Introduction:
To ensure that the installation of pipes, Fittings & Accessories and related activities are executed safely and in accordance with the contract requirements and that all quality assurance/ control activities required for the same are conducted in a systematic manner, work are inspected and in conformance is verified and documented
SCOPE:
This Method Statement describes/defines the procedures involved in the Installation and Testing, Commissioning of Fire Fighting System such as Pipes, Fittings and Accessories in order to confirm proper operation
REFERENCES:
- Mechanical Approved Materials & Equipment (Data sheet/ Submittal)
- Approved Mechanical power Project Drawing
- Project Specification, United States Standard, IEEE Standard & Etc. Local Law 21-2011 Waste Management.
- FIRE AND LIFE SAFETY CODE OF PRACTICE July 2018.
- Federal Law No.8 Regarding the Organization of labour Relations.
- Ministerial Order No.32-The Determination of Retentive method and measures for the protection of workers from the risk of the work (the ministry of labour and social affairs)
- OSHAD-RF & SF – Specific & Relevant COPs, Elements, and Mechanisms to be listed down based on activities and scope of work which will vary for each risk assessment.
OSHAD SF COP’s Version 3.1 July 2018.
- Ref OSHAD-SF Cop 34 Safe Use of Lifting Equipment and Lifting Accessories
V 3.0 July 2016.
- Ref OSHAD-SF Cop 14 Manual Handling and Ergonomics V 3.1 June 2017.
- Ref OSHAD-SF Cop 8.0 General Workplace Amenities V 3.1 June 2018.
- Ref OSHAD-SF Cop 2.0 Personal Protective Equipment V 3.1 June 2018.
- Ref OSHAD-SF Cop 15 Electrical Safety V 3.1 June 2017.
- Ref OSHAD-SF Cop 21 Permit to Work Systems V 3.0 July 2016.
- Ref OSHAD-SF Cop 23 Working at Heights V 3.0 July 2016
- Ref OSHAD-SF Cop 26 Scaffolding V 3.0 July 2016.
- Ref OSHAD-SF Cop 35 Portable Power Tools V 3.0 July 2016.
- Ref OSHAD-SF Cop 37 Ladders V 3.0 July 2016.
- Ref OSHAD-SF Cop 15 Mechanical Safety V 3.1 June 2017.
- Ref OSHAD-SF Cop 11 Safety in the Heat V 3.1 June 2017.
- Ref OSHAD-SF Cop 8 General Workplace Amenities V 3.0 July 2016.
DEFINITION:
NFPA – National Fire Protection Association
OD – Outer Diameter
PTFE – Polytetrafluoroethylene
RESPONSIBILITIES:
Project Manager:
- Overall responsible for the implementation of this method statement
- Responsible for ensuring that the work is performed in accordance with the specification and with the time & constraints.
- Coordinate with MEP Coordinator (Contractor) for obtaining the necessary resources for the project deployed as required.
- Submit progress report as per contractual requirements to Main Contractor.
- Ensure that all required submittal are made in timely manner.
- Coordination with the Contractor, Company, Engineers, Safety personnel and subcontractor for the safety and quality during the execution of the project.
Site Mechanical Engineer:
- Ensure that the activities are carried out according to the Specification, drawing and approved Method Statement.
- Ensuring Submittals and Company approval on relevant MEP drawing/ Material/ Suppliers/ Subcontractors/ Method Statement and Quality/HSE Documentation.
- Arrange all materials and tools required for installation as per agreed project schedule.
- Coordinate to MEP Coordinator & Construction Manager for obtaining the necessary resources for the project & deploy as required.
- Provide all necessary information and distribute the responsibilities to his construction team.
- Monitor that all in process tests are carried out and obtained approval from Client/ Main Contractor/ Consultant.
- Monitoring & ensuring that the works is performed in accordance within the time and cost constraints.
- Coordinate with the Safety Engineer to ensure that the works are carried out in a safe working practice.
- Pass all the revised information to the site General foreman and ensure that it’s being carried out properly for entire MEP System.
- Ensure all Mechanical work activities are in conformance with approved shop drawings, contract requirements/ specification, and Method Statement.
- Ensure that relevant and required Materials are requested on time in correct quantities.
- Provide Approved Shop drawings to site Engineer for proper site Installation.
- Advising Site Engineer on all Technical aspects regarding work methods, sequence of installation, testing and commissioning.
