QUALITY MANAGEMENT SYSTEM

MS for Installation & insulation of

buried chilled water piping
DOC.No: VKBS/HPCL/HVAC/08

HPGRDC
PROJECT

EMPLOYER HPCL

PMC EIL

CONTRACTOR VK Building Services Pvt. Ltd

METHOD STATEMENT FOR INSTALLATION &

INSULATION OF BURIED CHILLED WATER PIPING

VKBS EIL

Signature:

Date:

Name: Sahayaraj Binod Davis Mohan

Organization: VKBS VKBS VKBS

HVAC Work Method Statement 1

 QUALITY MANAGEMENT SYSTEM
MS for Installation & insulation of
buried chilled water piping
DOC.No: VKBS/HPCL/HVAC/08

INDEX

1. PURPOSE
2. REFERENCE
3. MATERIALS USED
4. TOOLS & EQUIPMENTS
5. HUMAN RESOURCES
6. SAFETY REQUIREMENTS
7. SURVEY AND SETTING OUT WORKS
8. STORAGE OF PIPES
9. PIPE TRENCH
10. INSTALLATION OF CHILLED WATER PIPES
12. HYDRO TESTING OF CHILLED WATER PIPES
13. INSULATION OF CHILLED WATER BURIED PIPES
14. RECORDS

HVAC Work Method Statement 2

 QUALITY MANAGEMENT SYSTEM
MS for Installation & insulation of
buried chilled water piping
DOC.No: VKBS/HPCL/HVAC/08

1.0 Purpose

Purpose of this method statement is to define the method of installation of

buried chilled water piping, pipe insulation and related activities.

2.0 References

 Approved Shop drawings.

 Technical data sheets.

3.0 Materials used

 M S Chilled water pipes, Class “C” conforming to standard IS 1239/3589

 Welding Rods E7018 & E6013
 Red Oxide primer paint
 Polyurethene Foam Saddles
 50 mm thick Poly-isocyanurate cylindrical pipe sections
 500 G Polyethylene sheet
 24 x 19G GI mesh
 20G GI Wire
 Sand cement plaster
 Hot bitumen and Tar felt
 Concrete pedestals
 Backfilling materials

4.0 Tools & Equipment

 Welding machines
 Impact drilling machine
 Angle grinders
 Tool box with spanner sets, hammers, Spirit levels, markers, Pipe wrench, measuring tape
 Gas cutting equipment
 Hydra crane
 Chain Pulley
 Excavator
 De-watering system

5.0 Human Resources

 Project Engineer
 Project supervisor
 Pipe fitter / Welder
 HSE Personnel

HVAC Work Method Statement 3

 QUALITY MANAGEMENT SYSTEM
MS for Installation & insulation of
buried chilled water piping
DOC.No: VKBS/HPCL/HVAC/08

 Civil labours

6.0 Safety requirements

 All workers involved must be equipped with necessary PPE including hard hats, safety
boots, safety goggles and harnesses.
 All workers must attend safety awareness and inductions.
 A toolbox talk will be a part of all operatives prior to commencement of each phase.
 Safety precautions shall be implemented to control hazards and prevent incidents to the
public.
 Operations adjacent to public access shall be reviewed and monitored by the safety
officer throughout the duration of works.
 Safety barriers, sign boards, first aid kits and fire extinguishers shall be used in the
location of works.

7.0 Survey and setting out of works

 The surveyor shall ensure that the survey equipment be calibrated and have valid
calibration certificate.
 Survey check points and other relevant data shall be recorded.
 Work shall be commenced in areas surveyed and where survey sheet is jointly signed.
 Existing services shall be located by use of cable detectors and trial excavations. They
shall be clearly marked at site.

HVAC Work Method Statement 4

 QUALITY MANAGEMENT SYSTEM
MS for Installation & insulation of
buried chilled water piping
DOC.No: VKBS/HPCL/HVAC/08

8.0 Storage of pipes

 Materials received at site shall be inspected and to ensure that
the materials are as per approved material submittals in terms of their
make and specifications. Pipe must not be painted if not inspected.
 All material while unloading shall not be dropped, but lowered to the ground.
 Pipe shall be stacked on a flat surface with adequate supports.
 While stacking, it shall be ensured that pipes of larger sizes are placed below and smaller
sizes on top.
 All other items such as valves, fittings, gauges, etc. shall be kept on racks with in site
stores and shall be segregated based on size, model, type etc. for easy retrieval.
 All supporting materials shall be stored in a covered area, segregated according to size,
type model etc. for easy retrieval.
 Any items found damaged or not suitable as per project requirements shall be removed
from site. If required to store, they shall be clearly marked and stored separately to
prevent any inadvertent use.

