9.

0 Method Statement for Chilled Water Pipe Installation

9.1 Objective

This Method Statement serves to document the procedure for the fabrication,
installation, welding and testing of the pipework system.

9.2 Shop Drawings

Shop drawing shall be prepared in accordance to the Construction Drawings.

9.3 Material and Machinery

Material
(a) Condensate pipe
(b) In situ polyurethane mixture
(c) Cement solvent
(d) Welding rods
(e) G. I. sheet
(f) Bolts and nuts
(g) HILTI® flush anchors M10 size
(h) Hanger rods
(i) Support bracket

Machinery
(a) Tools and equipments
(b) Chain blocks or other lifting equipment

9.4 Submission

All sample pipe and associate accessories shall be submitted to the respective
consultant for approval prior to installation works.

9.5 Manufacturing

Aboveground & underground chilled water pipe shall be G.I pipe class ‘C’ c/w poly –
urethane pre-insulated type (CFC free). All pipes shall end-capped to protect against
introduction of dirt or water. All delivery to site shall be check for rust, welding,
insulation or any deformities.
9.6 Transportation, Storage and Handling

Pipe shall be transported to site via lorries and pipes shall be hoisted to the respective
level via cranes. Fittings shall be transported in casings and shall be hoisted to the
respective level via the crane. Utilization of chain block during installation shall be
used if necessary. All pipes if possible shall be stored inside the building. If in the
event that external storage is inevitable, pipes shall be duly covered and raised up
above ground.

9.7 Installation

9.7.1 Hangers, Anchors and Supports

Pipe Supports

 Interval between support centers to centers shall be as follows:

Size Intervals for Horizontal Runs

(mm) Bare pipe(m) Pre-Insulated
pipe (m)
15 2.0 2.0
20 2.0 2.0
25 2.0 2.0
32 3.0 3.0
40 3.0 3.0
50 3.0 3.0
65 3.0 3.0
80 3.0 3.0
100 3.6 3.6

 Vertical run pipes shall be fastened to the building floor slabs at each level.
The additional brackets will be provided at middle height of each level if
necessary.

Pipe Hanging Rod & Adjustable Split Ring Straps

Hanger rod sizes shall be as follows

Pipe Sizes (mm) Rod Diameter (mm) Max. hanger Space (mm)
Up to 25 10 2000
32 to 50 10 3000
65 to 80 15 3000
100 15 3600

9.7.2 Pipes Suspended from Slab

Types of Pipe Support are as indicated in Equipment and Piping Installation Detail.
Calculation shall determine the support spacing, size and type. These shall be in
compliance to the specifications. There shall be minimum 2 support per length of
pipe. Trapeze type support shall be used where more that two pipes are running side
by side in parallel. Expansion type anchor bolts shall be correctly selected and
installed to prevent overloading. Positions of anchor-bolts are marked on the slab
above prior to drilling. Anchor-bolts are tightened together with the mild steel channel
(where required). The hangar rod and the clevis hangars are than bolted onto the
channel. The pipe is then lifted (large pipe using chain block) to sit onto the clevis
hangar.

9.7.3 Pipe Risers

Pipe risers to be anchored shall be via sleeve to pipe and wedge to sleeve and channel
method as indicated in Equipment and Piping Installation Detail. Pipe risers to be
guided only shall be as indicated in Equipment and Piping Installation Detail.

9.7.4 Pipe on Ground

Pipe running on ground level shall be installed as indicated in Equipment and Piping
Installation Detail.

9.7.5 Insulation

As pipes are pre-insulated, site insulation works shall be limited to joints and elbows.
Site insulation works shall be carried out only after completion, inspection, pressure
test and approval of the joint. All site insulation for pipes shall be jacketed first and
subsequently the polyurethane compound is poured it. The work sequence of
polyurethane insulation as below:

a) Clean the pipe prior to insulation works.

i. Clean pipe/ valve surface with cloth
ii. Clean surface of any grease and oil with detergent
iii. The pipe surface shall be kept dry before applying insulation material.
b) Pre-insulated pipe are insulated in the factory, site in-situ polyurethane
chemical injection is carried out for all welding joints, elbows, fittings, valves
and flexible joints.
c) Preparation for in-situ insulation
i. Wrap G.26 G I Sheet over joint areas and overlap existing adjacent
jacket with minimum 25mm
ii. Rivet at overlapping area and tape all ends.
iii. Drill 2 holes approximate 25mm diameter near the overlapping area
with minimum 100mm spacing between the 2 holes.
iv. Mix and stir correct portion of isocynate and resin for approximately
20 seconds as per manufacturer’s recommendation. Then pour the
mixture into 1 hole until it overflows on both holes.
 v. Allow approximately 4 to 5 minutes of reaction time.
vi. Trim the excess cured mixture and clean all areas.
vii. Cover the holes with riveted sheet

9.7.6 Penetration

All pipe penetration through floors and compartment walls shall be installed with the
appropriate fire seal and installation shall be verified by the fire seal supplier.

9.7.7 Pipe Sleeve Installation

a) All galvanized pipes passing through walls, floors shall be filled with pipe
sleeves of 1.0mm galvanized sheet metal, and shall be minimum one nominal
diameter larger than the service pipe.
b) Installation shall be done during the formwork activity or coordinated during
the brick work erection.
c) Where pipes penetrate floors and firewalls, the annular space between the
sleeve and the pipe shall be filled with mineral rock-wool and for fire-wall to
caulk with approved fire stopper at both ends.

9.8 Labelling, colour and coding

The application of labels and directional arrows is by means of prefabricated stickers.

(a) The surface of the pipe works shall be cleaned and free from grease before the
application of sticker.
(b) Wipe the surface of the pipe with a damp cloth for dust or rinse the cloth in soapy
water for greasy surface.
(c) Ensure that the surface is dry before application of sticker.
(d) After the works are in order, tested & witnessed, begin with the labeling and
coding of pipe work & using labeling stickers. The labeling shall be according to the
following abbreviations and colour scheme.

Pipe Content Abbreviation Basic Colour

Chilled Water Supply CHWS Dark Blue
Chilled Water Return CHWR Light Blue
9.9 Pressure Test

Pressure test shall be carried out over the whole system at 1.5 times the operating
pressure or minimum 150psi and hold for 24 hours.

7.10 Quality Control

Quality Control shall start from fabrication offsite, delivery until installation.

Quality Control shall include the following activity :

a) Checking of pipe delivered to site.
b) Checking of welding, hangars and installation
c) Pressure Test of pipework
d) Checking of Insulation Works