METHOD OF STATEMENT

FOR
INSTALLATION OF HVAC SYSTEM

CLIENT SAINT GOBAIN

CONSULTANT CRN

CONTRACTOR SREEWARI ENGINEERS PRIVATE LIMITED

FACILITY NAME CANTEEN - SAINT GOBAIN

DOCUMENT METHOD OF STATEMENT FOR INSTALLATION OF HVAC SYSTEMS

 INDEX

Table of Contents

Purpose

Scope

Responsibilities

Tools & Equipment

Materials

Handling & Storage

Installation Procedure

Inspection

Health & Safety

Risk Assessment
1. PURPOSE
The purpose of this Method Statement is to define the procedure step by step
to implement the correct practices for installation of Copper pipes & Fittings
through the guidelines contained herein so as to ensure that the job execution
complies with the requirements and services the intended function to
satisfactory level.

2. SCOPE & DESCRIPTION OF WORK

The method of statement is applicable for all copper pipes and fittings
installation works for the project as specified in project specification.

3. RESPONSIBLITES

It will be the responsibilities of PM and site engineer to ensure the availability of

coordinated drawings and the required materials as per the project
specification. Piping will be installed by the experienced foreman/fitters in the
supervision of site engineers.

3. TOOLS/EQUIPMENTS
Equipments that shall be used for the purpose are as follows:

ndard Tool Kit for Duct Fabricator

protection, Overalls, Body Harness

5. MATERIALS

6. HANDLING AND STORAGE

On receipt of Copper pipes & fittings, the materials shall be handled & stored in
line with the following procedure:

o Copper pipes and fittings will be stacked on a flat surface free from
sharp projections, stones or other objects likely to cause point
loading or pipe deformation.

o The storage area shall be kept in proper level, so that the stacked
pipes may be uniformly supported throughout their length.
 o Copper pipes will not be dropped on hard surfaces and will not be
dragged along the ground. Wherever possible the loading and
unloading of pipes will be carried out manually by hand.

o The stacks will be protected from direct sunlight by covering with

tarpaulin sheets.

o Prior to start Installation Material Inspection Request shall be

raised for MEP Consultants inspection & Approvals.

7. INSTALLATION PROCEDURE GENERAL

1. The ducts are made to conform to relevant standards and

specifications. It will be ensured that site measurements and approved
drawing meet the required standards.

2. MIR inspection will be carried out on the duct once it is delivered to

site. This is done to increase conformance to specifications before the ducts
are covered.

3. Ensure that there is no pressure age of air from between the pieces by
using recommended gasket on the TDF flanges. Use quality bolts and nuts
(approved brands) to join the pieces.

4. Use appropriately sized drill to mark the location of hangers in the

slab or more.

5. Choose the correct sizes of anchor bolts; insert them into the drilled
location and use a hammer to fix it firmly.

6. Where structural steelwork will require support, beam clamps, glider

clips, or other devices that do not require welding or drilling of the steelwork
shall be used to attach them to the steelwork.
 7. Choose the threaded rod that has the appropriate length and
diameter; fix it by carefully twisting the anchor bolt. Make sure you exercise
caution to avoid damaging the threads.

8. Lift the ducts one at a time through hoisting up the support level,
make sure it is positioned and aligned to the specified level in the construction
drawing.

9. Use nuts and bolts to join the duct. Ensure that you have all the
accessories needed to complete the installation, such as supports and hangers.

10. Follow the approved drawing and specification while placing the
hanger support. Provide approved gasket before you place the duct over it.
The sizes of support will vary depending on the approved project drawing and
specification.

11. Using the approved installation details as a guide, use nuts and
washer to fix the support.

12. Special channel support should be used for vertical ducts. Make sure
this support is bolted on the inner surface before it is fixed on the wall

13. Fabricated fittings should be used for all duck connections. Avoid
diagonal runs. Unless otherwise stated in the project drawing, duct should be
located horizontally and vertically.

14. Ductwork penetrating external walls and floors shall be sealed to the
wall.

15. Ductwork that passes through floors, ceilings and walls should be
padded and sealed with a sealant. Also, it should get a fire rating if it will be
passing through fire-rated floors or walls. Fire damper should be installed at
the point where the ductwork penetrates the fire rated walls.

16. Install fire dampers in compliance with project specification and

SMACNA standards.
 17. If required, fire dampers/motorized smoke will be installed according
to the approved shop drawing and any other damper should be fusible link
type.

