statement details the method of performing the various activities involved in the course of works for field installation works of Plumbing system for Building Package-01 Project. These method statements are applicable only for thePlumbing system Installation of various building in this project.

  • PURPOSE

This method statement gives guidelines contained herein so as to ensure that the job execution complies with the requirement of the specification and the authorities concerned and serves the intended purpose to satisfactory level.

  • SCOPE

This method statement covers the nature and type of work forPlumbing works includes the installation of potable water line, drain lines and vents for all rooms including HVAC room, toilets, shower room, etc for all building and frequency at which inspections are to be carried out.

  • ASTM : American Society for Testing and Materials
    • ASME : American Society of Mechanical Engineers
    • ASHRAE :American Society of Heating Refrigerating and Air Conditioning Engineers Inc.
    • IAPMO : International Association of Plumbing and Mechanical Codes
    • ASSE : American Society of Safety Engineers
    • UPC : Uniform Plumbing Code
    • NFPA : National Fire Protection Association
    • UL : Underwriters Laboratories, Inc.
    • FM : Factory Mutual Engineering Corporation
    • ISO : International Organization for Standardization
    • Project Specifications
    • Project IFC Drawings
    • Inspection and Test Plan for HVAC System
  • DEFINITIONS


  • DUTIES AND RESPONSIBILITIES

All workers who are involved in plumbing work shall be oriented to the nature of work, to ensure that the procedure is followed accordingly and to assure that the safety requirements is strictly adhered.

The contractor shall check all documents to ensure that the work is being carried out following the latest revision of issued IFC drawing.

Staff and foreman involved in the Works, whether he is working with GS E&C or Subcontractor, shalltake the responsibilities according to his entitled positions and the Works.

  • SITE MANAGER

The Site Manager shall be responsible for the over-all direction, coordination and control of all site activities and all construction works including HSE and quality control, etc

  • CONSTRUCTION MANAGER

The Construction Manager shall report to and receive technical direction from the Site Manager and developing and arranging the site construction team to the site necessary to manage and supervise theconstruction works including HSE and quality control, etc.The Construction Manager shall be responsible for the overall implementation and monitoring of all the activities for the successful completion of construction works.

  • QC INSPECTOR

The QC Inspectorshall be responsible for performing the inspection and test in accordance with Inspection and Test Plan as approved by Company. And also QC Inspectorshall prepare hold point inspections and the corresponding work releases by reviewing records and test results as proof that work inspected conforms to specification.

  • SAFETY SUPERVISOR

The Safety Supervisor shall be responsible for the organization of Health Safety and Environment (HSE) activities on site. To ensure that all safety plans, safety rules and regulations are being implemented accordingly. And also Safety Supervisor shall prepare prior to the start of the work a safety plan that must be implemented and observed during the Plumbing piping and Sanitary Drainage works and safety awareness of workers during the activity

  • PLUMBING SITE SUPERVISOR

The PLUMBINGSupervisor shall be report to and receive project direction from the construction manager.The PLUMBINGSupervisorshall be directly involved in the planning and execution of the activities in the Plumbing piping and Sanitary Drainage works. And also PLUMBINGSupervisor shall prepare prior to the start of work, a safety action, controlling of construction schedule, including submittal and inspection of materials that must be implemented and observed during the PLUMBING work.

  • PLUMBING FORMAN

The Forman shall be responsible for the direct execution of works involve in the PLUMBING work according to the plan and shall directly control and give instruction to the working personnel. The Forman shall also ensure that works are done with utmost regard to safety and quality.

  • METHOD STATEMENT FOR EQUIPMENT INSTALLATION

All units shall be inspected by contractor and company prior to start work and after inspecting the units, protect them properly in storage until their actual installation at site. The Contractor shall be installedPlumbing equipmentas per approved layout.

