Pipe

1.
Scope
This method statement outlines the detailed procedures for the installation and testing of Chilled Water
(CHW) and Low Temperature Hot Water (LTHW) pipes and accessories made of black steel. The scope of
this document includes material handling, storage, installation, and pressure testing of the piping
systems. All activities will be carried out in compliance with the project specifications, contract
documents, and relevant industry standards.
2. Reference Documents
2.1 Project Specifications

2.2 Approved Shop Drawings
2.3 ASME B31.3 Process Piping
2.4 ASME B31.9 Building Services Piping
2.5 SMACNA (Sheet Metal and Air Conditioning Contractors' National Association) Standards
2.6 Manufacturer’s Instructions and Recommendations
2.7 Local and International Safety Regulations
3. Tools & Equipment Required
To ensure the proper execution of CHW and LTHW piping installation, the following tools and equipment
will be required:
3.1 Welding Machine

3.2 Cutting Equipment (oxygen, acetylene cylinders, cutting torch, etc.)
3.3 Threading Machine
3.4 Scaffolding
3.5 Lifting Arrangement (Cranes, Chain Blocks, etc.)
3.6 Tool Box with necessary hand tools
3.7 Measuring Tape
3.8 Spirit Level
3.9 Plumb Bob
3.10 Steel Hammer
3.11 Electric Drilling Machine
3.12 Hole Saw Cutter
3.13 Personal Protective Equipment (PPE)
4. Storage of Pipes & Accessories
Proper storage of pipes and accessories is crucial to prevent damage and ensure quality installation. The
following procedures will be adhered to:
4.1 Pipes should be unloaded carefully to avoid any dropping or impact damage.
4.2 Pipes shall be stacked on a flat, clean surface with adequate support to prevent bending or warping.
4.3 All pipe ends must be capped to prevent ingress of debris, dirt, or moisture.
4.4 Damaged or unsuitable materials will be clearly marked and stored separately to prevent their use.
4.5 Store pipes and accessories in a designated area, sheltered from adverse weather conditions.
5. Pre-Installation Requirements
Before commencing the installation of CHW and LTHW piping systems, the following pre-installation
activities will be carried out:
5.1 Verify that all drawings used for installation are the latest approved versions.
5.2 Conduct a site survey to mark the pipe routing and support locations as per the approved drawings.
5.3 Coordinate the piping layout with other services to ensure no clashes and minimal bends/offsets.
5.4 Ensure that there is sufficient clearance around pipes for insulation and cladding applications.
5.6 Clean and apply primer or red oxide to all seamless black steel pipes before installation to prevent
corrosion.
6. Installation Procedure
6.1 Drilling & Support Fixing

6.1.1 Drill holes in ceilings/walls for fixing supports.
6.1.2 Fix anchors and threaded rods with clevis hangers or structural supports as applicable.
6.1.3 Ensure the threaded rod length allows for future adjustments and leveling of the piping.
6.2 Pipe Cutting & Preparation

6.2.1 Accurately cut pipes to site-determined measurements.
6.2.2 Prepare pipe ends according to the type of joints required (threaded, welded, etc.).
6.2.3 Perform threading as per fittings/coupling manufacturer’s recommendations.
6.2.4 Follow the approved welding procedure for end preparations of welded joints.
6.3 Pipe Installation
6.3.1 Clean pipe ends thoroughly to ensure no debris or dust is left inside.
6.3.2 Engage qualified and certified welders for welding tasks.
6.3.3 Install pipe sections at designated heights as per approved drawings, ensuring neatness and
alignment.
6.3.4 Insert rubber inserts between pipes and supports to prevent vibrations and noise.
6.3.5 Provide suitable sleeves at all wall and floor crossings.
6.4 Valve & Accessory Installation
6.4.1 Install valves at locations specified in the approved drawings.
6.4.2 Connect piping to valves and accessories at equipment locations as per approved drawings and
specifications.
6.4.3 Temporarily install blind plugs or valves on all drain, air vent, pressure gauge, thermometer, and
test point connections.
6.5 Support & Insulation
6.5.1 Ensure all pipe supports are installed as per the approved drawings.
6.5.2 During pipe installation, fit insulation to the pipework, leaving joints and fittings exposed until
pressure testing and inspection are completed and approved.
6.6 Inspection & Testing Preparation

