1.1 This “Method Statement” covers the nature and type of work for the Installation of Fire Fighting Pipes and fitting with Accessories and frequency at which the inspections are to be carried out.
1.2 This method statement gives guidelines contained herein so as to ensure that the job execution complies with the requirement of the specification and the authorities concerned and serves the intended purpose to satisfactory level.
1.3 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.
2. REFERENCES & RELATED DOCUMENTS:
2.1 Project Quality Plan – PQP
2.2 Quality Control Plan – QCP
2.3 Specification Sec
2.4 Approved MAR
2.5 Approved Shop Drawings.
2.6 Manufacturer Product Data Sheets
2.7 Manufacturer Installation Recommendations
3 ABBREVIATIONS:
3.1 Ref. Quality Control Plan
4 RESPONSIBILITIES:
4.1 Ref. Quality Control Plan
5 EQUIPMENT & TOOLS:
5.1 Water Tank with Hose
5.2 Hand Drilling Machine
5.3 Grooving Machine
5.4 Thread Cutting Machine
5.5 Pipe Cutter
5.6 Measuring Tape
5.7 Sprit Level
5.8 Plumb Bob
5.9 Hammer
5.10 Levelling Instrument
5.11 Ladders.
6 SAFETY :
6.1 Ensure only trained persons shall operate the power tools.
6.2 Ensure all concerned personals shall use PPE and all other items as required.
6.3 Ensure adequate lighting is provided in the working area at night time.
6.4 Ensure service shaft opening are provided with barricade, tape, safety nets.
7 WORK SEQUENCE & METHODOLOGY :
7.1 Check all material delivered to site is inspected properly by QA/QC Engineer and check it is stored properly as per manufacturer recommendations.
7.2 ITR shall be raised, for the inspection of Pipes and fittings received, By COMPANY Engineer.
7.3 Work shall be carried out by the site staff under strict supervision and guidance of the concerned Supervisors / Foremen’s / Engineers.
7.4 The QA/QC Engineer shall check all the installations as per the Installation Check list.
7.5 ITR Shall be prepared by QA/QC Engineer and will be submitted to COMPANY for their inspection and approval.
7.6 QA/QC Engineer shall coordinate with Main Contractor and arrange inspection for installation, by COMPANY Engineer.
7.7 QA/QC Engineer is responsible for all installation activities for getting the work inspected / approved by COMPANY Engineer.
8. INSTALLATION OF FIRE FIGHTING PIPES AND ACCESSORIES :
8.1 Fix the sleeves as per approved shop drawings and specification, during the construction of structural elements.
8.2 Ensure all fire fighting pipes are painted with one coat of etch type primer suitable for galvanized pipes and two coats of post office red enamel paint.
8.3 Piping connection 2” and below shall be made by threaded joints and piping connections 1 ½” and above are made by Grooved Joints as per specification and approved MAR.
8.4 The piping grooves shall be done by using grooving machine and depth and width of a groove shall be maintained as per Groove fitting manufacturer recommendations.
8.5 Mark the location of piping as per specification and approved shop drawing.
8.6 Install approved supports, brackets for piping as per specification, approved shop drawings and site requirements for each individual case (ie. Slab, Wall etc.)
8.7 Supports shall be installed as per specification and manufacturer recommendations.
8.8 Vertical fire fighting piping shall be placed on galvanized L angle or U channels and fastened with GI threaded rods.
8.9 Roller supports shall be installed for the pipes 200 mm and above and in the expansion joints.
8.10 Flexible Pipe connectors shall be installed in all Expansion Joints and Equipment piping connections (Ref. attachment 10.1).
8.11 Pipes shall be laid with gradient as per approved shop drawings and site conditions.
8.12 All the open ends of the pipes shall be protected properly at the end of each day’s work.
8.13 Drains shall be installed at branch lines consisting of gate valve and short threaded nipple and cap so that the system can be drained completely.
8.14 Valves, Piping specialties and accessories shall be installed as per manufacturer recommendation and approved shop drawings
8.15 Automatic Air vents shall be installed at high points in order to trap air from the fire fighting system.
8.16 Ball drain valve shall be installed between Fire Department connection and check valve and it will be drained to the nearest floor drain as per approved shop drawing.
8.17 Fire alarm devices shall be installed in the piping systems as per specification and approved shop drawing as per civil deference requirements.
8.18 Sprinkler Zone control valves, test assemblies and drain risers shall be installed as per the specification / approved shop drawings and manufacturer recommendations to Civil Deference requirement.
8.19 Pressure gauges shall be installed as per approved shop drawing and civil deference requirement.
8.20 Plug all open ends of pipes at the end of each day’s work using end caps.
8.21 Raise Request for Inspection of Installation of Fire Fighting Piping and fittings including supports / brackets, valves, piping specialties and accessories as per the approved shop drawing, by Consultant
8.22 After approval of installation of pipes and fittings, flushing shall be done for Fire Fighting Pipes with clean water to remove dust and debris that might have been present during construction work.
