Safe Work Method statement MEP

Testing & Commissioning of Fire Fighting Pump Set

Method Statement for The Testing & Commissioning of Fire Fighting Pump Set

Introduction:

This Method Statement describes/defines the procedures involved in the testing and Commissioning of Fire Fighting Pumps & Accessories in order to confirm proper operation.

SCOPE:

The Purpose of this method statement is to ensure that Installation of Fire Fighting Equipment & 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, works are inspected and conformance is verified and documented.

REFERENCES:

  1. Mechanical Approved Materials & Equipment (Data sheet/ Submittal)
  2. Approved Mechanical power Project Drawing
  3. Project Specification, United States Standard, IEEE Standard & Etc. Local Law 21-2011 Waste Management.
  4. FIRE AND LIFE SAFETY CODE OF PRACTICE July 2018.
  5. Federal Law No.8 Regarding the Organization of labour Relations.
  6. 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)
  7. 151 Specifications 15101: Rainwater Pipework/ Gutters
  8. 151 Specifications 15102 : Foul Drainage above ground
  9. Div151 Specifications 15103 : Drainage below ground
  10. Div151 Specifications 15104 : Pipelines Ancillaries
Method Statement For The Testing & Commissioning Of Fire Fighting Pump Set
    1. 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.

    1. Ref OSHAD-SF Cop 34 Safe Use of Lifting Equipment and Lifting Accessories

    V 3.0 July 2016.

    1. Ref OSHAD-SF Cop 14 Manual Handling and Ergonomics V 3.1 June 2017.
    2. Ref OSHAD-SF Cop 8.0 General Workplace Amenities V 3.1 June 2018.
    3. Ref OSHAD-SF Cop 2.0 Personal Protective Equipment V 3.1 June 2018.
    4. Ref OSHAD-SF Cop 15 Electrical Safety V 3.1 June 2017.
    5. Ref OSHAD-SF Cop 21 Permit to Work Systems V 3.0 July 2016.
    6. Ref OSHAD-SF Cop 23 Working at Heights V 3.0 July 2016
    7. Ref OSHAD-SF Cop 26 Scaffolding V 3.0 July 2016.
    8. Ref OSHAD-SF Cop 35 Portable Power Tools V 3.0 July 2016.
    9. Ref OSHAD-SF Cop 37 Ladders V 3.0 July 2016.
    10. Ref OSHAD-SF Cop 15 Mechanical Safety V 3.1 June 2017.
    11. Ref OSHAD-SF Cop 11 Safety in the Heat V 3.1 June 2017.
    12. Ref OSHAD-SF Cop 8 General Workplace Amenities V 3.0 July 2016.
    13. Occupational safety & health administration.
    14. Osha ets.
    15. Occupational health and safety.
    16. Occupational safety and health administration.
    17. Osha standard.
    18. Osha emergency temporary standard.
    19. Occupational health and safety ac.
    20. Osha safety

DEFINITION:

NFPA  – National Fire Protection Association

FHC     – Fire Hose Cabinet

FHR     – Fire Hose Reel

LV        – Landing Valve

RESPONSIBILITIES:

Project Manager:

  1. Will have the overall responsibility on the Project execution, quality and safety.
  2. Also he will maintain the planning progress and coordination of works with Main Contractor.
  3. Overall responsible for implementation of this method statement.
  4. Responsible for ensuring that the work is performed in accordance with the specification and within the time and constraints.
  5. Coordinate with MEP coordinator (Contractor) for obtaining the necessary resources for the project and deploys as required.
  6. Submit progress report as per contractual requirements to Main Contractor.
  7. Ensure that all required submittal are made in timely manner.
  8. Coordination with the Contractor, Company, Engineers, Safety Personnel and subcontractor for the safety and quality during the execution of the project.