6.6.1 Submit an inspection request for the chilled water piping installation to the consultant.
6.6.2 Ensure all necessary inspections are completed and approved before proceeding to hydraulic
pressure testing.
7. Pressure Testing Procedure
Pressure testing of the CHW and LTHW piping systems is a critical activity to ensure system integrity and
leak-free operation. The following steps outline the pressure testing procedure:
7.1 Preparation
7.1.1 Determine the testing pressure (1.5 times the working pressure) and PN ratings of the pipes,
fittings, and valves.
7.1.2 Decide whether to test the piping system in sections or as a whole, based on site conditions and
consultant advice.
7.1.3 Estimate the volume of the piping system and arrange the required quantity of clean water.
7.1.4 Set up temporary piping or hose connections for filling and draining water.
7.2 Testing
7.2.1 Fix temporary valves at air vent and drain points, and install pressure gauges.
7.2.2 Fill the piping system with clean water using a temporary pump, ensuring no air pockets remain.
7.2.3 Observe for any leakage during the initial filling. Arrest minor leaks immediately; for major leaks,
isolate the affected section.
7.2.4 After rectifying leaks, refill the system and ensure no further leaks are observed.
7.2.5 Gradually pressurize the system using a hydraulic test pump to the specified test pressure.
7.2.6 Monitor the entire piping system, including all joints and connections, for any signs of leakage.
7.2.7 Maintain the test pressure for a minimum of 4 hours and ensure there is no drop in pressure.
7.2.8 Document the test results and obtain approval from the consultant.
8. Responsibilities
8.1 Project Manager

8.1.1 Ensure overall project adherence to the method statement.
8.1.2 Oversee coordination among different teams and subcontractors.
8.1.3 Ensure all necessary resources (materials, manpower, equipment) are available.
8.2 QA/QC Inspector

8.2.1 Verify compliance with specifications and standards.
8.2.2 Conduct regular inspections and maintain detailed records.
8.2.3 Ensure all non-conformities are addressed promptly.
8.3 Supervisor
8.3.1 Supervise the installation activities on-site.
8.3.2 Ensure all activities comply with the method statement and safety regulations.
8.3.3 Coordinate with other trades to avoid clashes and ensure smooth progress.
9. Safety Precautions
Safety is paramount in all construction activities. The following safety precautions will be strictly
enforced:
9.1 All personnel must wear appropriate Personal Protective Equipment (PPE) at all times.
9.2 Conduct daily safety briefings and toolbox talks.
9.3 Ensure all equipment is in good working condition and regularly inspected.
9.4 Maintain a clean and organized work area to prevent accidents.
9.5 Implement proper lifting techniques and use lifting equipment for heavy materials.
9.6 Ensure all workers are aware of emergency procedures and first aid facilities.
10. Documentation
Proper documentation is essential for quality assurance and project tracking. The following
documentation will be maintained:
10.1 Inspection and test reports

10.2 Material delivery and storage records
10.3 Daily progress reports
10.4 Non-conformance reports and corrective actions
10.5 As-built drawings and any deviations from the approved design

Pipe

Uploaded by

Copyright:

Available Formats

Pipe

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Pipe

Uploaded by

Copyright:

Available Formats

1.

2.1 Project Specifications

3. Tools & Equipment Required

3.1 Welding Machine

6.1 Drilling & Support Fixing

6.2 Pipe Cutting & Preparation

6.6 Inspection & Testing Preparation

7. Pressure Testing Procedure

8.1 Project Manager

8.2 QA/QC Inspector

8.2.3 Ensure all non-conformities are addressed promptly.

10.1 Inspection and test reports

You might also like