Document Number

Doc. Unit n°
Project Area Originator Discipline Serial n° Rev. Page
Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

METHOD STATEMENT FOR INSTALLATION

OF GAS SUPPRESSION SYSTEM (FM200) IN
THE BATTERY ROOM OF 132 kV SUBSTATION

OWNER Approval:
Name:
Date (DD-MMM-YY):

Signature:

Document Class: Z

Pages modified under this revision: -

A 15-10-2019 IFR – Issued for Review THANA (SCI) KMR (SCI) SIEMENS MALAYSIA
WRITTEN BY (name & CHECKED BY (name & APPROVED BY
REV. DATE STATUS –REVISION MEMO signature) signature) (name & signature)
(DD-MM-YY)

Sections changed in last revision are identified by a vertical line in the left margin.
 Document Number
Doc. Unit n°
Project Area Originator Discipline Serial n° Rev. Page
Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

HOLD’s

HOLD REF.§ DESCRIPTION ACTION

 Document Number
Doc. Unit n°
Project Area Originator Discipline Serial n° Rev. Page
Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

Table of Contents

1.0 INTRODUCTION ...................................................................................................................4

2.0 SCOPE OF THE WORK ........................................................................................................4
3.0 SAFETY AT SITE..................................................................................................................4
4.0 DESCRIPTION OF WORK ....................................................................................................4
5.0 RESPONSIBILITIES/DUTIES ...............................................................................................4
6.0 LIST OF TOOLS ...................................................................................................................5
7.0 PREPARATION WORK.........................................................................................................5
8.0 WORK SEQUENCES ............................................................................................................5
9.0 HSSE PROCEDURES ........................................................................................................10
 Document Number
Doc. Unit n°
Project Area Originator Discipline Serial n° Rev. Page
Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

1.0 INTRODUCTION
ST Microelectronics Sdn. Bhd., hereinafter referred to as OWNER, is a
semiconductor solution providing manufacturing company at Tanjong Agas, Ledang in
Johor, Malaysia.
This Method Statement shall be applied for Installation of Gaseous Suppression
System (FM 200) in the new electrical substation (132/11kV) building at ST
Microelectronics Sdn. Bhd, Tanjong Agas, Ledang in Johor, Malaysia.

2.0 SCOPE OF THE WORK

The scope of work shall consist of installation of fire-fighting system in the new
electrical substation (132/11kV) building at ST Microelectronics Sdn. Bhd, Tanjong
Agas, Ledang in Johor, Malaysia with accordance to drawings/plans, details,
specifications and bill of quantities as tendered

3.0 SAFETY AT SITE

All employees and self-employed labor will comply with this method statement and
with the requirements of the Health and Safety at Work Act 1974 (OSHA) and all the
other relevant health and safety legislation, together with any specific site rules and
where applicable, the requirements from principle contractor's safety policy and
construction phase health and safety plan.

4.0 DESCRIPTION OF WORK

This installation procedure is intended for installation of gaseous suppression
system (FM 200) at battery room in the new electrical substation (132/11kV) building at
ST Microelectronics Sdn. Bhd, Tanjong Agas, Ledang in Johor, Malaysia. The purpose
of this guideline is to clarify the policy for installation procedure, quality, safety and other
management.

5.0 RESPONSIBILITIES/DUTIES
a) Project Manager
-Responsible in the overall control and ensuring that all works are well executed in
accordance to this procedure

b) Engineer/Supervisor
-Responsible for the method, implementation, site control, scheduling of test and
inspection, and measures to allow compliance to the safety requirements in the work.
 Document Number
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Project Area Originator Discipline Serial n° Rev. Page
Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

-Maintain quality standards by approving incoming materials, in-process

production, and finish products recording quality result. The scope includes check and
review the plans & specifications for the proper installation & quality implementation at
job site, perform pre-inspection to ensure that all installed materials are within the
standard in conformance to applicable drawings & specs, render monitoring and
surveillance on site to control the quality of work being implemented by the installation
group.