- Follow up site activities and ensure all relevant non-conformance issues (if any) are resolved and cleared out. Communication with QA/QC Engineer and HSE Engineer for preventive and corrective actions.
- Coordinate the progress of main contractor works to ensure installations of MEP works are considering preventive and corrective actions.
- Coordination with other Contractors/ Company to provide solutions affecting design development / Coordination matters.
- Responsible for the coordination of all electro-mechanical activities, coordination with other discipline and between various subcontractors on sites.
- Reviewing of MEP daily, Weekly & Monthly progress reports.
- Ensuring MEP subcontractor Payment Certificates are reviewed and approved for payment.
- Responsible for all related activities prior to completion of the project
Charge-hand/Foreman:
- Carrying out the works and the proper distribution of all the available resources in coordination with the Site Engineer on a daily basis.
- Continuous coordination and following Site Engineers instruction to meet quality requirements during the job execution.
- Incorporate all the QC & Safety requirements as requested by the company’s representative.
- Report to Site Engineer the accomplishment and problem encountered on daily basis.
QA/QC Department:
- Ensure all Inspections are raised and conducted as per the Contract Specifications, PQP, & ITPs.
- Ensure all Inspections, proper tools & tackles and manpower are used at all stages of work.
- Ensure Call current issues of procedures, approved material and shop drawing and standards are available at the point of use.
- Ensure the works comply with the contract requirements/ approved shop drawings to serve the purpose.
- Ensure the Total quality for Installation work. He shall liaise with Company for Inspection of Installation works.
- Inspect for any damages during handling, & Storage.
- Monitor the quality of work and ensure that fulfillment of specified requirement and that all quality records related to work are completed.
- Ensure the work is completed as per quality requirements. Contractor shall inspect the same work to initiate ITR for company approval.
- Maintain comprehensive inspection and test records for any further references.
Safety Officer/ Engineer:
- Tool Box talk has to be conducted and all the hazards have to be identified before starting the work.
- To make sure that the Personnel Protective Equipment (PPE) are used by the Task Force during executions of work at site.
- Risks related to the activity shall be assessed and addressed as required.
- To provide training for the work force in order to execute the activity safely.
- Carry out regular and random inspection on site and record observations.
METHOD OF WORK:
Material:
- Sprinkler System, Fire Hose Reel System
- FM-200, Pre-Action
Equipment/ Tools:
- Drilling Machine, Spirit level, General tool box, Threading machine & Thread sealant
- Welding machine, grooving machine, cutting machine, grinder, crane, chain block
- Pipe wrench, Spanner, screw driver, cutting saw, etc.
Pre-Installation Procedure:
- All materials shall be inspected upon receipt at site against the delivery note, packing list for completeness and visually inspected for physical damage. Inspection shall have been approved by the Consultant
- All material shall be loaded directly on the store area or safe place where it could be unpacked, lifted and shifted to the final position.
- All materials must be handeled with care during transportation and should not be dragged or dropped especially on hard surfaces.
- Before starting the Installation activities the approved material shall be ready and available at site.
- Area and access will be inspected to confirm that the site is ready and is safe to commence the work.
- All relevant documentation and material applicable to particular section of works will be checked by site Engineer before commencement of work.
- The latest revision of the Approved Shop drawing should be available at the installation area.
- Project Engineer/ Supervisor will ensure that safety requirements have been complied with and are in place.
- Project Engineer/ Supervisor will orient and familiarize all the workers and assistants involved in the installation regarding relevant approved drawings, technical submittals, installation procedures and details, acceptance criteria.
- Install the protection systems in accordance with NFPA rulings, listings and manufacturer’s recommendations. Locate where accessible for servicing and replacement.
Hanger And Supports Installation Guides:
Pipe Diameter (mm) | Maximum Hanger Spacing (mm) | Rod Size (mm) |
12 | 3000 | 10 |
25 | 3000 | 10 |
32 | 3000 | 10 |
40 | 3000 | 10 |
50 | 3000 | 10 |
65 | 3000 | 10 |
80 | 3000 | 10 |
100 | 3000 | 10 |
150 | 3000 | 12 |
200 | 3000 | 12 |
Receipt And Storage Of Material:
- The Store Keeper will verify quantities and physical appearances of the Materials /parts products or equipment, etc. received. He is responsible in the identification, packing, storage, protection or preservation etc.
