CLIENT

MECHANICAL SUB CONTRACTOR

Issued for
0 03.02.2021
Approval
Rev Date Description Prepared Checked Approved
 METHOD STATEMENT FOR INSTALLATION OF MS PIPING, VALVES AND
INSULATION

Sl. NO. DESCRIPTION PAGE NO.

1 PURPOSE 3

2 SCOPE 3

3 REFERENCES 4

4 EQUIPMENT AND TOOL LIST 5

5 RESPONSIBILITY 6

6 METHODOLOGY FOR CONDENSATE DRAIN PIPING 7-11

7 INSPECTION & TESTING 12

 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

1. PURPOSE:

The purpose of generating this Method Statement is to define the procedure step by step to implement
the correct practices for Installation, Pressure Testing & Insulation of Chilled Water Piping including
valves and accessories through the guide line contained herein so as to ensure that the job execution
complies with the requirements and serves the intended function to a satisfactory level.

2. SCOPE:

This Method Statement refers to various work procedures contained within project control documents,
which explains and covers the Installation, Pressure Testing & Insulation of Chilled Water Piping
including valves and accessories.

3. REFERENCES:

The following reference documents to the extent specified herein form a part of this method

Area Drawing Number Drawing Description

 Approved material submittal for MS Pipes

 Approved GFC/Shop drawings as listed below for reference.

 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

4. EQUIPMENT AND TOOL LIST:

4.1. Fork Lift or Crane with capacity & arrangement in line with the Manufacturer’s
recommendations, palletmover and as required at site.
4.2. Trolley
4.3. Portable hand tools.
4.4. Portable Drilling Machine/ Grinding Machine & Angle Cutter.
4.5. Spirit Level / Level Threads
4.6. Step Ladder
4.7. Scaffolding with platform.
4.8. Welding Machine
4.9. Chain Block/Pulley
4.10. Chisel & Hammer
4.11. Measurement Tape
 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

5. RESPONSIBILITY (MANPOWER & KEY PERSONNELS IN HIERARCHY)

RESPONSIBILITY MATRIX:

Project Site HSE Head Site

RESPONSIBILITY Manager Incharge / Officer Superviso Technicians
r
Overall Control √

Site Coordination √ √ √

Tools, Resource √ √

Material √ √

Site Safety √ √ √

Doc Verification √

Marking & √ √ √
installation

Leak testing √ √ √

Inspection √ √
 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

6. METHODOLOGY

Material Receipt

 The materials received at stores / site shall be checked for manufacture details, as per delivery note and
as per approved material submittal to ensure delivery is correct.
 Verification of quantity as per delivery notes/Identification label, country of origin, test certificates, shall
be done properly by Stores personnel.
 Unloading the material shall be done manually/ by crane and shifted to the store.
 Contractor will be responsible for arrangement of unloading the pipes at store.
 Responsibility for this lies with Contractor’s Site Incharge.
 Related Material information’s will be conveyed to client and will be integrated with requirements
and procedures of contractor

Material Handling

 Use hand gloves for shifting / unloading / loading / handling etc.

 Keep pipes and fittings out of areas where they may get run over by power equipment.
 Ensure HSE work permit shall be taken before starting the work at site.
 Manufacturer’s instructions for storage, lifting and handling shall be strictly followed.
 Packing to be maintained till the time of installation.
 Always be careful to avoid damage when handling.

Material Storage (Material Storage and Management Method)

 Storage will be provided indoors and pipe should be properly supported in storage to prevent sagging
or bending.
 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

 Find a flat area, free of sharp jagged rocks or debris, and that is relatively protected.

 Never set anything heavy, sharp or rough on top of the piping.

 All Material shall be stored at designated locations at Site stores

 All packings shall be kept above ground using supports so as to allow free air flow underneath.

 Materials should be kept in their original packages and should be stored on flat surfaces as per
manufacturer’s recommendations.

 Damaged materials should be kept separately in a marked area.

 All the stores should have adequate lighting condition & ventilation.

 All other items such as valves, fittings, gauges, etc. shall be kept on racks within site stores and shall be segregated
based on size, model, type etc. for easy retrieval.

 Insulation material shall be segregated as per size, thickness for easy retrieval.

 All supporting materials shall be stored in a proper storage area, segregated according to size, type, model, etc. for
easy retrieval

General Work Methodology

Preparatory Arrangements (Prior Preparations before Commencement of works)

 Ensure that approved materials are available to carry out the work.

 Proper materials including pipes, fittings and associated accessories are withdrawn from stores
according to approved shop drawing and good engineering practices.

 Physical verification of materials will be carried out for any damages prior to taking from stores.

 Prior to Commencement of work, areas and access will be inspected to confirm that Site is ready to
commence the work.

 All relevant documentation (Drawings) and Material applicable to particular section of works will
be checked by Site Supervisor prior to commencement of work.
 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

 The Site Engineer/ Site supervisor will give necessary instructions to tradesmen (Pipe
fitters/welders) and provide necessary approved GFC/Shop Drawings along with coordinated layouts.

 The Site Engineer/Foremen will also check that proper tools and equipment are available to carry out the
work and are in compliance with contract specification

 The Site Engineer also explains the tradesmen regarding safety precautions be observed

 Prior to testing, Site Engineer will ensure that calibrated pressure gauges are available and are in good
condition.

 Ensure the wall cutout, sleeves are provided as per the approved GFC/Shop drawing.

 Remove particles thoroughly for all sleeves and cutouts

 Ensure the surface is dry.

