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Document Code: QMS-OPR-

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PROJECT NAME & DETAILS

METHOD STATEMENT FOR

INSTALLATION &TESTING OF COMPRESSED AIR SYSTEM

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REVISION RECORD

This cover page is a record of all revisions of the document identified above by number and title. All previous cover pages are
hereby superseded and are to be destroyed.

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Rev. No. Date By Chkd. Approvals Description and Page Numbers of Revisions

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CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 RESPONSIBILITIES

6.0 EQUIPMENTS

7.0 PROCEDURE

8.0 ATTACHMENTS

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1.0 PURPOSE

The purpose of generating this method statement is to define the procedure & work sequence for the correct
practices for the Installation & Testing of Compressed Air System through the guidelines contained herein so as
to ensure that the job execution complies with the requirements of the contract specification& approved shop
drawings to which will serve for the intended function to the satisfactory level for all applicable areas in the
project.

2.0 SCOPE

This method statement covers all processes related to Installation & Testing of Compressed Air System.

This procedure is to be read in conjunction with the relevant ITP, outlining the responsibility and the quality
verification to be performed by various parties.

3.0 REFERENCES

 Latest Approved shop drawings for the required and applicable areas for Compressed Air System.
 Specifications
 Project Quality Plan
 Project HSE Plan

4.0 ABBREVIATIONS

PQP : Project Quality Plan

PSP : Project Safety Plan

QCP : Quality Control Procedure

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HSE : Health, Safety and Environment

MS : Method Statement

ITP : Inspection Test Plan

QA/QC : Quality Assurance / Quality Control Engineer.

WIR : Inspection and Test Request

MIR : Material Inspection Request

5.0 RESPONSIBILITIES:

 Responsibilities for ensuring that the steps in this procedure shall be carried out are specified at relevant steps in
the procedure:

 Project Manager
 Construction manager
 QA/QC Engineer
 Site Engineer
 HSE officer
 SK

5.1 Project Manager

 The work progress shall be carried out as per planned program and all the equipment’s required to execute the
works shall be available and in good condition as per project planned.
 Specific attention is paid to all safety measures and quality control in coordination with Safety Engineer and
QA/QC Engineer and in line with PSP and PQP.

5.2 Construction Manager

 Construction Manager is responsible to supervise and control the work on site.

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 Coordinating with QA/QC Engineers, Site Team & Foremen for all activities on site.
 Control and sign all WIRs before issuing to Consultant approval.

5.3 Site Engineer

 The method of statement to the system shall be implemented according to the Consultant project specifications
and approved shop drawings.
 Provision of all necessary information and distribution of responsibilities to his Construction team.
 The work progress shall be monitored in accordance with the planned work program and he will provide reports
to his superiors.
 The constant coordination with the Safety Engineer to ensure that the works are carried out in safe working
atmosphere.
 The constant coordination with the QA/QC Engineer for any works to be carried out and initiate for the
Inspection for the finished works.
 He will ensure the implementation of any request that might be raised by the Consultant.
 Efficient daily progress shall be obtained for all the equipment and manpower.
 He will engage in the work and check the same against the daily report received from the Foremen.
 The passage of all the revised information to the Foremen and ensure that it’s being carried out properly.

5.4 QA/QC Engineer (MEP):

 The monitoring of executions of works at site and should be as per the approved shop drawings and project
specifications.
 Ensure WIRs and MIRs are being raised for activities in timely manner and inspected by the Consultant.
 He will follow and carries out all the relevant tests as per project specifications.
 Obtain the required clearance prior to Consultant’s inspections.
 Should acquire any necessary civil works clearances and coordination.
 QA/QC Engineer will assist the Consultant Engineer/ Inspector during Inspection.
 Check & ensure work is completed prior to offer consultant for inspection.
 Coordination with site construction team.
 He will assist the Consultant Engineer/ Inspector during the inspection.
 Ensure all works have been completed prior to raise inspection to the consultant.

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5.5 Site Foreman

 The carrying-out of work and the proper distribution of all the available resources in coordination with the Site
Engineer on a daily basis.
 Daily reports of the works are achieved and coordinated for the future planning with the Site Engineer.
 Incorporate all the QA/QC and Safety requirements as requested by the concerned Engineer.
 Meeting with any type of unforeseen incident or requirement and reporting the same to the Site Engineer
immediately.

