PARCEL – 14B - PEARL

Method statement for Installation

,Insulation& Testing of Chilled Water
Pipes

MechaTronics MEP Contracting

MechaTronics ‫ميكاترونيكس‬
Electromechanical Contractor ‫لمقاولتا الكهرباء‬
W.L.L ‫م‬.‫م‬.‫والميكانيكاذ‬
Qatar, Doha P.O. Box 37269 C.R. No. 41292 41292 .‫تا‬.‫ س‬37269 .‫ب‬.‫ ص‬،‫ الدوحة‬،‫قطر‬
Tel.+(974) 44649172 Fax. +(974) 44649206 44649206 :‫ ف‬+974 44649172 : ‫تا‬
+974

:Contents
SI No: Description
Page ref:

1.0 PURPOSE 3

2.0 SCOPE OF WORKS 3

3.0 REFERENCES 3

4.0 RESPONSIBILITY / SUPERVISION 3

5.0 TOOLS AND EQUIPMENTS 4

6.0 MATERIALS 4

7.0 WORK PROCEDURE 6

8.0 TESTING AND COMMISSIONING PROCEDURE 6

9.0 QUALITY CONTROL 8

10.0 HEALTH, SAFETY AND ENVIRONMENT

Attachments
APPENDIX 1 JSA & RISK ASSESSMENT SHEET
11.0 APPENDIX 2 MATERIALS INSPECTION REQUEST 10+
APPENDIX 3 SITE INSPECTION REQUEST

+974 44649206 : ‫ فاكس‬- +974 46491724 :‫ تليفون‬. ‫ – الدوحة – قطر‬37269 ‫ ب‬.‫ ص‬- 41292 : ‫ سجل تجارى‬a g e |
C.R. No.: 41292 – P.O. Box: 37269 DOHA–QATAR Tel:+974 44649172 – Fax:+974 44649206
MechaTronics ‫ميكاترونيكس‬
Electromechanical Contractor ‫لمقاولتا الكهرباء‬
W.L.L ‫م‬.‫م‬.‫والميكانيكاذ‬
Qatar, Doha P.O. Box 37269 C.R. No. 41292 41292 .‫تا‬.‫ س‬37269 .‫ب‬.‫ ص‬،‫ الدوحة‬،‫قطر‬
Tel.+(974) 44649172 Fax. +(974) 44649206 44649206 :‫ ف‬+974 44649172 : ‫تا‬
+974

1. Scope & Purpose:

0.1 The objective of this method statement is to establish the necessary guidelines for the
installation, testing & commissioning of Chilled Water Pipes in accordance with the contract
requirements.
0.2 This method statement aims that quality assurance and control activities are conducted
in a systematic and safe manner, works are inspected and conformance is verified and
documented.

2. SCOPE OF WORKS
This method statement is applicable for the Installation, testing & commissioning of PEARL QATAR-
PORTO ARABIA-PARCEL 14B project.

3. REFERENCES

1. ASHRAE Standards
2. Qatar Construction Specification 2010 and QCDD
3. Approved System Design Calculations
4. Approved Fire Fighting System Plan Layout and Shop Drawing
5. Approved Material Submittal For Fire Fighting System

4. RESPONSIBILITY I SUPERVISION

1. Project Manager
In overall, the Project manager will be responsible in project execution and ensuring quality and
safety in all the activities. Also, maintaining the planning progress and coordination of works with the
main contractor.

2. Construction Manager
Construction manager is responsible for the day to day activities at site. For materials, drawing,
testing and commissioning and allocation of departmental resources to work areas at site. Be visible in
the health and safety process, constantly monitoring the project environment and performance. Provide
the force and resource necessary for project compliance with agreed safety procedures and standard.

3. QA/QC Engineer / Inspector

He is the responsible for the overseeing the quality requirements and quality control measures for
the project in coordination with the project engineers. He shall conduct inspection as per method
statement and ensure all the procedures in the method statement are implemented and followed. He will
ensure that all necessary record such as request for inspection and test report and material approval
must be in place prior to commence with the works.

4. Project Engineer
He is responsible for ensuring the project is fit for the purpose and adheres to the project budget
and schedule. Ensuring all relevant safety objectives and legal requirements are observed and
accounting for engineering tasks to ensure they meet the contract requirements. He will develop project