6.0 LIST OF TOOLS

I. A set of open-end spanners with sizes from 7mm up to 32mm
II. Alternatively, a set of adjustable spanner size 305mm and 460mm.
III. Hex Key (Allen Key) size = 4 mm.
IV. Screwdrivers
V. Pipe wrenches in adequate size
VI. Drilling Machine
VII. Drill bits as required
VIII. Thread cutting machine
IX. Cutter / Hacksaw
X. Measuring tools
XI. Leveling tools
XII. Leak spray liquid
XIII. Vacuum cleaner for suction of drilling dust at delicate sites
XIV. Cleaning materials such as brooms, rags, oil suction powder, etc.
XV. Cylinder Trolley
XVI. Pipe / Thread seals

7.0 PREPARATION WORK

Supervisor shall emphasize the awareness of tools handling to workers during toolbox
meeting every morning before commencement of work on the specific job safety.

8.0 WORK SEQUENCES

Contractor shall prepare Job Method Statement (JMS) and submit for Owner approval
prior to commencement of general civil work. The method of general civil works shall be as
follows: -
8.1 Material Preparation.
a. Good condition of all material arrived at site need be ensured prior to
carrying out the assembly and installation of the system.
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Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

b. Match of protected areas and cylinder storage areas with the drawings in
layout and size need to be ensured. Any discrepancies to be informed to
the project manager.

8.2 Transport and Storage of Materials

a. The cylinder(s) must be fitted with valve outlet caps whenever they are
moved or when they are not connected to the manifold.
b. When the cylinders and associated equipment arrive on site, they shall
be stored in a dry room within a temperature range of 0oC and 50oC until
they are needed for installation.
c. When storing the cylinders, secure them so that they don’t fall or roll.
d. Avoid exposing the cylinders to direct sunlight and heat.

NOTE:
The SR200-HFC227ea cylinder valve is fitted with a safety burst disc that vents the
gas when the pressure within the cylinder reaches 50 bar. Depending on the filling
density of the cylinder this pressure can be reached at a temperature range of 55oC
to 80oC.

The cylinders must not be dropped or rolled when transporting or moving them. A
suitable trolley should be used to move the cylinders. For safety precautions, always
wear thick gloves and safety shoes when handling the cylinders.

8.3 Installation of the cylinder(s), actuator, pipe distribution network and discharge
nozzle (See Appendix A)
A. Instructions for Installing a single cylinder
Wall Mounted Installation
I. Make sure there is at least 1 meter / 3 ft of free space is available in front of
the cylinder for installation purposes.
II. Check that the wall and floor surfaces are flat. If it is uneven, repair them so
that the cylinder can be safely and accurately installed.
III. If the floor is damp or is likely to be wet, the cylinder must be placed on top
of metal grates or panels to keep it off the floor. This is to avoid corrosion on
the bottom of the cylinders.
IV. Refer to the layout drawings and isometrics to mark out the position of the
cylinder brackets on the wall.
V. The mounting height for the cylinder brackets shall be adjusted accordingly
with due allowance for the thickness of the grates or panels.
VI. Make the necessary adjustments on the cylinder placement.
VII. Place the bracket against the wall and mark out the 10mm diameter holes
for the wall plugs / anchor bolts.
VIII. Drill the holes for the M10 or 3/8" wall plugs and insert the plugs in.
IX. Fix the bracket onto the wall
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Project Area Originator Discipline Serial n° Rev. Page
Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