18. There should be provision of an access door for inspection,

calibration, adjustment and maintenance of dampers in line with the project
specification.

19. As each duct section gets completed, check and make necessary
adjustments to ensure that the ducts are in the correct level and alignment.

20. Use polyurethane to seal the open end of the duct temporarily, get
rid of all construction debris and clean up the site before leaving.

21. Repeat for other part of the ducts until the whole ducts are
connected.

22. Carry out a thorough inspection after the installation is complete.

8. Installation of Volume Control Dampers/Fire Dampers/ Collar control

damper.

1. Confirm the position of the dampers you want to fix on the duct from
the project drawing. Mark and cut it to the specified size. (You will only need to
cut when there is no opening in the duct already).

2. Double check the location for the requirement of installation

tolerances and clearances as specified in the drawing.

3. Shift the volume control/fire damper (VCD/FD) to the right position

manually and make sure that the damper channel frame and the duct
companion flange match.

4. Ensure that the joint is airtight by applying gasket and make sure you
fasten the clamp on the duct flange.
 5. To install, insert type of volume control damper, insert the VCD/FD
inside the duct into position through the opening provided by cutting slot
which has to be closed and sealed later.

6. Fix the VCD/FD in the duct using the correct size of bolts and nuts.

9. How to install Manual Duct Hoisting at a high level

1. Mark the point where the support is located. Drill the anchor bolt and
place the rod and angle bar to the support.

2. Use a pulley and a hoisting rope for the duct support and use the rope
to tighten the duct.

3. Put measures in place that will prevent slipping and tripping when
lifting and lowering the duct. Make sure you make a barricade and also provide
a warning sign.

4. The ductworks should be lifted gradually and one part at a time and it
can be done mechanically or manually as the weight gets evenly distributed
throughout the length of the ductwork, ensuring that all dimensions and levels
conform are in line with the approved construction drawing. If the need arises
to use mechanical lifting accessories, they must be rated and certified before
being used. All certification for lifting accessories and equipment must be done
before the equipment is used. The equipment should be inspected and
certified by a safety officer.

5. Use recommended scaffolding that has toe board protection and it

should have the approval of a scaffolding inspector.

6. Slowly hoist the duct until the desired height is reached. Slip the angle
bar below the duct and then release the rope from the duct. Same process will
follow.
10. Proposed Control Measures to Reduce the Risks (use additional sheet if
necessary)

1. A three ton truck will be used to transport GI conduits and accessories

to site. Vehicles and machinery older than 10 years will not be used and they
will all be inspected by main contractor logistic department personnel. Be
mindful of the site traffic signs and the speed limit of 20 km/h.

2. The entire loading and offloading of GI conduits material will be

inspected by main contractor lifting team. The main contractor will provide a
Third party certified mobile crane operator, signaler, accessories and other
appointed persons; he will also ensure that the lifting permit is in place. All
activity that involves loading and offloading will be controlled by the Main
contractor lifting supervisor.

3. A standard storage area with proper covering and shading will be

provided for all GI conduits materials. The material should be stored at least
1.5m from the ground. Appropriate stopper/wedges will be made available.

4. The company makes sure that every employee is safety inducted

and

5. JSA & PTB will be carried out and briefed daily before the
commencement of work on site by a concerned supervisor or engineer.

6. All personnel involved in the installation of GI conduits and

accessories will undergo training by HSE officers on manual handling and safety
precautions and procedures that have to do with working at height.

7. All power tools and hand tools will be subjected to inspection,

quarterly PAT testing, before being used to ensure they are fit for use. All
power tools must be 110 V (depends on your country) and must come with
double insulated cables. Color coding will be maintained as per main
contractor procedure.
 8. Air Leakage Test for Ductwork All ductwork shall be tested for air
leakage in accordance. The joints on ductwork shall be tested by using Light
luminous generators. All openings such as fan outlets, grilles, access panels,
test holes, etc. shall be sealed before the light luminous is introduced. If light
luminous leaks from any joint, that joint shall be made good. The light test shall
be repeated until all joints are tested and to be properly sealed

QUALITY PROCEDURES IN DUCTING WORKS.

Continuous supervision and frequent inspection should maintain the

specified standards and according to approved drawings, within the time
frame of project programmed.

The work should be carried out in compliance with project quality

control plan.

The consultant and the client must be notified at the time of delivery of
the duct material.