Site Mechanical Engineer:

  1. Ensure that the activities are carried out according to the Specification, drawing and approved Method Statement.
  2. Ensuring Submittals and Company approval on relevant MEP drawing/ Material/ Suppliers/ Subcontractors/ Method Statement and Quality/HSE Documentation.
  3. Arrange all materials and tools required for installation as per agreed project schedule.
  4. Coordinate to MEP Coordinator & Construction Manager for obtaining the necessary resources for the project & deploy as required.
  5. Provide all necessary information and distribute the responsibilities to his construction team.
  6. Monitor that a;; in process tests are carried out and obtained approval from Client/ Main Contractor/ Consultant.
  7. Monitoring & ensuring that the works is performed in accordance within the time and cost constraints.
  8. Coordinate with the Safety Engineer to ensure that the works are carried out in a safe working practice.
  9. Pass all the revised information to the site General foreman and ensure that it’s being carried out properly for entire MEP System.
  10. Ensure all Mechanical work activities are in conformance with approved shop drawings, contract requirements/ specification, and Method Statement.
  11. Ensure that relevant and required Materials are requested on time in correct quantities.
  12. Provide Approved Shop drawings to site Engineer for proper site Installation.
  13. Advising Site Engineer on all Technical aspects regarding work methods, sequence of installation, testing and commissioning.
  14. 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.
  15. Coordinate the progress of main contractor works to ensure installations of MEP works are considering preventive and corrective actions.
  16. Coordination with other Contractors/ Company to provide solutions affecting design development / Coordination matters.
  17. Responsible for the coordination of all electromechanical activities, coordination with other discipline and between various subcontractors on sits.
  18. Reviewing of MEP daily, Weekly & Monthly progress reports.
  19. Ensuring MEP subcontractor Payment Certificates are reviewed and approved for payment.
  20. Responsible for all related activities prior to completion of the project.

Charge-hand/Foreman:

  1. Carrying out the works and the proper distribution of all the available resources in coordination with the Site Engineer on a daily basis.
  2. Continuous coordination and following Site Engineers instruction to meet quality requirements during the job execution.
  3. Incorporate all the QC & Safety requirements as requested by the company’s representative.
  4. Report to Site Engineer the accomplishment and problem encountered on daily basis.

QA/QC Department:

  1. Ensure all Inspections are raised and conducted as per the Contract Specifications, PQP, & ITPs.
  2. Ensure all Inspections, proper tools & tackles and manpower are used at all stages of work.
  3. Ensure Call current issues of procedures, approved material and shop drawing and standards are available at the point of use.
  4. Ensure the works comply with the contract requirements/ approved shop drawings to serve the purpose.
  5. Ensure the Total quality for Installation work. He shall liaise with Company for Inspection of Installation works.
  6. Inspect for any damages during handling, & Storage.
  7. Monitor the quality of work and ensure that fulfillment of specified requirement and that all quality records related to work are completed.
  8. Ensure the work is completed as per quality requirements. Contractor shall inspect the same work to initiate ITR for company approval.
  9. Maintain comprehensive inspection and test records for any further references.

Safety Officer/ Engineer:

  1. Tool Box talk has to be conducted and all the hazards have to be identified before starting the work.
  2. To make sure that the Personnel Protective Equipment (PPE) are used by the Task Force during executions of work at site.
  3. Risks related to the activity shall be assessed and addressed as required.
  4. To provide training for the work force in order to execute the activity safely.
  5. Carry out regular and random inspection on site and record observations.

METHOD OF WORK:

Material:

  1. None

Equipment/ Tools:

  1. Calibrated Flow Meter
  2. Calibrated Pressure Gauge
  3. Drilling Machine
  4. Hand Tools
  5. General Tool Box
  6. Spanner Set
  7. PPE’s

PROCEDURE / EXECUTION OF WORK:

  1. Before carrying   out   the   commissioning   activities   of  the   fire  pump,   the   following   pre-commissioning  checks shall be ensured:
  2. The installation activities of the fire pump have been completed.
  3. The system has been checked against the approved shop drawings.
  4. Ensure that the sprinklers,  fire hose reel, landing valve, fire pump  and necessary accessories have been installed.
  5. The leak test of the piping has been completed and accepted.
  6. Ensure that the flushing of the piping is carried out and the pipes are free from obstruction.
  7. Check the supports which are installed  near to the valves are tensed.
  8. Check the pressure gauges in controller  / pressure  sensing line to confirm that the pressures in the system pipelines are in the acceptable 
  9. Check the pump  installed  in the  proper  direction  of flow in relation  to the  system  and  the suction  and discharge  connected  correctly  and are supported  with rigid stand  independent   of the pump assembly.
  10. All the motors and control wiring are connected  to the equipment  and the control panel.
  11. Check the fire water tank with water,  diesel tank with diesel, battery  with acid are filled as per the required.
  12. Ensure that all instrument  used for testing  and commissioning  shall calibrated  and with valid calibration  test certificates.

