CLIENT

MECHANICAL SUB CONTRACTOR

Issued for
0 03.02.2021
Approval
Rev Date Description Prepared Checked Approved
 METHOD STATEMENT FOR CONDENSATE DRAIN PIPING

DEVELOPMENT OF DC-3, Mahape Navi Mumbai

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 7-12

7 INSPECTION & TESTING 13

 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

1. PURPOSE:

The purpose of this method statement is to define construction sequence in relation to the
Installation of Condensate drainpipe. The aim is to set out the procedures, precautions to be
observed during unloading, lifting, shifting, storing and installation. All works will be carried out in
accordance with site safety rules and regulations as guided by HSE Management. This method
statement shall be read in conjunction with project specification, relevant codes for installation &
testing.

2. SCOPE:

This method statement defines the construction methodology for the Installation of Condensate
drainpipe. The work will be coordinated with other services during the execution of work in
line with the specifications, approved MAS, approved shop drawings safety and quality
requirements.

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 UPVC Pipes

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

 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

4. EQUIPMENT AND TOOL LIST:

Item

Description Purpose

1 PPE for all staffs and labours For safe work

(includes welder’s PPE)

2 Measuring Tape For Measuring

3 Fire extinguisher & Fire Blankets For fire protection

4 Electrical Extension board with Cables For power supply

5 Fitter standard toolbox For Installation

6 Pipe Stand For pipe fabrication

7 Grinding Machine For pipe fabrication

8 Plumb For level checking

9 Spirit Level For level checking

10 Hacksaw blade with frame For pipe cutting

11 Drilling machine For drilling

 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

5. RESPONSIBILITY (MANPOWER & KEY PERSONNELS IN HIERARCHY)

RESPONSIBILITY MATRIX:

Project Site Site HSE Head Site

RESPONSIBILITY Manager Manager Enginee / Officer Superviso Technicians
r r
Overall Control √

Site Coordination √ √ √ √

Tools, Resource √ √

Material √ √

Site Safety √ √ √

Doc Verification √

Marking & √ √ √
installation

Leak testing √ √ √

Inspection √ √
 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

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 and shifted to the store.
 Contractor will be responsible for arrangement of unloading the pipes at store.
 Responsibility for this lies with Contractor’s Storekeeper.
 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 or outdoors if stored outdoors pipe should be protected from direct
sunlight through tarpaulin and pipe should be properly supported in storage to prevent sagging or
bending.
 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

 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.

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
CONDENSATE DRAIN PIPING

 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 Condensate drain piping

 Foremen will carry out a site survey and mark the route of condensate water 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.

 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

 Assemble of UPVC pipes and Fittings by using Solvent cement. Ensure that joints are clean before
applying solvent cement.

 Fix the female elbow with cover to be located at proper height as per approved shop drawing. Ensure
the line and alignment with wall tiling.

 Spacing between supports /hangers will be maintained in accordance with latest approved GFC/shop
drawings/typical installation drawing & manufacturer's recommendations.

 Ensure all open ends of pipes, fittings and valves are covered with End cap before leaving
workspace.

 ‘P’ traps shall be made at the unit for condensate drainpipes.

 Slope shall be maintained as per approved shop drawing.

 Pipes crossing the fire walls shall be sealed with fire sealant around the sleeves on both sides.

 For normal walls foam shall be applied in the gaps between pipe and sleeve on both sides.

 Condensates drain pipes are connected from the equipment to nearest manhole or traps and from
there are connected to plumbing storm water / drainage system.
 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

T YPI CAL I NST ALLAT ION OF C ONDENSA T E DRAIN PIP E FOR AHU

T YP ICAL C ONDENSAT E WAT R DRAIN CONNECT ION FOR FCU

 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

SOLVENT CEMENT JOINTING

 Careful precautions shall be made while using the solvent and glue.

 Surfaces which are meant for jointing shall be cleaned using a cleaning fluid.

 This cleaning fluid removes all dirt and machine release agents and softens the surface which is ready
for chemical solvent jointing

 Measure the length of pipe required making the allowance for any pipe fittings to be used. Cut the
pipe to the measured length. Ensure that the ends are cut square and clean all burrs

 Using a brush apply an even layer solvent cement to the spigot and socket mating s u r f a c e s .