Upon the arrival of ducting materials, inspection will be carried out by

the consultant ensure that the ducts are complying with the approved
material submittal.

The duct material shell be stored and handled in accordance with

If, in the time of arrival the areas are not ready for installation, materials
should be properly tagged and stored, protected from environment
effect, for later use.

To verify the drawings for respective floor, revision number and

To unload the factory fabricated ducts safely floor wise.

Check that the ducting materials delivered to site are as per
standards,(gauge thickness) using gauge.

Check that ducts sizes are as per drawings using measurement tape.

To check the ducts materials quantity as per the packing list. (Straight
duct bends and taper).

To ensure that the ducts are provided with cross brazing.

To ensure that the ducts delivered to the site are fabricated with good
quality galvanized sheets there must not be any peeling of the
galvanized layer

To check that necessary scaffoldings are erected for carrying out the
erection work.

To check the duct routes and ensure that marking is done as per the
drawing.

To ensure the holes marking should not foul with the post tension slab
marking.

To check the anchor fastener size and type before drilling.

To ensure that the drilling is done perpendicular to the ceiling.

To check the duct support to support distance according to the standard

To check the threaded rod diameter according to the duct size

To check whether washers are provided in between the shells of the

anchor fastener and the nut
To ensure that the nut is properly fastened to the ceiling so that the
threaded rod is fixed rigid to the ceiling.

To check whether the threaded rod fixed protrudes only for 50mm from
the bottom of ducts

To check the support angle size, length and hole to hole distance

To check the angle frames and support angles are properly painted

To check the duct boxing is done as per requirement of site condition

To check the rivets are of proper size and the angle frames hole sizes
match.

To check the corners are properly provided for TDF/TDC type ducts.

To check the c-cleats joints are given for duct as per standards.

To ensure that the width of the folding provision given in the ducts for C
cleat is 18mm

erected.

To check and ensure the ducts separated for acoustic insulation

To check the flanges hole size and bolt size

To check and ensure the gaskets are provided for flange joints
To ensure that only GI nut Bolt is used.

To check the flanges for proper bolt nut tightening

To check and ensure that vanes are provided inside the bigger size
bends.

To ensure the flange corners and wherever required places are applied
with proper silicon sealant

After erection to check the alignment of ducting.

To ensure that the duct supports should be properly cut and grounded in
the ends.

The duct supports must be properly aligned.

To check the BOD as per drawing and site requirements.

To check the taper duct and bends are provided as per drawing.

To check all the fasteners of all the support angles fastened properly.

To check whether the branch tapings are taken before thermal

insulation.

To check and ensure the collar dampers are fixed before thermal
insulation.

To check the location of the collar dampers as per drawing

To check the collar sizes as per the drawing/BOQ

 To check the fixing of collar dampers should not be back to back of the
duct

To ensure the take-off or shoe pieces are fixed in the direction of air flow
in ducts.
QUALITY PROCEDURES IN ERECTION OF DIFFUSSERS:

Continuous supervision and frequent inspection should maintain the

specified standards and according to approver drawing, within the time
of project programmed

The work should be carried out in compliance with project quality

control plan

To check the sample thoroughly before submitting for approval

To check the colour of the diffuser is as per the consultant approval

The consultant and the client must be notified at the time of delivery of
the diffuser

Upon the arrival of diffusers inspection will be carried out by the

consultant, Ensure that the ducts are complying with the approved
material submittal.

The diffuser shall be stored and handled in accordance with

If, in the time of arrival the areas are not ready for installation, material
should be properly tagged and stored protected from environment
effect for later use.

To check the diffuser sizes are as per the drawing

To unload the diffuser properly and ensure to place under the roof

To separate the diffusers size vise

To check the supply diffusers are accompanied with proper collar

damper.

To check the diffusers neck sizes are as per the BOQ/drawing

To check and verify the neck sizes of the diffusers are properly matched
with the neck sizes of spill box.

To check the diffusers are properly screwed with the spill boxes

To check and ensure the non-regular type diffusers are seated properly
on the grid

To check that the diffusers are provided with proper supports.

To check and ensure the supply d

condition.

To check whether the inner core of the diffusers are freely removable.

To ensure that the collar dampers are provided with adjustable screw.

To check the marking of the diffusers mounting at the gypsum board

before erection of the diffusers

To check the straightness of the marking for both the sides of the
diffusers at gypsum board areas
 To ensure that the supply and return air diffusers are placed at a
minimum of 6-8 feet spacing each other.