COMMISSIONING CHECK:

  1. Ensure that all equipment included, should be thoroughly  cleaned and checked.
  2. Ensure that all foreign debris is thoroughly flushed out from the whole pipework 
  3. All automatic controls  and safety devices shall be inspected  and checked for service ability before the working fluid or electricity is applied to the system.
  4. 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.
  5. Ensure that all apparatus are working as per specification.
  6. Ensure that all instruments are correctly  calibrated  with certificates  and are accurate.  Calibration certificates           for   the   instruments     used   will   be   provided    during the   time of   testing    and commissioning.
  7. Ensure that all services are tested and control systems  are functioning  correctly  and are properly set, sequenced  or interlocked.
  8. All the systems should be checked  by opening the drain valve & isolation  valve were  the flow of water  is reaching as per the standard.
  9. Check that the pump is free to rotate by hand. Do not operate  the pump if it is bound or if it drags even slightly until cause of trouble  is determined  and corrected.
  10. Ensure that   the  start-up   is  carried   out  for  the  pumps   by  manufacturer/supplier      prior   to commissioning.
  11. Check the Lubricate oil-lubricated

COMMISSIONING PROCEDURE:

  1. The pump and  engine  manufacturers   or their  authorized   local representative   are  to be present  for the pre- commissioning  checks of the fire pumps
  2. Check the bolts through the base plate into the concrete  base for tightness  and check the level.
  3. Check the engine cooling has been piped to drain
  4. Check the pump gland packing cooling water has been piped to the drain.
  5. Check the exhaust  piping has been correctly  fitted and supported   and open to safe place outside building.
  6. Check all engine batteries wires and control panel wires are connected  correctly and tight.
  7. Check engine oil level is sufficient for testing the pump.
  8. Check battery fluid level and top up if necessary.
  9. Check coolant level and top up if necessary.
  10. Check pressure switch is wired to panel.
  11. Check the shaft alignment between diesel engine and pump is correct.
  12. Check the suction and discharge piping completed as per the drawing.
  13. Open the suction valve and check any leakage in the piping.
  14. Check cooling water to engine is flowing using the bypass valve.
  15. Close the bypass valve and open cooling solenoid valves
  16. Put the selector  switch  on the diesel engine  manual  mode, check water  flowing through the cooling line to the drain.
  17. Check the diesel tank connection to the diesel engine, the inlet and outlet connections  are correct
  18. Check the diesel tank is filled.
  19. Open the diesel  tank  outlet  valve and  bleed  the  air  from the  diesel  engine  using  bleed pump on the diesel engine.
  20. Check the control wiring from diesel pump controller to diesel engine is correct.
  21. Connect the battery cables to the battery  and check voltage is correct on the diesel engine.
  22. Open suction and discharge valves ensure  no leakage in the piping.
  23. Set the mode selector switch on the diesel engine in MANUAL mode.
  24. Check the engine cooling water is flowing through  the cooling line and discharge to drain.
  25. Start the engine by battery 1 cracking switch.
  26. Check the following parameters and ensure  all within the limits.
    • Diesel engine RPM
    • Engine oil pressure
    • Engine temperature.
    • Engine cooling line pressure.
  27. Set the pressure relief valve (PRV) to required.
  28. Change the mode selector switch on the diesel engine in MANUAL STOP mode. Engine will stop.