5.6 Safety Officer

 The implementation of all safety measures in accordance with the HSE plan and that the whole work force is
aware of its proper implementation.
 The implementation of safety measures is adequate to maintain a safe working environment on the work
activity.
 Inspection of all the site activities and training personnel in accident prevention and its proper reporting to the
Construction Manager and the Project Manager.
 The site is maintained in a clean and tidy manner.
 Ensure only trained persons shall operate the power tools.
 Ensure all concerned personals shall use PPE and all other items as required.
 Ensure adequate lighting is provided in the working area at night time.
 Ensure high risk elevated areas are provided are barricade, tape, safety nets and provided with ladders.
 Ensure service area/inspection area openings are provided with barricade, tape, and safety nets.
 Ensure safe access to site work at all times.

5.7 Store Keeper (SK)

 Responsible for overall Store operations in making sure to store the material delivery to the site and keep it in
suitable area that will keep the material in safe from rusty and damage.
 One who will acknowledge the receiving of materials at site in coordination with QA/QC & concerned
Engineer.

6.0 EQUIPMENT:

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 Tool box
 Hammer drill
 Grinder
 Level bar
 Hack saw
 Hammer
 Step Ladder / Scaffolding
 Hand pump
 Pressure Gauges
 Pipe Cutter
 Flat / Round file
 Gas welding (Brazing) Set
 Nitrogen Purging Set
 Pipeline Pressure Testing Accessories
 Bending Tool
 Measuring tape
 Marker
 Drill machine
 Concrete bit
 Anchor punch
Screw driver (flat & set)
Fix spanner (4mm to 32 mm)
Adjustable spanner
Spirit level
 Safety requirements tools such as safety shoes, safety helmet, safety glasses, fluorescent vest, and safety gloves
to ensure maximum ability of safe work and dust mask when required.
Calibrated Pressure Gauges

7.0 PROCEDURE

7.1 Safety

 Ensure only trained persons shall operate the power tools, welding set other related instruments

 Ensure all concerned personnel shall use PPE (Personal Protective Equipment) and all other items as required.

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 Ensure adequate lighting is provided in the working area at night time.

 Ensure service area/work area openings are provided with barricade, tape, and safety nets.

 Ensure that all people engaged in the Vacuum pipelines are experienced & have received proper & adequate training
related to procedures & test equipment utilized for the particular activity.

 Test instruments and test leads should be maintained in a safe condition and test methods enable not to create danger
on either the operator or other personnel.

 Ensure that warning labels are available on the Vacuum pipelines.

7.2 INSTALLATION PROCEDURE

7.2.1 PRE REQUIREMENTS

All materials and documentation relevant to a particular section of works will be checked by the Construction
Department prior to the commencement of work ensuring that these are of the correct type as reviewed by the client.

 Prior to the commencement of any construction activity, areas and access will be inspected to confirm that they are in a
suitable condition for construction works to commence.
 Before commencement any construction activity, pre-inspections will be carried out on all material prior to them
leaving the storage area
 On receipt of the materials at site, necessary precautions shall be taken for unloading, shifting & storage as follows:

 Materials shall be stored in a covered and dry space at all times.

All materials received at site shall be inspected and ensured that the materials are as per approved material submittal
through Material Inspection Request.
Any discrepancies, damage etc. found will be notified and reported for further action.
 Material found not suitable for site use will be removed from site immediately.
Factory supplied plastic end caps shall be provided on each end of pipe to prevent pipe ends damage and to
 Avoid ingress of dirt and moisture accumulating inside the pipes.

7.2.2. Pre-installation Check

 Handing over of the area has been given by the Main Contractor to commence the work and all the activities of
preceding trades have been completed.
 Coordination for locations and elevations has been carried out and all gridlines and benchmarks are clearly marked by
the Main Contractor. If applicable all structural openings must be signed off.
 Ensure that all safety requirements are in place in accordance with project safety plan, including relevant permits to
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work. All ladders and scaffoldings to be used must be properly erected as per manufacturer’s recommendation and
must be checked by the Safety Officer and/or competent person.
 All scaffolding must be tagged and inspected by the safety department.
 Check the hand tools to be in good working conditions and is suitable for the purpose. Temporary supply for electric
tools must be arranged properly and connection leads are not damaged.
 Ensure that all operatives are aware of the correct material handling and installation procedures to ensure best quality
of workmanship. In addition wherever required, operatives are to be certified and competent to perform this activity
on the project, and are aware of the safe working requirements contained within this document and associated risk
assessment.
 All necessary working permits shall be acquired prior to starting the activity which the permits will be applied for.
Openings / penetration covers will not be removed until permits are received from the Safety Department.
 Exclusion zones shall be provided, if required, to control the work area.
 Ensure that the latest revision of the approved shop drawing is being issued for construction.
 Temporary lighting and ventilation must be adequate on the working area.
 All access to ceiling level work area will be by means of mobile tower / scaffold and as per requirements.
 Ensure that the work area is suitably cordoned off to prevent persons not involved in the activity from straying into the
work area. The scaffold must be erected by a competent trained employee and then inspected by the competent
person prior to use, and after every alteration, or if it remains in one position for a duration of 7 days. Materials
must not be carried up the access ladder at any time.