To ensure that the installed diffusers are covered properly using

polythene sheet to prevent dust accumulation

To check that that there is no gap between diffuser and the spill box

Identification should be provided to differentiate the supply and return

air diffusers

QUALITY PROCEDURES IN ERECTION OF PLENUM BOXES:

Continuous supervision and frequent inspections should maintain the

specified standards and according to approved drawing within the time
frame of project programmed.

The work should be carried out in compliance with project quality

control plan

To check the sample thoroughly before submitting for approval

The consultant and client must be notified at time of delivery of the

material.

Upon the arrival of plenum box, inspection will be carried out by the
consultant.

The plenum boxes shall be stored and handled in accordance with

To unload the diffusers properly and ensure to place under the roof
If, in the time of arrival the areas are not ready for installation materials
should be properly tagged and stored, protected from environment
effect, for later use.

To check the dimension of the spill box like length, width, & height

To check the mounting hole for dog chain provision

To check the neck size and spigot connection size sizes are as per the
drawing.

To check the spill box neck to be screwed with the diffuser

dog chain

To ensure that the four corner of the spill boxes are properly supported
with the chains

To ensure that the spill boxes spigot connections are made towards the
air flow direction.

To ensure that the spill box is not behind the take-off collar.

To check the dog chain tightened properly to avoid the load on the grid
sealing.

To check the spill box to be erected before gypsum board fixing

To check that the flexible duct is properly connected with the spill box
spigot at one end and the other end with the butterfly damper

To check that there is no gap between the spill box neck and diffuser
collar.
QUALITY PROCEDURES IN ERECTION OF FLEXIBLE DUCTS:

Continuous supervision and frequent inspections should maintain the

specified standards and according to approved drawings. Within the
time frame of project programmed.

The work should be carried out in compliance with project quality

control plan.

To check the sample thoroughly before submitting for approval.

The consultant and the client must be notified at the time if delivery of
the material.

Upon the arrival of flexible ducts inspection will be carried out by the
consultant.

The flexible ducts shall be stored and handled in accordance with

To unload the flexible ducts properly and ensure to place under the roof.

If, in time of arrival the areas are not ready for installation, materials
should be properly tagged and stored, protected from environment
effect, for later use.

To check the diameter of the flexible duct is as per packing list.

To ensure the length of the flexible duct required for each diffuser to be
cut properly.

To ensure the flexible duct glass wool is not coming out while cutting
and fixing.
 To ensure that the flexible duct must be inserted into the spigot and the
round color for a length of 50% of the round collar diameter.

To ensure tightening of Jubilee clamp for the both the side of the flexible
duct.(i.e.at damper side and spill box side)

tape.

To check and ensure the length of flexible duct connected is not more
than 1.5 meter.

To ensure that flexible duct connections for more than 1 meter are
provided with supports using 2 inch GI flat strip with dog chain to
prevent sagging.

To ensure that the flexible duct connected should not be under tension.

To ensure that the flexible ducts should not sag.

To ensure that the flexible ducts should not be zigzag fashion.

QUALITY PROCEDURES IN ERECTION OF VOLUME CONTROL DAMPERS:

Continuous supervision and frequent inspections should maintain the

specified standards and according to approved drawings, within the time
frame of project programmed.

The work should be carried out in compliance with project Quality control
plan.

To check the sample thoroughly before submitting for approval.

The consultant and the client must be notified at the time of delivery of the
material.

Upon the arrival of volume control damper inspection will be carried out by
the consultant.

The volume control damper shall be stored and handled in accordance with

To unload the volume control damper properly and ensure to place under
the roof.

If, in the time of arrival the areas are not ready for installation, materials
should be properly tagged and stored, protected from environment effect,
for later use.

To check the dimension of the volume control damper is as per packing list.

To check the location of the VCD`s as per drawing.

To ensure that the leaves of the VCD`s fully open and close at the extreme
conditions.

To check for the hole sizes and spacing match in both the duct and the VCD
flanges.

To check whether gaskets are provided in between flanges.

To check whether the operating handle is in the accessible area.

To check whether the operating handle does not foul obstruction while
operating.
To check whether the gaskets are provided in the edges of the VCD leaves.

To check that the VCD leaves fall in the direction of flow.

To check rubber bush is provided for the leaf shaft.

To ensure that only GI nut bolt is used.