COMMISSIONING OF ELECTRICAL FIRE PUMP:

  1. Check the fixing bolts in the pump concrete base for tightness  and check the level.
  2. Check the pump  gland packing cooling water  has been piped to the drain  and adjust  the gland  packing  nuts  for proper  dripping  when  water  has  been  supplied  to the  Electric Pumps.
  3. Check the electrical  motor wiring between  control  panel and motor that  the  connections have been made as per manufacturer  wiring diagram.
  4. Check all motor wires and control panel wires are tight.
  5. Check control fuses in control panel are in working  condition
  6. Check pressure switch is wired to control panel.
  7. Check the shaft alignment between pump and motor
  8. Turn ON  isolator  and  check the  incoming  power  supply  voltage  matching  the  controller specification; check the control circuit is energized.
  9. Check panel lights in working condition.
  10. Press the START button and STOP button     Motor start  rotating,  check the rotation  is correct, and change if it is wrong.
  11. Press the START button again and check the  following parameters   and ensure  all within the limits.
    • Motor RPM
    • Voltage
    • Amps
  12. Release water through  test valve, motor will start  when  the pressure   drops  below  cut-in pressure   and  stop  when  pressure   reach  above  cut-out  pressure   and  expiration   of run period time.

 

COMMISSIONING OF JOCKEY PUMP:

  1. Check the fixing bolts in the pump concrete base for tightness and check the level.
  2. Check the mechanical seal for leaks when water has been supplied to the Electric Pumps.
  3. Check the electrical  motor  wiring  between   control  panels  and  motor  that  the  correct connections  have been made.
  4. Check all motor wires and control panel wires are tight.
  5. Check control fuses in control panel are in working Condition
  6. Check pressure switch is wired to control panel.
  7. Turn on isolator  and  check the  incoming  power  supply  voltage  matching  the  controller specification;  check the control circuit is energized.
  8. Check panel lights in working condition.
  9. Turn the controller in HAND mode, check the motor rotation,  and change the connection  if it is opposite.
  10. Turn the selector switch to OFF, motor will stop.
  11. Set the cut-in, cut-out pressure
  12. Change the  controllers  in AUTO mode, release  water  through  test valve,  motor will start when the pressure  drops  below cut-in pressure  and stop when pressure  reach above cut• out pressure.

DIESEL PUMP PERFORMANCE TEST:

  1. Field acceptance Test for Diesel Driven pump set.
  2. Authorised representative shall be present  for the field acceptance 
  3. All the authorities having jurisdiction  shall be notified as to the time and place of the field acceptance 
  4. A Copy Of the manufacturers   certified  pump  test  characteristic   curves  shall be available for comparison  of the results  of the field acceptance 
  5. The fire pumps   as installed   shall the  performance   as indicated   on  the  manufacturers certified  shop test characteristic  curves within the accuracy limits of the test equipment.
  6. Start the engine manually from the controller.
  7. Regulate the discharge valve to achieve various flow readings
  8. Close the test line(O% load test)
  9. Record the following data of each test point.
    • Pump discharge
    • Suction pressure.
    • Flow
    • Pump RPM.
    • Engine temperature.
    • Oil pressure.
  10. Regulate the discharge valve to achieve (50%load)
  11. Record the following data of each test point.
    • Pump discharge pressure.
    • Suction pressure.
    • Pump RPM.
    • Engine temperature.
    • Oil pressure.
  12. Regulate the discharge valve to achieve (75%load)
  13. Record the following data of each test point.
    • Pump discharge pressure.
    • Suction pressure.
    • Pump RPM.
    • Engine temperature.
    • Oil pressure.
  14. Regulate the discharge valve to achieve (100%load)
  15. Record the following data of each test point
    • Pump discharge pressure.
    • Suction pressure.
    • Pump RPM
    • Engine temperature.
    • Oil pressure.
  16. Regulate the discharge valve to achieve (150%load)
  17. Record the following data of each test point
    • Pump discharge pressure
    • suction pressure
    • Flow
    • Pump RPM
    • engine temperature
    • Oil pressure.
  18. Important test points are at 150% rated capacity and shut off, Intermediate  points shall be taken to help to develop pump performance 
  19. Close the test line; stop the pump by manual stop push button.
  20. On completion of test, the calculated reading are used to plot a graph of the test points  and are compared  with the manufacturers   pump  characteristic   curves a study of these  curves will show the performance  picture of the pump as it was tested.