Installation of MS piping

 Foremen will carry out a site survey and mark the route of MS piping as per approved GFC/Shop
drawings of respective services. If there are any discrepancies or difficulties in executing the work,
those should be brought to the notice of Project Engineer for corrective action.
 Co-ordination with other trades will be carried out while marking the route of piping. And checking
of levels and beam depth if any will also be co-operated.
 Determine the position of support and fix the supports using anchor bolts and ensure all
fixing are tight and secure. While drilling the soffits, ensure that there is no damage to
embedded services in the slab.
 Install the pipes in position on the supports. Wherever possible pre-assembly of pipes and
fittings at ground level will be carried out.
 Assemble the pipes and fittings as per approved shop drawing.
 Check and ensure sufficient clearance around pipe is available for insulation.
 After consultant or site engineer representative inspection. Prior to installation clean all pipes
and apply primer / red oxide.
 Cut the pipes accurately to measurements determined at site.

 Prepare the pipe ends according to the type of joints i.e.. Threaded joints, welded joints / grooved coupling joints.
 The end preparation shall be done at site work shop.
 Threading & grooving as applicable shall be done as per fittings / couplings manufacturers recommendations.
 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

 End preparations for welded joints shall be done as per approved welding procedure.
 After the end preparation clean the pipe ends and ensure no material and dust are left inside.
 Qualified and approved welders by consultant shall be engaged in welding works.
 Install the pipe spools at heights as per approved drawings in a neat and tidy manner.
 Align and level the piping as per approved drawings.
 Sleeves / openings of suitable sizes shall be provided at wall crossings.
 Install the piping connections with valves and accessories wherever equipment are installed.
 For AHU’s and FCU’s, not installed, complete the by pass connections as per approved drawing.
 Fix the blind plugs / temporary valves on all drain, air vent, pressure gauge, thermometer and testpoints tapings as
applicable.
 Check and ensure proper supporting is provided as per approved drawings.
 Make temporary tapping provisions at multiple points for easy and quick filling and draining of pressure testing
water.
 Ensure all joints are properly tightened.
 Ensure the Hydro-testing done as per Method statement of Hydro testing submitted by ABS
 Proceed with insulation only after satisfactory completion of hydro-static pressure testing.
 For all pipe sizes, insulation pipe section of suitable thickness, as per approved drawings / submittals may be used.
 Adhesive of even coat is applied on the inner surface of the insulation section.
 Pipe section is slipped over the pipe longitudinal joints of pipe section is sealed with an overlap of aluminum foil.
Avoid longitudinal joints facing upwards.
 Adjoining sections of insulation is butted firmly together by application of adhesive on the sides.
 Seal all joints with aluminum tape.

INSULATION OF VALVES AND FITTINGS

 Insulate valves, strainers, flanges and other fittings with identical material thickness and finish like the
piping insulation.
 Fill all edges with filler sliced from the same insulation material and ensure no air gaps.
 For site shaping of sections cut, scrape, or miter to fit contour of pipe fitting or valve.
 For insulation of elbows cut one or more wedge shaped slices and fix firmly. Pack joints with slices of
insulation
 When insulating flanges and flanged fittings the insulation cover to extend at least 50 mm onto the
adjacent pipes to permit easy stripping of insulation to attend to valve for maintenance.
 Insulate strainers to permit removal of mesh without disturbing the insulation of strainer

Cladding of Chilled Water Piping

 All external ceiling voids and plant room chilled water piping shall be cladded as per approved drawings
 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

and submittals.
 Aluminium sheets of approved type, quantity and thickness are cut as required and rolled in the rolling
machine to give cylindrical profile and to form the longitudinal and circumferential groove.
 Slip the rolled aluminium profile on to the insulated pipe. Care shall be taken to ensure no damage to
insulation.
 Match the longitudinal grooves of the rolled profile and join by GI/Aluminium pop rivets / stainless steel
screws as applicable
 The screw / rivets sizes shall be optimum, so that they do not pierce the insulation
 Fix the successive cladding and match the circumferential groove of previous cladding and fix screws /
rivets.
 All longitudinal and circumferential joints are properly sealed using clear sealant.
 The valves, strainer NRV, flexible joints, pumps etc. are cladded by demountable boxes to allow
maintenance access.
 Care shall be taken to ensure, the cladding surface is free from abbration, scratches, dirt etc.
 Cladding shall be firmly fixed on the pipe.
 Raise the “Request for Inspection” for the inspection by consultant and obtain approval.
 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

7. Inspection & Testing

 Raise inspection for Installation of Chilled Water Pipes, Fittings & Valves.
 Inspection and testing of MS pipe to be done as per Method statement of Hydro testing of MS pipe.

 Inspection requests has to be raised for leak testing activities and to be forwarded prior to one
day in advance for Client inspection.
 METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

RECORDS:

 All inspection formats and other records shall be as per project approved forms.

 Leak test report is prepared by the engineer with the parameters recorded during the test.

 The inspection formats shall be used in accordance with the requirements of Client documentation
procedures

8. Health and Safety Control Measures Safety

 All activities will be executed in accordance with contractors HSE Plan and HSE guidelines.
 Safety risk assessment shall be performed for every job or task, which has the potential for harm.
 Ensure Personal Protective Equipment (PPE) is available with all the workers.
 All required equipment and tools should be checked before start of work for suitability and integrity.
 All safety Guidelines shall be adhered as per approved HSE Plan.
 Necessary permit to work to be obtained as per the site requirement.

9. HOUSE-KEEPING:

 Effective housekeeping can eliminate some workplace hazards and helps to get job done safely and
properly.
 The work area shall be maintained neat and tidy as reasonably practical all the times.
METHOD STATEMENT FOR MS
PIPING, Valves and Insulation

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