- The QCE will be responsible for performing the incoming material/ part/ product / or equipment’s inspection and arranging for client’s Inspection where required.
- The Project Manager will be responsible for overall activities including disposition of non-conformances, on hold items concerned to materials.
- The Quality Manager will ensure that all activities of Material Control are performed in accordance with this procedure.
Fabrication of Threaded Pipes:
- The floor where the threading machine is placed will be protected with a cover of PVC sheets to avoid oil splash on the concrete floor.
- Threading will be provided to 2” pipe sizes and below.
- The threading machine will be inspected daily before starting the work.
- Scale, slag, dirt, and debris will be removed from the pipe and fittings before machined process.
- The pipes will be cut to the actual required length and threaded from both side.
- The pipe will be tapered and the threads will be cleaned using steel brush and file.
- All threading residuals will be removed to restore full inside diameter.
- The joint compound will be applied on the male portion of the thread for fitting assembly.
- The branches will be either assembled at the fabrication or on spot.
- The pipes will be hanged to the proper level and will be connected to the cross-main.
- Pipe work will be protected from foreign matters.
Fabrication of Grooved Pipe:
- The floor where the grooving machine is placed will be protected with a cover of PVC sheets to avoid oil splash portion on the concrete floor.
- Grooving will be provided to 2 ½” pipe sizes and above.
- Roller of the grooving machine will be checked for wear and tear.
- Pipes will be inspected to ensure plain ends. (No Beveled ends).
- The OD of the groove will be measured. The OD of the groove should be within the manufacturer recommended range.
- Before assembly, the grooved joints will be cleaned from any dust, debris, etc.
- The branches will be assembled at the fabrication shop or on spot. All the ends will be plugged.
Installation Procedure For Above Ground Fire Fighting Pipe System :
- Coordination with other trades is checked to avoid conflicts or routings. Where major change in routes are necessary, it shall be reflected on the shop drawing.
- Survey and verification of pipe routing is carried out as per the approved shop drawing and coordination drawing. After which the anchor bolts be drilled according to the required support spacing.
- Marking of supports must be done as per routing of pipes. Distance between supports shall be as per specification and load carrying capacity of the hanger.
- Drilling must be done for the expansion/ anchor bolt installation.
- Install rods and clamps aligned to the direction of the pipe.
- Pipes and fittings are joined together as per the method stated above.
- For horizontal fixing, the pipes are carefully raised to the high level and fixed into the clamps. Supports and clamps shall be as per specified.
- Fix pipe properly to the clamps provided with the correction location and level as per the approved shop drawing.
- Risers are installed fixing pipes vertically into the clamps and joining riser pipes from below. Supports and clamps shall be as per specified
- The clamps should not be fastened very tightly as damages can occur due to thermal expansions of pipes. Expansion and contraction shall be provided as per specification.
- Manufacturer’s recommendations are followed as applicable
- In case of open end pipe, end shall be capped and protected from any possible damages.
- M10 Anchors will be used to support 4” and below pipes while M12 Anchors will be used to support 6”pipes and above as recommended by NFPA.
- Bolts, nuts and washers will be installed of each applicable size.
- The approved type of pipe support / Hanger will be attached to the threaded rods, nuts and washers will be installed as well.
- Piping will be installed so that system can be drained. Pipes will slope to main drain valve. Where piping cannot be fully drained, nipple and cap will be installed for drainage. Piping will drain to grade or to air gap sewer receptor.
- The branch lines will be hanged to the proper level and will be connected to the cross main.
- Where piping is embedded in masonry or concrete, sleeves will be provided as per specification. Clean internally the pipes internally during construction and installation. Provide clearance for access to valves, anchors, swing joints.
Installation of Feed Mains / Wet Stand Pipes:
- Install a complete combined fire stand Pipe and sprinkler system with all piping, valves, hangers, signs, valves, tests, etc., as per approved shop drawings.
- Furnish and install all drain piping, flushing, and connections, drain plugs, drain valves, etc., at drain points and all low points.
- Seal all valves, not provided with tamper switches, in open position by approved means. Flushing connection shall be as per NFPA 13.
- Piping shall generally be run parallel to walls and beams.
- Coordinate with other trades before finalizing the location of any piping to avoid interfering with their work.
- Care shall be exercise in the installation of the piping so that the system will drain by gravity, back through branches.
Installation of Sprinkler Heads & Accessories:
Note: Installation of sprinkler heads will commence only after 2nd pipe work flushing.