7.2.3 INSTALLATION OF COMPRESSED AIR SYSTEM

 The piped distribution system shall use GI pipes manufactured from hot dipped galvanised steel to BS 1387 grade.
 Pipes shall be degreased suitable for oxygen use and cleanliness end caps is to be maintained by filling each pipe
with dry, clean, oil and oxygen free nitrogen, fitting suitable and protectively wrapping.
 Mark out the position for any support channel or brackets in accordance with shop drawing in reference from the
gridlines marked by MC. The pipeline should be adequately supported at sufficient intervals in accordance with
Table A to prevent sagging or distortion.
 All pipe work, pipe supports and brackets shall be painted with 2 undercoats and 2 finishing coats of sky blue colour
paint.
 Ensure that horizontal and vertical pipe runs are correctly aligned and supported as indicated in the table below for
galvanized pipe work.
 Horizontal compressed air pipes shall be pitched down 1% towards the air consumption point.
Note: Drain points are not required as we are using desiccant dryers.

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INTERVAL FOR INTERVALS FOR

NOMINAL BORE
HORIZONTAL RUNS VERTICAL RUNS
 Where it is OF PIPE essential for
pipes to mm m m cross electric
cables or 15 0.75 1.5 conduit, they
should be 22 to 28 1 1.8 supported at
intervals on either side
28 to 35 1 2
of the crossing to
prevent 42 1.2 2.4 them from
touching 54 1.4 3.5 the cables or
conduit.
 Drill the position of the anchor supports using the correct size of drill bit on the soffit of the concrete slab then
cleans the drilled holes. Fix the Internally threaded anchor with flared end for flush setting for fixing of Pipe
Supports as per the approved material submittal.
 Install the 10mm rods to the drop anchor fixtures on the concrete slab and to be fitted with the GI slotted angle
channels. Install the munsen rings as per the approved shop drawings to keep the proper distance between the pipe
lines.
 All pipes shall be inspected for cleanliness prior to installation and further cleaning shall be carried out after the
works has been completed. Pipes and fittings shall be wiped to remove grease, oil or dirt from the surfaces to be
bonded.
 Pipes shall be cut at right angles to the required length using a sharp pipe wheel cutter and ends shall be chamfered
& reamed to remove burrs and smooth finish shall be done by utilizing flat/ round file.
 Expanded joints should be made using the appropriate tools and dies. Only where the cut pipe has either
deformation or a burr which significantly restricts the flow of gas will deburring be necessary.
 Bending of GI tubes below 35mm will be done at site with proper bending tools as follows;

a. With the handles at 180 degrees and the tube-holding clip raised out of the way, insert the tube in the forming-
wheel groove.

b. Place the tube-holding clip over the tube and bring the handle into an approximately right angle position, engaging
the forming shoe over the tube. The zero mark on the forming wheel should then be even with the front edge of
the forming shoe.

c. Bend by pulling the handles toward each other in a smooth, continuous motion.

d. Remove the bent tube by pivoting the handle to a right angle with the tube, disengaging the forming shoe. Then
release the tube-holding clip.

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 Laying of the pipelines should be handled with care to avoid any physical damage to the material and keep the
system clean. Generally, Gas pipes should be kept away from areas where they may be subject to any of the
following:
 Mechanical damage
 Chemical damage
 Excessive heat
 Splashing, dripping or permanent contact with oil or grease
 Bituminous compounds, electrical sparks
 Check dimensions and elevations to finished face of floor, walls and columns after the route of the pipe is being
coordinated with other services. Pipes shall be levelled correctly from finished floor level.
 The installation of the pipes shall be neat, plumb and is installed parallel or perpendicular to the building fabric.
 Pipe lines dropping down through the wall shall be concealed up to the outlet points.
 Pipelines should be identified in accordance with BS 1387 and contract specifications and colour banding for the
pipelines should be used outside of the plant room. Colour band identification should be applied near to valves,
junctions, walls etc. Each gas should be identified in 6 mm letters. Self-adhesive plastic labels of approved
manufacturer may be used for this purpose.
 A band 150 mm wide is usually adequate. All colour-coded tapes applied by the pipe manufacturers should be
removed before the systems are identified, in accordance with this paragraph.
 Work Inspection Request for the installation shall be raised to the Consultants for approval.
 Photographs of the installation must be taken for documentation purposes.