X. Tighten the nut for the wall plug according to the manufacturer's
recommendation.

B. Installing the cylinder(s)

I. Move the first cylinder into place. The valve outlet can be oriented to
the left or right depending on the location of the pressure gauge.
NOTE: When connecting the discharge hose to the manifold, ensure
that the discharge hoses can be connected to the manifold with a
smooth bend.
II. Move the remaining cylinders into place.
III. Continue to install the cylinders and the cylinder brackets until the
entire battery is complete.
IV. Unscrew the valve outlet protection cap from the cylinder valve. Store
then in a secure place as they must be used whenever the cylinders
are moved.
V. Use the valve outlet adaptor to connect a single cylinder to the pipe
network. Where multiple cylinders are used fit one end of the discharge
hose to the valve outlet and the other to the check valve at the
manifold.
VI. Should the pressure gauge orientation be not in the correct position,
to correct it, turn the gauge in using a spanner until it stops. Then turn
back a MAXIMUM OF ONE REVOLUTION for correct orientation of
the gauge.
VII. Check for leaks using a liquid leak tester or a soap solution. Check that
the pressure of the cylinder is at 25 Bar. Notify engineer if any cylinder
shows a low reading.
VIII. For the pressure gauge with integrated limit switch, connect the
pressure gauge with integrated limit switch in a single wire loop (in
series).
IX. The following instruction is for installation of multiple cylinders with a
master and slave cylinders configuration. Remove the plastic
protection caps from the slave cylinders valve head. Make sure that no
contamination or foreign objects have entered the bore hole of the
valve.
X. Screw the pneumatic actuator onto the valve by hand. DO NOT
TIGHTEN THE ACTUATOR YET. Proceed to install the pneumatic
actuating hoses next. This is to ensure that the pneumatic hoses can
be installed easily.
XI. On the master cylinder, the pilot connection plug must be removed,
and a nipple shall be installed in its place. To connect the pneumatic
actuating hoses, the nipples must be screwed onto the pneumatic
actuators first. Use 4-6 rounds of Teflon tape on the thread connection
to the pneumatic actuator. Tighten the connection using a spanner
until it stops.
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Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

XII. Connect the pneumatic hose onto the actuator. At the last cylinder, a
vent plug must be installed to complete the pneumatic line.
Note: The safety relief valve is located directly below the pilot
connection plug. NEVER remove this safety relief valve otherwise gas
will escape from this outlet.
XIII. When all the actuating hoses have been installed, tighten the
pneumatic actuators to the valve by hand until it stops.
Note: to ensure that the valve is functioning properly, all actuating
components must be tightened by hand until it stops. (use a torque of
50 +/-15 Nm.)

C. Installing the Electric Solenoid Actuator

I. The electric solenoid actuator is installed on the master cylinder valve.
For single cylinder system, the electric solenoid actuator is fitted
directly on the cylinder valve.
II. Check that the electric solenoid actuator is in the armed position. If the
actuator is in the released position, a red mark can be seen clearly on
the actuator pin. Reset the actuator using the supplied reset tool.
III. To reset the actuator, screw in the reset tool onto the actuator until it
stops and a small 'click' is heard. Remove the reset tool and check that
the actuator is in the armed position.
IV. Terminate the electrical connection to the electric solenoid actuator.
NOTE: OBSERVE THE POLARITY OF THE SOLENOID ACTUATOR.
THE ACUATOR WILL NOT WORK IF IT IS WRONGLY
CONNECTED.
V. Test the operation of the solenoid actuator as follows: -
a. Energize the actuator and check that the pin fully extends without
delay.
b. Reset the electric actuator using the reset tool.
VI. Fit the electric actuator onto the pilot or master cylinder valve by hand.
Make it hand tight or use a torque of 50 +0/-15 Nm.
VII. A plastic protective cap is fitted on the top of the electric solenoid
actuator. Do not remove this cap unless a manual actuator is required.

D. Installation of the low-pressure pipe distribution network

I. Piping should be installed in accordance with good commercial
practice. Pipe threads should be cleaned of oil and swarf. Threaded
joints should be sealed using PTFE on the male threads. Care should
be taken to avoid possible restrictions due to foreign matter, faulty
fabrication or improper installation. The piping system should be
securely supported with due allowance for agent thrust forces and
thermal expansion/contraction, and should not be subjected to
mechanical, chemical, vibration, corrosion or other damages. Where
explosions are likely, the piping system should be attached to supports
that are least likely to be displaced. Galvanized steel pipes are
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Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