  • Hot Water Generator Installation
    • Place the HWG as per approved layout.
    • Place the equipment on the foundation or Marking for drilling work at hanger’s point.
    • Place the vibration isolation pads between HWG and foundation or Drilling & installation of anchor fastener in the required position as per drawing.
    • Connect the all inlet & discharge line either flange or screw connection with necessary accessories with proper supportsuch that it should not be stressed.
    • Connect the power and control Cables to the unit Control Panel as per the wiring diagram supplied by themanufacturer along with the unit.
    • Connect the drain piping to the unitdrain outlet.
    • Eye Wash Installation
      • Place the ES as per approved layout.
      • Marking for drilling work at hanger’s point.
      • Top operate unit, fill unit with clean potable water and add bacteriostatic additive (suppliedwith unit).

N.B. Unit should be inspected regularly and water in unit should be changedat least once every six months.

  • Waste water is directed into drain opening in tank basin. 3 ft. long drain hose in basin directs discharge into floor drain.
  • METHOD STATEMENT FOR PLUMBING INSTALLATION

Plumbing pipes are site routed in order to avoid obstructions to electrical cable, equipment, access or maintenance and to avoid any extra load on the system. All plumbing installation and insulation shall be performed in accordance with the design criteria and specification.

  • Potable water pipe installation for Poly Propylene Pipes (if any)
    • Mark the route of piping for supports and prepare the walls to receive the pipes.
    • Mark the location of supports at specified intervals. Check the wall/floor opening accordingly.
    • Make provision for fixing anchor fastener in slab or in purlin fix support rod with suitable system as like double nut and washer.
    • Fix pipe clamp with GI threaded rod.
    • Check the pipes and fittings to be jointed are of required sizes.
    • Cut the pipe to required length by proper cutting tool. Clean the pipes & fittings to be jointed.
    • Pipes and fittings should be clean.Remove burrs & filings from the outside & inside.
    • Apply solvent cement to the outside & the inside surface of the fitting.
    • While both surfaces are still wet with solvent cement, insert the pipe into the fitting, rotating with 90 during insertion.
    • Wipe the excess cement from pipe surface. Hold the joint for 30 Sec/1Min, during which avoid any load on the joint.
    • Leave the system for 12 hr before filling the water.
    • While making a transition connection to metal threads use threaded sealants. Like Teflon tape or same as suitable.

Note. Installation of Copper Pipe Soldering is detailed in M/S for Refrigerant piping installation.

  • Condensate drain,Sewer, Waste and Vent pipe installation
    • Mark the route of piping in wall / floor.
    • If in walls, the wall has to be chased for the minimum required diameter of the pipes to be used.
    • If under floor, the pipe has to be laid before floor concreting of the area.
    • Check that the pipe is correctly prepared and that the rubber seal is properly seated in its housing, markthe length of pipe to be pushed.
    • Make sure that both the pipe ends and ring seal socket are dry, clean & free from dust.
    • Lubricate evenly around the spigot.
    • Make sure that the components to be jointed are correctly aligned.
    • Push the spigot into the socket and see the marking is visible.
    • Level the pipes and check the alignment.
    • For jointing, suitable fitting for solvent weld with the pipe – make sure both the pipe & fitting are dry, cleanand free from dust.
    • Apply the solvent cement evenly around the pipe, spigot end, align and push the fitting.
    • Outside of joints should be cleared from excess solvents.
    • Allow to dry at least for six (6) hours prior to testing.
  • Chemical Drain pipe installation
    • Mark the route of piping in wall / floor.
    • If in walls, the wall has to be chased for the minimum required diameter of the pipes to be used.
    • If under floor, the pipe has to be laid before floor concreting of the area.
    • For Cutting; Pipe must be squarely cut to allow for the proper interfacing of the pipe end and the fitting socket bottom. This can be accomplished with a miter box saw.
    • For DEBURRING; Use file to remove burrs from the end of pipe. A slight chamfer about 15° should be added to the end to permit easier insertion of the pipe into the fitting. Failure to chamfer the edge of the pipe may remove cementfrom the socket, causing the joint to leak.
    • INSPECTION AND CLEANING; visually inspect the inside of the pipe and fitting sockets and remove all dirt, grease or moisture with a clean dry rag. Measure the fitting socket depth and mark this distance on the pipe O.D. Clean the surfaceof the pipe and fitting socket by using a cleaner.
    • APPLICATION OF SOLVENT CEMENT; Apply the solvent cement evenly and quickly around the outside of the pipe at a width a little greater than the depth of the fitting socket. Apply a light coat ofcement evenly around the inside of the fitting socket.
    • JOINT ASSEMBLY; immediately insert the pipe into the socket up to the entry mark, align pipe and socket, hold in position for a few seconds.
    • CLEAN UP; Remove all excess cement from around the pipe and fitting with a dry cotton rag. This must be done while the cement is still soft.
    • For jointing, suitable fitting for solvent weld with the pipe – make sure both the pipe & fitting are dry, cleanand free from dust.
    • AFTER JOINTING; Joints should not be moved or distributed for 10-15 minutes then the jointed pipe may be handled with care allow 4 hours if the jointed pipe lengths are to be laid in a trench.
    • FLANGE ASSEMBLY
      • Join the flange to the pipe as outlined in the solvent cementing section or in the threading section depending on the joining.
      • Align the flanges and gasket by inserting all of the bolt through the matching bolt holes proper mating of flanges and gaskets is very important for a positive seal.
      • Using a torque wrench, tighten each bolt in a gradual sequence as outlined by the flange sketch.