To check that the nuts and bolts are in full tight and are of uniform size.

To ensure that the VCD`s are not provided before bends.

It is advisable to have VCD`s in all the branch tapings.

To ensure that the lock nut is tightened after the leaves are set for the
requirement.

QUALITY PROCEDURES IN ERECTION OF FIRE DAMPERS:

Continuous supervision and frequent inspections should maintain the

specified standards and according to approved drawings, within the time
frame of project programmed.

The work should be carried out in compliance with project Quality Control
plan.

To check the sample thoroughly before submitting for approval.

The consultant and the client must be notified at the time of delivery of the
material.
Upon the arrival of fire damper inspection will be carried out by the
consultant.

The fire damper shall be stored and handled in accordance with

manufacturer`s instruction.

To unload the fire damper properly and ensure to place under the roof.

If, in the time of arrival the areas are not ready for installation, materials
should be properly tagged and stored, protected from environment effect,
for later use.

To check the dimension of the fire damper is as per packing list.

To check the location of the FD`s as per drawing.

To ensure that only GI nut bolt is used.

provision on both the sides.

lose in the case of fire.

To ensure that the stoppers are provided in the dampers to prevent the
rotation of the leaves.

To check for the hole sizes and spacing match in both the duct and the FD
flanges.

To check whether open close identification is

To check whether the gaskets are provided in the edges of the FD leaves.

To check that the FD leaves fall in the direction of flow.

To check that there is no obstruction for the spring action for fusible link

To check brass bush is provided for the leaf shaft.

To check that the nuts and bolts are in full tight and are of uniform size.

To ensure that proper supporting is given for wall mounted fire dampers.

QUALITY PROCEDURES IN DUCT THERMAL INSULATION:

Continuous supervision and frequent inspections should maintain the

specified standards and according to approved drawings, within the time
frame of project programmed.

The work should be carried out in compliance with project Quality Control
plan.

To check the sample thoroughly before submitting for approval.

The consultant and the client must be notified at the time delivery of the
material.

Upon the arrival of the insulation material inspection will be carried

out by the consultant.

instruction.
All cut edges should be of a "clean cut nature and not cut

-line of the ductwork, apply

nitrile rubber sheet directly onto the chalk out-line on the edge for a perfect
pattern.

To ensure that the nitrile rubber sheet does not overlap when wrapped on
the duct.

To ensure that the joints are wrapped with thick (5mm width) self-adhesive
tape.

To ensure that the insulation joints taped in both longitudinal and transverse
direction.

To ensure that for flange joint, the insulation material covers the entire
flange and with 4 inches overlap on either side of the flanges.

To ensure that the support angle is packed with one layer of insulation
material.
GLASS WOOL INSULATION:

Use the correct size of knife and brush,

For large surface areas the use of paint roller may be the advisable.

All the ducts surfaces should be cleaned before insulation.

Plan out the proposed layout and dimensions of the ductwork, mark sizes
with a marking pen, to speed up pre-fabrication production.

To ensure that the adhesive used is as per approved specification.

To ensure that the adhesive is applied on both the duct and the material
surface.

To ensure that for every 2 feet heavy duty 1 inch PVC tape has to be
provided.

ACCOUSTIC INSULATION

Use the correct size of knife and brush.

All the ductwork inner surfaces should be cleaned before insulation.

Plan out the proposed layout and dimensions of the ductwork, mark sizes
with a marking pen, to speed up pre-fabrication production.

To ensure that the glass wool (Rigid board), tissue paper &perforated sheet
used is as per approved specification.

The holes must be properly marked at maximum of 10inch spacing, drilled

and shall not be punched.

To ensure that only GI nut bolt is used.

To ensure that the headless bolts are used with washers on both sides.

To ensure that only RP tissue paper used to cover glass wool should have
100 to 150 mm overlap.

To ensure that RP tissue paper is folded inwards at the edges to cover the
glass wool.
To ensure that the perforated sheet covering the RP tissue over laps in the
corners.

To ensure that perforated sheet is folded in wards at the edges to cover the
glass wool and RP tissue paper.

To ensure that L' channel (GI) is provided in the edges of the ducts covering
the entire sandwich.

QUALITY PROCEDURES IN AIR HANDLING UNIT ASSEMBLY:

Continuous supervision and frequent inspections should maintain the

specified standards and according to approved drawings, within the time
frame of project programmed

The work should be carried out in compliance with project Quality control
plan.