recommended as they are less likely to corrode within a short period

of time. If rust flakes or particles are present within the pipe, they may
come loose during a discharge and may be able to block off the orifices
in the nozzles thus jeopardizing the release. Also, the rust cloud / spray
may ruin the ceiling tiles or may damage sensitive equipment within
the enclosure. Special coatings or corrosion resistant materials must
be used in corrosive environments.
II. After installation of the pipe work it is recommended to flush the pipe
work in order to remove dirt / particles, sealing material, cutting burrs,
etc. as well as to verify that flow is continuous and that the piping is
unobstructed. Flushing should be performed prior to the pressure
testing of the pipe work and after any rectification work on the pipe
network using dry air or other compressed gas. Make sure that no one
is in any of the rooms in which the pipe work is to be flushed. Where
necessary, filter bags should be used to collect any dirt or particles
being blown out of the pipe work especially if there are equipment in
the room.
III. The pipe work should be leak tested prior to installing the discharge
nozzles. Leak testing of the distribution pipe work should be carried
out as follows: -
a. Verify that all manifold check valves are fitted onto the manifold (if
used). Plug off the nozzle points using suitable plugs.
b. Connect the nitrogen test supply cylinder assembly to the manifold.
c. Make sure that no one is in any of the rooms in which the pipe work is
to be tested.
d. Slowly pressurize the distribution pipe network to 3 bar.
e. Check the pipe network for leaks. If there are no leaks, proceed to
pressure test the pipe work to 3 bar for about 10 minutes. Any pressure
drop should not exceed 20% of the test pressure.
f. Release the pressure slowly after testing.
g. If rectification work was carried out, flush the pipe work first prior to
pressure test the pipe work again.

E. Installation of the Discharge nozzle

I. Install the appropriate nozzles with the correct orifice sizes in their
designated locations as per the piping isometric drawing & plan.
II. Screw the discharge nozzles into their fittings,

F. Miscellaneous
I. Install the SR200-HFC227ea entrance warning signs on all entry doors
into the protected area.
II. Install the SR200-HFC227ea manual release warning signs adjacent
to the master cylinder equipped with the manual release.
III. Check the integrity of the protected area for excessive openings which
could result in unacceptable leakage of the clean agent but with
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Type

STM MUAR 0011 M&E MST 0001 0001 A 1/10

CADANGAN MENDIRIKAN SATU (1) UNIT BANGUNAN STESEN

ELEKTRIK 132/11kV SUBSTATION YANG BARU DI TANJONG AGAS,
INDUSTRIAL AREA, 84007 LEDANG, JOHOR, MALAYSIA (FIRE
PROTECTION SYSTEM)

sufficient venting to prevent overpressure following the SR200-

HFC227ea agent discharge.
NOTE: A fan integrity test may be used to ascertain the integrity of the
enclosure.
IV. Check the interconnections between the electric solenoid actuator and
the control panel, as well as the pressure switches and the audio visual
alarms plus equipment and ventilation systems shutdown.

9.0 HSSE PROCEDURES

Each SR200-HFC227ea cylinder is filled with the required weight of gas (indicated on the
cylinder label) and pressurized with nitrogen to 25 bars at a reference temperature of 21oC.
Safety precautions adhered to in the handling of the SR200-HFC227ea cylinder(s) due to the
inherent risks of pressurized tanks as well as the weight of the cylinder(s) itself. Some safety
precautions to follow are: -

I. The valve outlet cap shall always be screwed onto the cylinder whenever the cylinder is
moved, being loaded or unloaded.
II. Always use suitable lifting gear, (forklift, truck or hoist) when loading or unloading cylinder.
III. Do not offload the cylinder by dropping them to the ground.
IV. Use a suitable cylinder trolley to move the cylinders. Do not roll them on the ground.
V. At site, if the cylinder(s) are not to be installed immediately, secure them using ropes or
belts in an upright position. The storage area must be dry and, in a place, where they will
not be damaged.
VI. Do not remove the valve outlet cap from the cylinder unless the cylinders are securely held
in position by its clamps or brackets.
VII. Never attempt to remove an SR200 valve from a pressurized cylinder.
VIII. Do not use extreme force (hammers, long levers, pipe wrench, etc.) on any part of the
valve or actuating components.
IX. Cylinders, valves, and actuating components SHALL NOT BE drilled, brazed, welded,
machined or stamped. Only cleaning and painting of the cylinders is permitted.
X. In the event of any abnormalities such as jammed or deformed valves, cracks or other
apparent weaknesses, keep away and inform the appropriate engineer.
XI. Heavy protective gloves (preferably textile or leather) should be worn at all times for the
manual handling of cylinders to minimize the risk of hand injury. During discharge, all
connected parts of the cylinder and valve are likely to become very cold and there is a risk
of "frostbite" if any of the parts are handled at that time with unprotected hands, particularly
if hands are wet.
XII. Safety footwear shall always be worn at all times.