 The cement shall be applied in a length wise direction and not in a circular motion

 Immediately after the cement application ensure that the pipe is suitably anchored

 Surplus cement shall be removed with the help of a cloth

 Leave the joints for 5 minutes and handle with reasonable care

 Plug all open ends of pipe work to prevent the entry of foreign particles

STEP 1 STEP 2
 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

STEP 3

7. Inspection & Testing

 Condensate drainpipes shall be installed for AHU, FCU equipment’s.

 Water test shall be done for all condensate drainpipes.

 All the outlets shall be covered with test plugs and water is filled into the pipe testing circuit.

 Start Water filling in the pipes and hold up to a hold time of 12 hours.

 visual inspection shall be carried out on all the joints for leakages

 Leak testing approval shall be subject to engineer’s acceptance.

 If any leaks are observed, the defects are identified and rectified and again leak testing has to be
carried out till satisfactory results are achieved.

 The in process works shall be monitored for quality of workmanship and installation against
approved shop drawing by Site Engineer.
 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

 Inspection requests has to be raised for leak testing activities and to be forwarded prior to one
day in advance for Client inspection.

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
CONDENSATE DRAIN PIPING

10. MANUFACTURERS OEM

Systems should be installed in a good and workmanlike manner consistent with normal
industry standards and in conformance with all local safety, fire and Industrial code
requirements. Failure to follow proper installation practices, procedures or techniques can
result in system failure, property damage or personal injury.
Follow manufacturers’ instructions for all related products.

PIPE CUTTING
Cut pipe square. As joints are sealed at the base of the fitting socket. An angled 1
cut may result in joint failure.
Acceptable tools include miter saw, mechanical cut off saw or wheel cutter. Wheel
type cutters must employ a blade designed for plastics.

2 RE MOVE BURR AND BEVEL

Remove all burr from inside and outside of pipe with a file, or deburring tool. Chamfer

(bevel) the end of the pipe 10°-15° CLEAN: Remove surface dirt, grease, or moisture with

a clean dry cloth.

3
DRY FIT
With light pressure, pipe should go one third to one half of the way into the
fitting socket. Pipes and fittings that are too tight or too loose
 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

should not be used.

4
APPLICATOR
Use an applicator that is one half the pipe diameter.
• Too large an applicator will force excessive cement into the inside of
small diameter fittings. Too small applicator will not apply sufficient
cement to large diameter systems.

CEMENT 5

Apply a full even layer of cement to the outside of a pipe and medium layer of
cement to the inside of a fitting.

6
JOIN PIPE AND FITTINGS

Assemble pipe and fitting socket till it contacts socket bottom. Give pipe a
quarter turn. Hold pipe and fitting together until the pipe does not back
out.

Remove excessive cement from the exterior. A properly made joint will
show a continuous bead of cement around the perimeter.

SUPP ORT SPA CING :

Adequate supports for any piping system are a matter of great importance. In practice,
 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

support spacing’s are a function of pipe size operating temperatures, the location of heavy valves or
fittings and the mechanical properties of the pipe material.
To ensure the satisfactory operation of a UPVC piping system, the location and type of hangers should
be carefully considered. Hangers should not compress, distort, cut or abrade the piping.
All piping should be supported with an approved hanger at intervals sufficiently close to maintain correct
pipe alignment and to prevent sagging or grade reversal. Pipe should also be supported at all branch ends
and at all changes of direction. Support trap arms as close as possible to the trap.
(1) Concentrated loads should be supported directly to eliminate high stress concentrations. Should
this be impractical then the pipe must be supported immediately adjacent to the load.
(2) In systems where large fluctuations in temperature occur, allowances must be made for
expansion and contraction of the piping system. Since changes in direction in the system are
usually sufficient to allow for expansion and contraction hangers must be placed so as not to
restrict this movement.
(3) Since plastic pipe expands or contracts approximately five times greater than those of steel,
hangers should not restrict this movement.
(4) Hangers should provide as much bearing surface as possible. To prevent damage to the pipe,
file smooth any sharp edges or burrs on the hangers or supports.
(5) Support spacing for horizontal piping systems is determined by the maximum operating
temperature the system will encounter. The piping should be supported on uniform centers
with supports that do not restrict the axial movement.
(6) For vertical lines, it is recommended that an engineer should design the vertical supports
according to the vertical
load involved.
 METHOD STATEMENT FOR
CONDENSATE DRAIN PIPING

6|Page