To check the sample thoroughly before submitting for approval

The consultant and the client must be notified at the time of delivery of the
material.

Upon the arrival of the AHU materials inspection will be carried out by the
consultant.

instruction.

To unload the material properly and ensure to place under the proof...
If, in the time of arrival the areas are not ready for installation, materials
should properly tagged and stored, protected from environment effect, for
later use.

To ensure that the materials are as per approved specifications.

To ensure that there is clearance in the site for the AHU assembly.

To ensure that the AHU room walls are plastered and painted.

To ensure that the cooling coils are shifted with utmost care.

To ensure that the AHU blowers are shifted with utmost care.

To ensure that the flooring is complete in the AHU rooms.

To ensure that the foundation for placing the AHU is ready.

To ensure height of the foundation is as per the approved drawing.

To ensure that the aluminium profiles and the corners suit.

QUALITY CHECK IN FCU ERECTION:

Continuous supervision and frequent inspections should maintain the

specified standards and according to approved drawings, within the time
frame of project programmed.

The work should be carried out in compliance with project Quality control
plan.

To check the sample thoroughly before submitting for approval.

The consultant and the client must be notified at the time of delivery of the
material.

Upon the arrival of the

consultant.

The material shall be stored and handled in accordance with manufacturer`s

instruction.

To unload the material properly and ensure to place under the roof...

If, in the time of arrival the areas are not ready for installation, materials
should be properly tagged and stored, protected from environment effect,
for later use.

To ensure that the materials are as per approved specifications.

To ensure that there is clearance in the site for the FCU erection.

To ensure that the fan coil units are suspended properly in the four corners
rigidly.

To ensure that while suspending the unit, a proper slope is given for the
water to flow towards the drain pipe.

To ensure that the noise level in operating condition does not cross beyond
the decibel level mentioned by the consultant/ client.

To ensure that there is access for removal of the fan motor assembly for
maintenance purpose.

To ensure that the cooling coils are fabricated as per specifications.

To ensure that the cooling coil can be removed easily for maintenance
without affecting the other sections of the FCU's.

To ensure that the filter is not clogged with dust.

To ensure that the supply and the return water pipes connecting the cooling
coils matches with the specification.

To ensure that the U trap is given in the drain line.

To ensure that a slope of 1:50mm is given for the drain line.

To ensure that the chilled water pipe lines runs parallel to each other and
supported properly.

To ensure that the cables are terminated properly in the units.

QUALITY CHECK IN VENTILLATION FAN ERECTION:

Continuous supervision and frequent inspections should maintain the

specified standards and according to approved drawings, within the time
frame of project programmed.

The work should be carried out in compliance with project Quality Control
Plan.

To check the sample thoroughly before submitting for approval.

The consultant and the client must be notified at the time of delivery of the
material.

Upon the arrival of the fans inspection will be carried out by the consultant.
instruction.

To unload the material properly and ensure to place under the roof.

If, in the time of arrival the areas are not ready for installation, materials
should be properly tagged and stored, protected from environment effect,
for later use.

To ensure that the materials are as per approved specifications.

WALL MOUNTED FANS/CEILING SUSPENDED:

To ensure that the direction of air flow is as per requirement.

To ensure that the fan is wall mounted properly at the required height.

To ensure that the fan is mounted with zero level (parallel to the ceiling).

To ensure that the fan motor is accessible for service after its installation.

To ensure that to ensure that the cable terminations are done properly.

To ensure that there is no gap or opening in the casing of fan except for the
suction and discharge ends.

To ensure that the mouth connections done are of flange type and not cleat
connection.

To ensure that the nut bolts are properly fastened in the flanges.

To ensure that the GI nut bolts are used.

To ensure that gaskets are provided in between the flanges.

 FLOOR MOUNTED VENTILATION FANS:

To ensure that the foundation are laid for the assembly of the fan.

To ensure that fans are properly fastened to the foundation.

To ensure that the vibration isolators are placed underneath the base.