- Apply the PTFE tape only to the male portion of the sprinkler.
- Install the upright sprinkler head using the wrench provided by the manufacturer.
- Install upright sprinklers in such a way that the arms are parallel to the branch pipe.
- Maintain a clearance of 1” between the deflector of upright sprinkler and ceiling.
- Install the drops to the center of tiles as per the approved reflected ceiling plan.
- Ensure that sprinkler heads have the correct finish and temperature rating.
- Fix the sprinkler floor control valve as per the approved shop drawing. Ensure that valves are located at an accessible location.
- Ensure that the arrow of the water flow detector switch points to the direction of the water flow.
- Ensure that the sight glass of the test / drain valve is free of damage.
- Ensure that test / drain valves are provided as shown on the drawings.
- Inspection Request will be raised for Consultant’s Inspection and approval.
Pressure Testing:
Ensure that circuit to be tested is completed in all aspects as follows:
- The piping is laid to the correct standard and is in the right location.
- The pipe diameters are as per the approved drawing.
- Check physically whether all joints are finished properly.
- Water shall be filled at the lowest point to ensure no trapped air remain at the circuit.
- Ensure that the components in the circuit are capable of withstanding the pressure.
- Recently calibrated pressure gauge should be installed at the extremities of the piping circuit to be tested.
- Ensure that the components in the circuit are capable of withstanding the testing pressure.
- Once the above is checked and found acceptable, proceed with filling water, which is to be done from the lowest point of the circuit. This is to ensure that the air from the system to avoid fluctuations in pressure. The air is to be vented out at the highest point by means of air vents or partially opened valves.
- Piping shall be pressurized gradually until reaches the test pressure using manual pump located at a convenient location and shall be provided with an Isolation valve just before the pressure gauge.
- No pressure shall be applied against the closed gate valve. All valves shall be in open position but not completely back seated during testing. End valves shall be capped.
- Piping shall be tested at a pressure of 1.5 times the system working pressure as per project specification; whichever is greater. Pressure shall be maintained for at least 24 hours.
- Physically inspect the entire circuit for leaks. If any leaks are detected, work shall be corrected immediately prior to proceeding further.
- Leak (if any) will be repaired as necessary and pipe work will be retested.
- The test pressure shall be released slowly as not to produce shocks and sudden contractions that might damage the piping.
- After inspection approval, pipe end are capped and protected from any possible damages.
- The drain point will be plugged and the highest point of the system will be considered as the water supply point for pressure testing.
Pre-Commissioning and Commissioning Checks:
- Ensure that all equipment included, should be thoroughly cleaned and checked.
- Ensure that all foreign debris is thoroughly flushed out from the whole pipework system.
- All automatic controls and safety devices shall be inspected and checked for service before the working fluid or electricity ability is applied to the system.
- When various installations have been completed and pre- commissioning has been done, setting of work is to be carried out in the entire installation prior to the issuance of completion certificate.
- Ensure that all apparatus are working as per specification.
- Ensure that all instruments are correctly calibrated and accurate.
- Ensure that all services are tested and control systems are functioning correctly and are properly set, sequenced or interlocked.
Final Acceptance Test:
- After the commissioning of the entire installation, final acceptance tests shall be carried out prior to the issuance of Performance Certificate in accordance with the programmed to be agreed with the Consultant.
- Should the results of the acceptance Test do not conform to the required performance, adjustment and modification to the system is necessary to be carried out.
- Prior to the issuance of Certificate of Completion, tests shall be carried out whenever required by the authorities having jurisdiction over the said performance tests.
Health Risk Assessment:
- All the above operations shall be executed strictly in accordance with Project Occupational Health, Safety, Security and Environmental Plan.
- Prior to the commencement of any activities, the workforce will receive a safety induction on the project site safety requirements; this safety induction will include Project HSE Policy, Project details and layout, Site management team, general site HSE requirements, emergency procedure including Emergency contact numbers, Roles and responsibilities of the workers, Site discipline, general environmental awareness, PPE requirements.
- The HSE roles and responsibilities shall be delivered to all staff (construction manager, engineer, supervisor, foremen, and charge hand).
- Work will commence as per safety regulations laid in the contract specifications and project safety plan.
- Housekeeping shall be of good standard and debris shall be removed.
- All activities will be performed according to the control measures and instructions prescribed in the attached Risk Assessment Sheets.