8.23 Plug all connections / branches / drains and fill with clean water for hydro testing.
9 INSTALLATION OF FIRE FIGHTING PIPES –BELOW GRADE :
9.1 Ensure the compaction of trench and pipe bedding is completed and inspected and approved by Company and the level of pipes is as per approved shop drawing.
9.2 Ensure additional excavation is done at every joint to provide sufficient room for jointing and also pipe should not test on socket.
9.3 Pipes shall be laid with gradient as per approved shop drawing and site conditions.
9.4 Ensure that pipes are properly aligned, before starting joints.
9.5 The interior of socket, particularly the grooves in gasket located on retained bead should be cleaned properly before starting assembly.
9.6 Use lubricant supplied by pipe manufacturer.
9.7 Joints to be done with gaskets supplied by manufacturer, which shall be cleaned properly and bend from both sided and then place it on to the socket with bulb leading.
9.8 When inserting gasket flexing at two places will occur, push the flex of both sides at same time so that rubber gasket firmly bedded in its seat.
9.9 Ensure the gasket is not proud of the mouth of pipe, so that spigot can enter the socket easily.
9.10 Apply a thin film of lubricant to the inside surface of gasket and to the pipe spigot, particularly found the edge.
9.11 Enter the spigot into the socket until concentric contact with gasket is made. The axes of pipes previously laid and of the pipe of fitting to be assembled must be correct aligned
9.12 Joint assembly is completed by forcing the spigot end of the entering past the gasket which is thus compressed until the first painted strip in the end of pipe disappears and second is approximately flushed with the socket face.
9.13 If the joint is difficult to assemble, the spigot should be removed and rotated through 90º before attempting to assemble a second time.
9.14 If the joint is still difficult to assemble, the spigot should be removed and the position of gasket should be examined.
9.15 Ensure the pipe is free dirt and soil, which will trap inside the sleeve.
9.16 Sleeve should fit the pipe snugly, to reduce any water inside to a minimum and there shall not be any damages on sleeve.
9.17 After completing the assembly of the pipe line, pipes must be covered by soil bridges of at least 50 cm, joints must remain uncover for pressure test.
9.18 Thrust blocks to provide at every junction and at a very change in direction of pipes, to resist the thrust due to test pressure and unexpected surge during operation.
9.19 All the open ends of the pipes shall be protected properly at the end of each day works.
9.20 Valves piping specialties and accessories shall be installed as per manufacturers’ recommendations and approved drawing.
9.21 All valves shall be installed suitably to permit easy access for future maintenance, with in the valve pits.
9.22 After completion of installation pipes under the roads shall be concrete encased sd per specification and approved drawings.
9.23 Raise request for inspection of installation of Fire Fighting Piping and Fittings including valves, specialties and accessories as per approved shop drawings by COMPANY Engineer.
9.24 After approval of installation of pipes and fittings, flushing shall be done to remove dust and debris that might have been present during construction work.
9.25 Plug connections/branches and fill with clean water for hydro-testing.
10. TESTING OF FIRE FIGHTING PIPING, FITTINGS AND ACCESSORIES :
10.1 Care shall be taken to all the equipment's, apparatus, devices to a pressure exceeding its prescribed test pressure as obtained from its name plate data or product catalogs.
10.2 Care shall be taken to Equipment's, apparatus and devices that might be damaged by the test pressure shall be removed or blanked off.
10.3 Ensure All Valves are in open condition before starting pressure test; NO pressure shall be applied against closed valves.
10.4 Ensure Temporary blank flanges are anchored firmly in a way to accommodate all developed end trust.
10.5 The Piping system shall be tested closed by plugging all openings in the system in a proper way and filled slowly with water.
10.6 Ensure all system is free from air lock.
10.7 Ensure water is reached to the entire system by releasing plugs temporarily.
10.8 Pressure shall be applied to the system by means of hand pump drawing from a water container. The pump discharge shall be connected to the system through a globe valve, check valve and calibrated pressure gauge of suitable range to have the test pressure range in the middle of the range.
10.9 Subject the Fire Fighting piping system hydro-test at 200 psi for 2 hours.
10.10 Repair the leaks and defects if any until satisfactory results are obtained.
10.11 Test pressure shall be measured and recorded at highest point of the system.
10.12 Raise request for inspection of hydro-testing to witness the same, by COMPANY Engineer.
10.13 After approval of inspection of hydro testing, release the water gradually and protect the piping installation, and end cap the pipe.
10.14 Upon approval of installation of pipes and accessories standpipe shall be connected to the interior water distribution piping as per the approved shop drawing.
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