METHOD OF

STATEMENT
COMMUNICATION PIPE
[Document subtitle]
 METHOD OF STATEMENT COMMUNICATION PIPE

1. Tapping and Communication pipe line

a. Confirmation of service connections transfer

i. The final list of service connection to be transferred shall be confirmed

with respective PENGURUSAN AIR SELANGOR (AIS) office. This is
to avoid transfers of unauthorised/illegal or connection with arrears.

ii. Determine the number of services sharing each connection. The

following combination shall be applicable;

- 1 service (1 consumer account) tapping size shall be 32mm.

- 2 services (2 consumer accounts) tapping size shall be 63mm.
- 3 – 5 services (3 – 5 consumer accounts) tapping size shall be
63mm.

iii. The transfer of communication pipe to the newly laid pipe line shall only
be carried after a successful pressure and leakage test pipeline shall be
flushed with clean water to remove any debris, stones and other which
may get into the pipe.

b. Pressure setting of the pipe line

i. The air valves, pressure recorder and the gauge are set at the same
location on the pipe line as for the pressure and leakage tests. The
pressure in the pipe line is set to the intended test pressure of 6 bar for
the tapping and the communication pipe test. This pressure is maintained
at all time.

c. Excavation

i. Safety signboards barriers, cones and hazard tape shall be put up and
strung in the proper places to avoid any untoward accident.

ii. The following equipments/materials shall be made available and ready

for use at all times during excavation.

- Water pump, to dewater flooded pit

- Diamond cutter or equivalent to cut across metal pavement
- Any other equipments deemed necessary
- Suitable back-filling material (sand, crusher run, earth) stocked
pile within the excavation area.

iii. The location for the tapping point is identified and an area sufficient for a
single man working is marked out on the pavement and cut with the
diamond cutter.

iv. The excavation shall be carried out to the bottom of the pipe using
excavator with suitable bucket width to allow sufficient working space to

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 fix the saddle. The excavated material shall place in a lorry and cart away
to an approve dump site.

v. Suitable imported earth/sand shall be backfill into the trench after the
installation and testing of the completion of the test with proper
compaction to bring it back to the formation level.

d. Tapping

i. The point of tapping shall be brush away of all debris, sand etc to have a
clean surface to fix the tapping saddle.

ii. The polyethylene sleeve over the corresponding area shall be cut and
removed tidily to reveal the pipe surface.

iii. Ensure that the correct size of the approved saddle and ferrule are being
used. The saddle is carefully fixed on to the pipe. The bolts and nuts on
each side of the saddle are tightened alternately to ensure that the tapping
hole is fixed firmly on the crown of the pipe.

iv. The ferrule is screwed on to the saddle with sealant tape (PTFE) to
ensure proper water tightness. Ensure sufficient strength is used to
tighten the ferrule. Excessive force will cause the saddle to crack and
subsequently induce leak in the future. The tapping machine is then
screwed on to the ferrule.

v. Use the appropriate size of tapping machine according to the

combination. The tapping/drilling is carried out under-pressure. The
tapping is carried out steadily to avoid damaging the internal concrete
lined in the pipe.

vi. Retrieve the drill when it completely cuts through the pipe cleanly and
the ferrule is then shut off. The tapping machine shall be removed from
the ferrule.

vii. Ensure that there is no leak around the tapping as well as the ferrule. The
tapping is now ready to be connected to the communication pipe.

e. Installation of communication pipe (ferrule to stop-cock before meter point)

i. The communication pipe material shall be stainless steel grade 304

schedule 40. Specials and fitting is of the same material.

ii. Ensure that the correct size of communication pipe and sufficient number
of specials (elbow, socket, male thread adaptor, jam nut, nipple etc) are
available for proper installation.

iii. Appropriate specials and fittings shall be use to change direction, joint
one piece of pipe to another. At no time, bending and twisting of
stainless steel pipe is allowed.

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 iv. The required piece of pipe shall be measured, cut and diced on site.
Ensure sufficient thread length on the pipe to make a proper strong
connection.

v. One side of the meter stand shall be installed through a concrete base.
The base of the meter stand shall be 600mm x 600mm x 50mm concrete
with BRC 10 shall be pre-cast. The slab shall be cast with two
appropriate circular openings (x mm. apart) ready for the stand.

vi. A stop-cock of the proper size is fixed at the end of the communication
pipe at the meter stand.

vii. Ensure the communication pipe to be installed is free of dirt, debris from
the cut and diced end.

viii. All threaded joint shall be screwed on with PTFE tape to ensure water
tightness of the joint.

f. Pressure testing of the communication pipe. (ferrule to stop-cock before meter).

The test shall be carried out between the ferrules and the stop cocks before the
meter point.

i. Preparation work on the test section.

The trench in the test section shall be backfilled and compacted.

However certain joints and fittings shall be left accessible for subsequent
inspection during the tests and backfilled when the test is completed.

ii. Turn of the stop-cock at the meter stand so as to bleed the air out of the
communication pipe for testing.

iii. Turn of the ferrule slowly and allow the water to fill up the
communication pipe. Closed the stop-cock when air is completely
discharged from the communication pipe.

iv. Check the pressure gauge installed on the pipe line at the beginning of
the process. Ensure it still at the required test pressure. Use the hand
pump to increase the pressure to required level.

v. Should there be any drop in the test pressure noted and the cause of the
failure (pressure drop) shall be investigate and rectified.

vi. The test shall be considered to have passed when there is no reduction in
pressure during the 10 minutes observation time.

vii. The process shall be repeated for the next tapping and communication
pipe installations.

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3. Installation of Meter Stands

i. Determine the location of meter stands with the consultant/PENGURUSAN AIR

SELANGOR (AIS). Under normal circumstances the location shall be;

- Outside the property boundary (fence)

- Near the front gate
- Easy to access (meter reading, disconnection, meter change)

ii. The pipe material shall be stainless steel grade 304 schedule 40. Specials and fitting
is of the same material.

iii. Ensure that the correct size of communication pipe and sufficient number of specials
(elbow, socket, male thread adaptor, jam nut, nipple etc) are available for proper
installation.

iv. Ensure sufficient thread length on the pipe to make a proper strong connection.
Ensure sufficient strength is used to tighten the connections. Excessive force will
cause the fittings and specials to deform and crack. Subsequently induce leak in the
future.

v. Joint the threaded pipes, short pieces, elbow, lockable valve, gate valve and nipple to
complete the incoming end to the vertical pipe stand. The inner meter stand shall put
through the concrete base fixed earlier.

vi. Inform the consumer of the temporary supply interruption while transferring the
meter and the other half of meter stand.

vii. Shut off the stop cock of the existing incoming communication pipe. Carefully
dismantle the existing meter stand from the meter to the elbow at the bottom of the
stand.

viii. Ensure the threaded end of the consumer service pipe is still in good condition and
capable to the jointed to the new stand.

ix. Using a suitable socket and stainless steel pipe to make up the gap between existing
service pipe (consumer end) and the new meter position.

x. Complete the installation by transferring and fixing the meter from the old stand to
the new stainless steel stand Turn on the stop cock from the new supply through the
meter to the consumer premise.

xi. Backfill the tapping pit and the trench to the new meter stand.

xii. Inspect the existing service pipe (assume GI) and prepare it to receive a new
connection. Confirm with the consumer and ensure the supply has resumed.

xiii. Backfill the trench and reinstate to original position as far as possible. Remove and
cart away the other half of the meter stand.