WARNINGS

1- Do not over – torque flange bolts.

2- Use the proper bolt tightening sequence.

3- Make sure the system is in proper alignment.

4- Flat washers

  • Under Ground Drainage Work
    • Trenching & Bedding
      • Prior to start of excavation, make sure that the pipe line coordinates and elevation has been checked and verified by the surveyor.
      • Excavation and sand bedding shall be done mainly by equipment (excavators and loaders), manual excavation is required in cases where equipment are not possible or where manual excavation is more convenient in a specific area.
      • Excavated materials shall be placed at a suitable distance from the edge of excavation so that materials do not fall back into the trench.
      • Depth of trench shall be dug deep enough to provide a ground bed of at least 150 mm from the bottom of the pipe.
      • Clean sand bedding layer of 150 mm thickness shall be compacted to at least 95% Proctor density.
      • The trench bottom shall be continuous, smooth, and free of rocks and to the line and grade shown on the approved installation drawings.
    • Backfilling
      • Make sure that Inspection & Testing has been done and approved before any backfilling works starts.
      • Protect top 30 cm of the pipe by backfilling using sand (if available).
      • Backfill the remain trench by backfilling material (25 cm max. thickness)
      • Backfilling shall be done mainly by equipment (loaders & compactors) while some labors spreading manually the sand and backfill materials wherever required.
    • Laying
      • Before start of the pipe lying, the bottom of the trench shall be dry, continuous, smoothand free of rocks and to the line and grade shown on the installation drawings.
      • Pipe location, elevation and slope shall be maintained by a surveyor. A survey report shall be made after final installation.
      • Sand beds shall be placed at the bottom of pipes for underground drainage work (and supports for buried pipes) to meet the exact elevation and slope of the pipe being installed. The sand bed shall be then adjusted accordingly to maintain the pipe on the ground is on a firm bed for its entire length.
      • Excavation a little deeper on the place where the pipe is to be joined shall be done to allow access for the installer for proper joining method.
      • Pipe shall be installed continuously downhill without low points and high points.
      • Pipe is to be anchored by partial sand and/or mortar covering of the pipe to prevent floatation and to maintain its alignment and level.
  • At the end of every work shift, personnel performing the pipe installation shall ensure that the pipe ends are capped to prevent entry of foreign materials.
    • Reservation in the manhole base shall be done in order to allow connections to manhole after manhole pouring.
    • Grouting shall be applied between manhole and outside diameter of pipe.
    • In case of drain outlets connections (at the landscape area), no external connection is allowed (e.g. No-hub coupling) only push on connection is allowed.
    • Plumbing pipe Insulation

Pipe insulation shall be installed in accordance with plumbing system standard detail or as per equipment manufacturer’s recommendation.

Note. Insulation of Plumbing Pipe is detailed in M/S for Refrigerant piping insulation.

  1. METHOD STATEMENT FOR PLUMBING SYSTEM TEST

Testing shall be carried out under the supervision of Contractor & Company with allcalibrated tools and equipment’s.

Field test / Inspection report format will be used for this purpose.