Health and Safety

o Risk assessment for all activities has been carried out and attached as
annexure, all necessary control measures should be taken as mention in the
risk assessment.

o Adequate safe access to the installation area shall be provided

o Workmen shall wear all appropriate safety personal protective equipment

such as helmet, coverall clothing, safety shoes, goggles and gloves etc,,
wherever required

o If work is at high level, only approved scaffolding and safety belts should be
used

o Sufficient light shall be ensured before start of the work

o Safe work permit shall be obtained where require as per the directives of
HSE officer

Risk Assessment

o All workers may suffer sprains or fractures if they trip over waste including
brick bands and pallet debris

o All workers could suffer from back injury if regularly lifting/carrying heavy
o Serious head and other injuries to workers, others on site and members of
the public

o All workers could suffer foot injuries

1.PURPOSE

The purpose of this Method Statement is to define the procedure step by

step to implement the correct practices for installation of Copper pipes &
Fittings through the guidelines contained herein so as to ensure that the job
execution complies with the requirements and services the intended function
to satisfactory level.

2. SCOPE & DESCRIPTION OF WORK

The method of statement is applicable for all copper pipes and fittings
installation works for the project as specified in project specification.

3. RESPONSIBLITES

It will be the responsibilities of PM and site engineer to ensure the availability of

coordinated drawings and the required materials as per the project
specification. Piping will be installed by the experienced foreman/fitters in the
supervision of site engineers.

4. TOOLS/EQUIPMENTS
Equipment that shall be used for the purpose are as follows:

Tool box for mechanical /Hand tools

 Leveling instruments

flex coated Brazing Rods

Blow-Torch Heating torch

Thermometer (Heating gauge indicator if any)

Grinding machine, drilling machine & cutting machine

Oxygen & Acetylene cylinder & cutting outfit

Appl

5. MATERIALS

Copper pipe and Fittings shall be in line with the specification and approved
Material submittal

6. HANDLING AND STORAGE

On receipt of Copper pipes & fittings, the materials shall be handled & stored in
line with the following procedure:

o Copper pipes and fittings will be stacked on a flat surface free from
sharp projections, stones or other objects likely to cause point
loading or pipe deformation.

o The storage area shall be kept in proper level, so that the stacked
pipes may be uniformly supported throughout their length.

o Copper pipes will not be dropped on hard surfaces and will not be
dragged along the ground. Wherever possible the loading and
unloading of pipes will be carried out manually by hand.
 o The stacks will be protected from direct sunlight by covering with
tarpaulin sheets.

o Prior to start Installation Material Inspection Request shall be

raised for MEP Consultants inspection & Approvals.

7. INSTALLATION PROCEDURE GENERAL

PRE-INSTALLATION PROCEDURE

All workers to attend safety induction conducted by main contractor and

given specific training on the safe installation methods.

Task lighting to be ensured prior to start of Brazing copper pipes

including riser piping.

Riser checklists to be filled and kept updated till completion of riser

pipes brazing activities.

Copper pipes brazing jointing works as indicated on the approved shop

drawing and as per site requirements.

The site Engineer ,Site Supervisor will give necessary instructions to

certified welders tradesmen provided necessary approved construction/shop
drawings of latest revision with coordinated layouts.

The site engineer and supervisor also supervisor explains to the credited

INSPECTION GUIDANCE FOR BRAZING WORKS

The engineer/supervisor will complete the inspection checklist and

follow the inspection & test plan detailed in this procedure. The intent of this
procedure is to establish a high level of assurance that the end product meets
the specification requirements and consultant satisfaction. The QA/QC
inspectors should verify the approved procedures for brazing are followed and
the inspections and the testing records are completed.

COPPER PIPE PREPARTION OF BRAZING JOINTS:

Prior to alignment of pipes for brazing each length of pipe will be

thoroughly to ensure that no visible defects are present. Checks the materials
as per the standard and specification and get approval from the
consultant/Employer representative.

from the edge inside and outside) shall be thoroughly cleaned from the rust,
paint oil scale or the other foreign materials, which are harmful for welding
and brazing alloy heat build-up quality.

Each length of pipe shall be thoroughly cleaned by blowing air from

both ends of the pipe, protect and cover the openings of pipes with suitable
cap or polyethylene sheet in order to avoid any foreign material entering.

Ensure all both pipe are clean without any dirt or oil deposits before
inserting to the socket which is index socket fittings, pressing firmly to reach
stopper tip from socket start leveling until its firmed follow procedure below.

For proper aligning external alloy rods are suitable to use particularly for
wall thickness of the copper pipe and its diameter size of the copper pipe to
insure proper usage

Pre-Heating temperature must be 700to 750°C (COPPER PIPES).Heat the

assembled joints between pipe and index fittings evenly on all sides while
heating build up encircling direction either left to right depends on the welder.

