METHOD STATEMENT FOR INSTALLATION, TESTING AND

COMMISSIONING OF UNDER GROUND & ABOVE GROUND PVC PIPE

SYSTEM

PROJECT

CLIENT
MAIN CONTRACTOR
:
PMC

CONSULTANT

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 Manufactures 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 Reels 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 Pumps 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 Consultants 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.

HEALTH AND SAFETY

1. Work shall strictly follow as per the Manufacturers/ Clients / Consultants
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