  1. Potable water pipe Test(Hydrostat Test)

Refer to ASME 31.9 Para 937.3 Hydrostatic testing

  1. The section of the pipe which would undergo testing would be identified and to be informed to Contractor/Company to witness the test.
    1. Visual inspection would be carried out and any defects found to be rectified.
    1. Provision for plugging all open ends would be made and suitable vent to be provided for bleeding air.
    1. The pipe work would be slowly filled with potable water. The air shall be bled out at plugs and vents, tillthe entire air escapes.
    1. The hydraulic pressure would be applied to the envisaged section by means of manually operated test pump.
    1. The pressure shall be maximum working pressure (2bar) plus 50%.
    1. Pipes shall be tested under a hydrostatic pressure of 3 bars.
    1. After application of pressure, verify joints, fittings and valves for possible leaks and rectify, if required.
    1. The pressure would be maintained for at least 2 hours. During this time, the test pump will be removedfrom the test site.
    1. The result would be filled in the approved format and records maintained.
  1. Condensate drain, Sewer, Waste pipe Test (Head Pressure Test)

Refer to ASME 31.9 Para 937.3 Hydrostatic testing

  1. The section of the pipe which would undergo testing would be identified and to be informed to Contractor/Company to witness the test.
    1. Visual inspection would be carried out and any defects found to be rectified.
    1. The pipes and joints shall be head pressure tested 3.0 M head for 1 hour
    1. The pressure testing shall be done by using potable water.
    1. Before doing the pressure test, proper venting shall be done at the end of the pipe.
    1. Each joint of pipes and fittings shall be inspected individually for any leakage.
    1. Check all the pipes are routed for required point and the joints are completed if any left over.
  2. QUALITY CONTROL
  1. Quality Control Plan
    1. Aquality assurance system shall be established to ensure conformance to related standards, codes, specification and procedures.
    1. Site Management, Supervisors and Safety Officer will closely supervise and monitor all phase of works to ensure full compliance with the procedures of Safety and work methodology.
    1. Significant stages of work shall be ensured by Site Supervisor /Quality Control Inspector to be conforming to the drawings and specification including:
  2. Use of approved materials.
  3. Set out of work before commencing installation.
  4. Check installed materials.
    1. Inspection TestRequest (ITR) shall be submitted 24 hours before the date and time of inspection for each stage of work as per approved inspection and Test Plan.
  1. Inspection and Test Plan
    1. All inspections and tests as identified in the Inspection and Test Plan.
    1. Inspection and Test Plan shall be completed by the SUB COTRACTOR and will be reviewed and approved by the CONTRACTOR.
  1. SAFETY PLAN

The responsible supervisor will periodically check the condition of the barriers, and where necessary refurbishment will be conducted.

  1. Safety Role and PTW
    1. Appropriate PTW is introduced and applied for approval from the central Safety Management.
    1. Training programs and competence standards are established and maintained.
    1. Monitoring/auditing/reviewing of PTW system is established and maintained.
    1. PTW is processed properly as follows:
  2. Defining, requesting and approving the work scope
  3. Hazard Identification, Risk Assessment and Proposed Controls
  4. Approval of Proposed Controls – Hold Point
  5. Implementing Risk Controls
  6. Permission to Proceed/Issuing the PTW – Hold Point
  7. Managing the Work after Issue of PTW
    1. Use of PPE
      1. All personnel will be issued with PPE and instructed to maintain safe working practices always. The PlumbingSupervisor will be responsible to confirm that safety procedures are followed.
      1. PPE’s for ear protection (ear muffs, earplugs, etc.) must be used in areas where the noise level is high (above 85 dBA).
      1. Personnel executing the work will always confirm that:
  8. Eye Protectors (goggles /shields /spectacles) are suitable for the work being carried out.
  9. Adequate and appropriate respiratory protection is available while entering confined space.
  10. Appropriate type of hand gloves is used for the activity to be performed.
  1. Hand Tool and Equipment
    1. Construction equipment, machines, tools and measuring instrument to be used in the works will be thoroughly inspected to confirm its working condition prior to used.
    1. Operator will be trained and instructed in the safe use of the equipment.
    1. All power hand tools and Equipment’s to be inspected and tagged.
Md Abu Zaed Khan
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