Apply solder or brazing Alloy rod to the mouth of the fittings when
reaches the correct temperature the solder alloy will flow freely into the joints.
Briefly reapply the blowtorch and wipe off any excess flux residues (solders).
 BRAZING/WELDING CONFORMANCE:

Welding/Brazing alloy of piping shall be performed in accordance with

the approved WPS based on project specifications and applicable codes for BS
standards; hence there is no welding or brazing procedure specification on the
project mentioned.

Oxy-acetylene welding to BS 26340 Class 11 with filler rods to BS 1453

and BS EN 12536 as appropriate. Arc welding to BS 4515 BS 2971 class 11.

Bronze welding of copper tube & pipes oxy-acetylene and insert gas shall
be in accordance with BS 1724.

shall be as per ITP. All welds and brazing joints will be 100% visually examined
conformity to drawing shall be done for all the lines checking that all
components supports ,brackets ,etc. are installed as per approved materials
an

Flange connection shall be according to ANSI standard. Otherwise stated

by approving consultant.

While brazing refrigerant pipes, flush them with nitrogen gas. Use a
pressure regulator to maintain a flow rate of 1.76 ft3/h (0.05 m3/h) or
more.

All the equipment used for welding & brazing shall be in good condition.

Raise inspection (WIR) to consultant, all fabrication shall be visually

inspected and acceptance criteria d shop drawing details and
specification of the project.

Pressure Testing of Piped Services Before carrying out pressure test,

spotted open-up inspection for joints shall be required to inspect the
internal finishing after brazing to ensure the quality of the workmanship.
 Refrigerant systems and circuits shall be pressure tested with nitrogen
gas to test pressures as indicated 550PSIG as per the manufacturer
recommendation.

Testing pressure in the system for not less than 12 hours suggested,
without leakage or loss of pressure.

Cleaning and Protection

o
practices will be followed to keep the area clean, tidy and clear of
any tripping hazards.

o Usable, left-over or surplus material will either be returned to the

stores or will be shifted to the location where similar type of
materials can be used for successive installation. Debris and
scrapped materials will be removed from the locations in project
premises.

o The installed Pipes shall be cleaned and covered properly by

Polyethylene sheets to protect the Pipes from deposition of
construction dust.

8. Inspection & Testing:

Welding/Brazing alloy of piping shall be performed in accordance with

the approved WPS based on project specifications and applicable codes for BS
standards; hence there is no welding or brazing procedure specification on the
project mentioned.

Oxy-acetylene welding to BS 26340 Class 11 with filler rods to BS 1453

and BS EN 12536 as appropriate. Arc welding to BS 4515 BS 2971 class 11.
 Bronze welding of copper tube & pipes oxy-acetylene and insert gas shall
be in accordance with BS 1724.

Flange connection shall be according to ANSI standard. Otherwise stated

by approving consultant.

While brazing refrigerant pipes, flush them with nitrogen gas. Use a
pressure regulator to maintain a flow rate of 1.76 ft3/h (0.05 m3/h) or
more.

All the equipment used for welding & brazing shall be in good condition.

Raise inspection (WIR) to consultant, all fabrication shall be visually

inspected and acceptance criteria d shop drawing details and
specification of the project.

Pressure Testing of Piped Services Before carrying out pressure test,

spotted open-up inspection for joints shall be required to inspect the
internal finishing after brazing to ensure the quality of the workmanship.

Refrigerant systems and circuits shall be pressure tested with nitrogen

gas to test pressures as indicated 550PSIG as per the manufacturer
recommendation.

Testing pressure in the system for not less than 12 hours suggested,
without leakage or loss of pressure.
 Health and Safety

o Risk assessment for all activities has been carried out and attached
as annexure, all necessary control measures should be taken as
mention in the risk assessment.

o Adequate safe access to the installation area shall be provided

o Workmen shall wear all appropriate safety personal protective

equipment such as helmet, coverall clothing, safety shoes, goggles
and gloves etc,, wherever required

o If work is at high level, only approved scaffolding and safety belts

should be used

o Sufficient light shall be ensured before start of the work

o Safe work permit shall be obtained where require as per the

directives of HSE officer

Risk Assessment

o All workers may suffer sprains or fractures if they trip over

waste including brick bands and pallet debris

o All workers could suffer from back injury if regularly

lifting/carrying heavy

o Serious head and other injuries to workers, others on site and

members of the public

o All workers could suffer foot injuries