HVAC Work Method Statement 5

 QUALITY MANAGEMENT SYSTEM
MS for Installation & insulation of
buried chilled water piping
DOC.No: VKBS/HPCL/HVAC/08

9.0 Pipe Trench work

 After survey and marking of the pipe routing is done, the
trench is made to depths based on the BOP shown in the approved shop
drawing.
 The trench is to be dug so that the pipes may be laid to the required allignment and
required depth.
 Ensure that the trench is dry, free from obstructions, depressions, debris, loose soil,
stones etc. The trench shall be de-watered if required.
 Where ever pipes are crossing the rods, the pipes shall be passed through hume pipes.
 Any turf for use in top soil or other surface materials shall be set aside, turf being
carefully rolled and stacked.
 Brick pedestals of size 225(W) x 300(D) shall be placed at every 3000 mm intervals on
25mm thick sand bed and 75 mm thick cement concrete.
 All suitable broken surface materials and hard core shall be set aside on one side for use
in subsequent re-instatement.

10.0 Installation of Chilled wáter pipes pipes

 Prior to placing pipes on to the pedestal, PUF saddles are positioned as per the approved
shop drawing on the brick pedestal.
 Cut the pipes using gas cutting equipment accurately to measurements determined at site.
 End preparations for welded joints shall be done as per approved welding procedure.
 After the end preparation clean the pipes ends and ensure no material and dust and left inside.
 Qualified and approved welders by consultant shall be engaged in welding work.
 The pipes are lowered and placed on to the PUF saddles by using hydra crane.
 Minimum space between pipe to pipe are to be maintained for welding purpose during
future expansion and maintanance.
 After the pipes are correctly positioned the pipe and fitting joints are welded by arc
welding procedure.
 The procedure is repeated through the entire length of the pipe line.
 Welding joints are tested by DP test, Radiography and pressure test.

HVAC Work Method Statement 6

 QUALITY MANAGEMENT SYSTEM
MS for Installation & insulation of
buried chilled water piping
DOC.No: VKBS/HPCL/HVAC/08

11.0 Hydrotesting of Chilled wáter pipes

 The hydro testing of pipes are carried out after a section of
pipes are installed in the trench.
 Loop supply and return pipes on one end.
 During initial water filling, employ sufficient manpower to monitor the entire length of piping
system for possible leakage.
 Install calibrated pressure guages on both supply and return pipes.
 Fill the wáter in the system slowly so that air is released completely.
 After completely filling the system with wáter, the system is pressurized using a
hydraulic pump upto 1.5 times the working pressure.
 During hot ambient conditions system pressure may raise due to increase in the ambient
temperature. Ensure under no circumstance the system is pressurized above 1.5 times the
maximum working pressure.
 Observe the pressure gauge reading for 8 hours and ensure that there are no leakages.
 The hydraulic pressure testing shall be witnessed by consultants.
 On completion of hydro test the pipe shall be painted with one coat red primer paint.

12.0 Insulation of buried chilled wáter pipes

 After completion of hydro test, release the wáter from the system and de-water the
trench. Ensure that the trench is free from stagnent wáter and dry.
 Poly-isocynuarate insulation pipe sections are fixed on to the pipe using approved
adhesives.
 Two layers of 500G Poly-ethylene sheet is wrapped around the insulation material.
 GI wire mesh of size 24x19G is covered over the poly-ethylene wrapping and tied firmly
with 20G GI lancing wire.
 Over the GI wire mesh layer two layers of 6mm sand cement plastering is carried out.
 On completion of sand cement plastering two layers of wáter proofing tar felt is wrapped
and applied with hot bitumin.

13.0 Records

 Signed off Material Inspection Request.

HVAC Work Method Statement 7

 QUALITY MANAGEMENT SYSTEM
MS for Installation & insulation of
buried chilled water piping
DOC.No: VKBS/HPCL/HVAC/08

 Signed off installation check list for chilled water pipe and
clearance for hydro test.
 Signed off hydro test report and clearance for insulation works.
 Signed off checklist at each stage of insulation process and
clearance for back filling.

HVAC Work Method Statement 8