7.2.4 JOINTING PROCEDURE FOR GALVANIZED TUBE

 Screwed pipe work and joints for all pipes.
 Pipe ends will be threaded by the use of an appropriate threading machine.
 The machine die head will be suitable to cut tapered type threads.
 Threads will be cut to the correct thread length.
 After the suitable thread has been cut, burrs, surplus oil will be removed prior to the selected fitting being screwed
in place.
 Threads shall be applied with thread joint compound of the approved type.
 By means of an appropriate pipe wrench, the selected fitting will be screwed onto the pipe thread to the correct
tightness required without causing any damage to the pipe/fitting.

 When pipe and fitting is fully tightened, clean of any excess jointing compound, and paint exposed threads with
approved cold galvanizing compound.

7.2.5 FINAL CONNECTION

 Final connections to compressor will be full line size flexible connections of type shown on the construction
drawing located as close as possible to the compressor. Ensuring pipe work is adequately supported independently
to the flexible connectors.

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7.2.6 Standing Pressure Tests for Positive Pressure Compressed Air Piping System

 After successful completion of the initial pressure tests, Compressed Air piping shall be subjected to a standing
pressure test.
 Tests shall be conducted after the final installation of station outlet valve bodies, face plates, and other distribution
system components (e.g., pressure alarm devices, pressure indicators, line pressure relief valves, manufactured
assemblies, hose, etc.)
 The source valves shall be closed during this test.
 The piping system shall be subjected to a 24 hour standing pressure test using oil-free, dry nitrogen NF.
 Test Pressure shall be 20% above the normal system operating line pressure.
 At the conclusion of the tests, there shall be no change in the test pressure other than that attributed to changes of
ambient temperature.
 Leaks, if any shall be located, repaired (if permitted) or replaced (if required), and retested.

7.3 Installation of Equipment and Accessories

7.3.1 Compressed Air System

 Installation of Compressed Air System will be as per the approved drawings and material approval.
 The compressor systems must always be handled with care.
 It may be either lift by Fork lift or by mobile crane.
 Compressor system has been designed to operate in a frost free room with air temperature as per manufacturer
recommendation and specification.
 Free space should be left around the unit so it can be cleaned and serviced.
 The compressor system has a Dryer & filters assembly and control system.
 Electrical connections to the systems as per the manufacturer recommendation and tender specification.
 The electrical installation will be carried out by a qualified electrician.
 Compressor system will be connected with gas alarms as per the project specification.
 Compressed air system shall be integrated with BMS system.
 Intake air for the compressor is from the room by means of louvers.
Note-Motorised damper is not required as the compressor can get the sufficient air within the room, through louvers.

7.3.2 Zone Valve Box.

 In single and multiple configurations, valve box assemblies will be installed at specified locations as per the

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approved drawing.
 Zone valve box assemblies will be ganged together in a vertical stack for multiple configurations. Boxes will be
joined using the mounting brackets and screws already in place on each box. Joining the boxes assures proper
spacing for the trim frame, installed after the walls have been finished.
 Secure the box mounting brackets, located on each side of the box, to the wall structural frame. Position the valve
box(es) so that the front edge of the box is flush to 1/4" below the finished wall surface. Box(es) should be level and
installed at the specified height/location on the wall as per the approved drawing.
 Braze tube extensions to the piping system as per NFPA 99, while using heat sink techniques appropriate for
protection of sealing materials in both the valve and gauge port plug.
 Unbolting and removing valves for heat protection during installation. During brazing, joints shall be continuously
purged with oil-free dry nitrogen.
 Install the appropriate gas identification label on each valve in the box assembly.

7.3.3 Alarms

 Remove alarm panel back box from shipping carton. Do not remove alarm front panel (wrapped in anti-static
shipping bag).
 Store all other components not removed in steps 1 inside shipping carton in a safe place forinstallation later.
 Prepare a rough wall opening large enough to accommodate alarm panel back box. Alarm panel back box must have
rigid vertical members for support on both left and right sides.
 Power to alarm panel shall enter through lower left or top left conduit hole in back box.
 Remove cardboard dust cover and insert alarm panel back box into wall opening. Secure with fasteners suitable for
vertical supports.
 Mounting brackets on each side of back box are adjustable and factory preset for 5/8” thick drywall. After drywall
installation, front edge of back box should be flush with finished surface of wall.
 Alarm panels will be integrated with the BMS system.

7.4 THIRD PARTY INSPECTION OF THE COMPRESSED AIR SYSTEM.

 Inspection and testing shall be conducted by third party as per the relevant standard.

8.0 ATTACHMENTS

8.1 Inspection & Test Plan

8.2 Installation Check Sheet
8.3 Testing Check Sheet
8.4 Risk Assessment

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