ELECTRICAL PUMP PERFORMANCE TEST:

  1. Field acceptance Test for Electric Driven pump set.
  2. Authorised representative   shall be present  for the field acceptance 
  3. All the authorities having jurisdiction  shall be notified as to the time and place of the field acceptance 
  4. A Copy Of the manufacturers   certified  pump  test  characteristic   curves  shall be available for comparison  of the results  of the field acceptance 
  5. The fire pumps   as installed   shall the  performance    as indicated   on  the  manufacturers certified  shop test characteristic  curves within the accuracy limits of the test equipment.
  6. Start the motor manually from the controller.
  7. Regulate the test valve to achieve various flow readings
  8. Close the test line(O% load test)
  9. Record the following data of each test point.
    • Pump discharge
    • Suction pressure.
    • Flow
    • Pump RPM.
    • Voltage
    • Ampere
  10. Regulate the test valve to achieve (50%load)
  11. Record the following data of each test point.
    • Pump discharge
    • Suction pressure.
    • Flow
    • Pump RPM.
    • Voltage
    • Ampere
  12. Regulate the test valve to achieve (75%load)
  13. Record the following data of each test point.
    • Pump discharge
    • Suction pressure.
    • Flow
    • Pump RPM.
    • Voltage
    • Ampere
  14. Regulate the test valve to achieve (100%load)
  15. Record the following data of each test point
    • Pump discharge
    • Suction pressure.
    • Flow

Osha ets. Occupational health and safety.

Health Risk Assessment:

  1. All the above operations shall be executed strictly in accordance with Project Occupational Health, Safety, Security and Environmental Plan.
  2. 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.
  3. The HSE roles and responsibilities shall be delivered to all staff (construction manager, engineer, supervisor, foremen, and charge hand).
  4. Work will commence as per safety regulations laid in the contract specifications and project safety plan.
  5. Housekeeping shall be of good standard and debris shall be removed.
  6. All activities will be performed according to the control measures and instructions prescribed in the attached Risk Assessment Sheets.
  7. Daily JSA will be done before the commencement of each shift and each new task.
  8. All Vehicles will have valid licenses and passes before entering the site.
  9. 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).
  10. Specific training shall be given for task specific tools and equipment’s; records shall be kept in HSE department.
  11. Heat stress training will be provided during summer time, records shall be kept in HSE department.
  12. Adequate cool drinking water, shade and hydrolyte shall be placed.
  13. Plant and equipment shall have back up alarms, lights and all other applicable safety devices.
  14. Provide Banks man when operating equipment reverse and moving the equipment where pedestrian movement is exist.
  15. Work on site will be supervised by a competent person (Qualified SE)
  16. Safety Lighting

Emergency Procedures:

  1. Contact numbers of personnel concerned to be displayed.
  2. Emergency response team to be designated and on standby:
  3. All emergency contact people are posted around the project and are being discussed during site safety meeting.
  4. Emergency routes and exists to be clearly marked.
  5. 1 vehicle with one driver will be available for any emergency.
  6.  Requirement of the Project Emergency Preparedness and Response plan shall be strictly followed.
  7.  In the event of an accident, contact the area HSE Supervisor. 
  8.  In case of Diesel Spillage contact the Environmental department.
  9.  Easy means of access will be available at all time.        
  10.  Contact numbers of all emergency supervisors will be distributed to site personnel (Site engineer, Safety officer, male nurse and concerned authorities and emergency services).
  11.  Injuries will have the highest priority to be directly dealt with at once.
  12.  There are different types of situations that we need to consider under this section. These are:
  13. Basic first aid
  14. Medical
  15. Property damage
  16. Environmental releases
  17. Fatality
  18. Fire
  19.  The nominated response team will consist of:
  20. Site nurse
  21. Safety Engineer/Officer
  22. Site Superintendent/Foreman
  23. 4no of operatives
  24. Basic first aids
  25. 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:

  1. Inspection & Test Plan
  2. Inspection and Test report for Fire fighting Pumps
  3. Testing and Commissioning checklist for fire fighting pumps
  4. Checklist
  5. Risk Assessment
  6. Quality Control Procedures
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Hira B

Hira B

I have done BS Electrical Engineering and Masters in Construction Management with 8+ years of working experience in UAE and Singapore. I lost my job in early 2020 during Pandemic and since then working as a Freelancer.

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