- Daily JSA will be done before the commencement of each shift and each new task.
- All Vehicles will have valid licenses and passes before entering the site.
- PPE shall be issued to all personnel (Mandatory PPE’s: Hard hat, Safety glass, high visibility vest, Safety shoes and cover all. Task specific PPE; Dust mask, goggles, hand gloves).
- Specific training shall be given for task specific tools and equipment’s; records shall be kept in HSE department.
- Heat stress training will be provided during summer time, records shall be kept in HSE department.
- Adequate cool drinking water, shade and hydrolyte shall be placed.
- Plant and equipment shall have back up alarms, lights and all other applicable safety devices.
- Provide Banks man when operating equipment reverse and moving the equipment where pedestrian movement is exist.
- Work on site will be supervised by a competent person (Qualified SE)
- Safety Lighting
Emergency Procedures:
- Contact numbers of personnel concerned to be displayed.
- Emergency response team to be designated and on standby:
- All emergency contact people are posted around the project and are being discussed during site safety meeting.
- Emergency routes and exists to be clearly marked.
- 1 vehicle with one driver will be available for any emergency.
- Requirement of the Project Emergency Preparedness and Response plan shall be strictly followed.
- In the event of an accident, contact the area HSE Supervisor.
- In case of Diesel Spillage contact the Environmental department.
- Easy means of access will be available at all time.
- Contact numbers of all emergency supervisors will be distributed to site personnel (Site engineer, Safety officer, male nurse and concerned authorities and emergency services).
- Injuries will have the highest priority to be directly dealt with at once.
- There are different types of situations that we need to consider under this section. These are:
- Basic first aid
- Medical
- Property damage
- Environmental releases
- Fatality
- Fire
- The nominated response team will consist of:
- Site nurse
- Safety Engineer/Officer
- Site Superintendent/Foreman
- 4no of operatives
- Basic first aids
- The injured person, if mobile, can make his way to the site clinic for treatment by a qualified site nurse that is available and logged in the first aid register.
Medical:
Under this section, there are two categories that we need to consider. They are as follows:
(1)- Conscious
If the patient is feeling un-well, he will immediately inform his supervisor and go to the site clinic to be assessed by the site nurse. The site nurse will then advise, or the patient will require further examination and he will be taken to the hospital.
(2)- Unconscious
If the patient had collapsed during his work, alarm must be raised to inform the response team. The team will then respond accordingly by the quickest possible way arriving at the location of the incident. Along with them, they will bring a first aid kit, an emergency stretcher and an emergency vehicle. Once they are on the scene, the site nurse will assess the patient and the team will then take the patient on the stretcher either to the site clinic or to the local hospital.
- Electrocution:
- If you see someone lying unconscious or “froze on the circuit,” the very first thing to do is shut off the power by opening the appropriate disconnect switch or circuit breaker. Don’t touch another person being shocked, If the power disconnect switch cannot be located quickly enough, it may be possible to dislodge the victim from the circuit they’re frozen on to by prying them or hitting them away with a dry wooden board or piece of nonmetallic conduit.
- Once the victim has been safely disconnected from the source of electric power, the immediate medical concerns for the victim should be respiration and circulation (breathing and pulse). Call nearest First aider to apply first aid to the electrocuted person. If a victim is still conscious after having been shocked, they need to be closely monitored and cared for until male nurse arrives.
- Rescue from Height:
- There will be rescue team with emergency rescue kit readily available at site in case of “Rescue from Height” is needed. The rescue team members are chosen from scaffolding team that has no acrophobia and has enough experience on working at height.
- Emergency response drill should be conducted as per Project Emergency Drill Schedule.
- Only the competent personnel will be allowed to install the system who has experience and trained by the supplier.
- Environmental:
- Working areas will be kept free as practicable from construction debris and equipment’s which are not actually in use.
- Proper access to the work areas should be maintained all the time. Particular attention to be paid to environmental hazards such as excessive dust emission, excessive noise from equipment, unpleasant odor of material or chemical to be used, etc. Hence a corresponding control measure will be performed as below mentioned but not limited on it:
- Water spraying for dust control
- Noise level monitoring
Complied with the materials safety data sheet recommendation regarding environmental aspect/impact of the material to be used.
ATTACHMENT:
- Inspection & Test Plan
- Checklist
- Risk Assessment
- Quality Control Procedures