+974 44649206 : ‫ فاكس‬- +974 46491724 :‫ تليفون‬. ‫ – الدوحة – قطر‬37269 ‫ ب‬.‫ ص‬- 41292 : ‫ سجل تجارى‬a g e |
C.R. No.: 41292 – P.O. Box: 37269 DOHA–QATAR Tel:+974 44649172 – Fax:+974 44649206
MechaTronics ‫ميكاترونيكس‬
Electromechanical Contractor ‫لمقاولتا الكهرباء‬
W.L.L ‫م‬.‫م‬.‫والميكانيكاذ‬
Qatar, Doha P.O. Box 37269 C.R. No. 41292 41292 .‫تا‬.‫ س‬37269 .‫ب‬.‫ ص‬،‫ الدوحة‬،‫قطر‬
Tel.+(974) 44649172 Fax. +(974) 44649206 44649206 :‫ ف‬+974 44649172 : ‫تا‬
+974

specific procedures for the work to be carried out. Interpreting client’s requirements, identifying and
addressing design parameters and engineering problems and ensuring solutions are implemented.
Ensuring all justifications for contractual variations during project is maintained to support subsequent
commercial claim. Evaluating, organizing and prioritizing work within the overall project schedule. He
will be direct reporting to project manager.

5. HSE Officer
Responsible for the overall Health and Safety aspects on site as per managing contractor
requirements.

6. Foreman
Responsible to assist the project engineer in implementing the installation as per approved
drawing and monitor all the project execution and installation works. Attend inspection, testing and
commissioning work together with QA/QC Engineer / Inspector.

5. TOOLS AND EQUIPMENTS

5.1 Standard Mechanical / Electrical Tools:

a) Socket Wrenches Set

b) Torque Wrench
c) Electric Drill and Impact Drill
d) Measuring Tape
e) Marker Pen
f) Chain block / Rope Pulley
g) Lever Bar
h) Adjustable Wrenches
i) Hammer
j) Combination Wrenches
k) Threading and Grooving Machine
l) Calibrated Pressure Gauges
m) Portable Grinder
n) Screw Drivers

5.2 Standard Safety PPE for all the Labors

a) Helmet / Hard Hat

b) Safety Shoes
c) Gloves
d) Safety Harness
e) Other PPE’s depending on the scope of work

5.3 Ladder / Scaffolding

6. MATERIALS

All materials and equipment of Chilled Water Pipes shall be in accordance of approved material
submittal.
f) Pipes
+974 44649206 : ‫ فاكس‬- +974 46491724 :‫ تليفون‬. ‫ – الدوحة – قطر‬37269 ‫ ب‬.‫ ص‬- 41292 : ‫ سجل تجارى‬a g e |
C.R. No.: 41292 – P.O. Box: 37269 DOHA–QATAR Tel:+974 44649172 – Fax:+974 44649206
MechaTronics ‫ميكاترونيكس‬
Electromechanical Contractor ‫لمقاولتا الكهرباء‬
W.L.L ‫م‬.‫م‬.‫والميكانيكاذ‬
Qatar, Doha P.O. Box 37269 C.R. No. 41292 41292 .‫تا‬.‫ س‬37269 .‫ب‬.‫ ص‬،‫ الدوحة‬،‫قطر‬
Tel.+(974) 44649172 Fax. +(974) 44649206 44649206 :‫ ف‬+974 44649172 : ‫تا‬
+974

g) Fittings
h) Valves
i) Insulation

7. WORK PROCEDURE

7.1 Pre Installation Requirements

a) Permission to start installation has been given by the main contractor.

b) All preceding trades have completed their works.
c) Chilled Water Pipes Installation Detail Shop Drawing has been approved and issued for
construction.
d) All materials required for installation are available, and are inspected and approved by the
Engineer.
e) Scaffolding necessary for installations are correctly built, safe & suitable for the purpose.
f) Temporary lighting & power source is available in location and protection settings are correct.
g) Details of installations & manufacturer’s recommendations if any are available on site.
h) Inspect all materials and verify that they are undamaged.
j) Ensure that the pipe sleeves are installed or that a pipe sleeve intact or inserted in the
Chilled Water pipe where a wall expected to be erected is crossed.
i) All shop drawing and material submittal are approved.

7.2 Painting of Pipes

a) Clean the pipe with cotton rag to remove any dust or grease on the pipes.
b) Apply Red Oxide Primer paint. Please ensure both sides (top & bottom) are painted evenly.
c) Put the painted pipes in a good ventilation condition for 24 hours to dry the paint.
d) Allow the surface to dry within 24 hrs. Before install the pipes.

7.3 Fabrication of pipe

7.3.1 Threading (50mm & below shall be threaded type)

a) Check to ensure the cutter, Reamer and Die head are swung to UP position.
b) Make the pipe at desired length; if it is being cut to length
c) Place the pipe in between the machine and cut it by using cutter. Use reamer to clear the edge.
d) Place the die head on the position.
e) Turn carriage hand wheel to bring dies against end of pipe. Continue applying pressure to hand
wheel to start dies.
f) When desired length of thread has been reached, de-press release handle to discharge latch. Die
head will open automatically.
g) Release foot switch and then turn carriage hand wheel clockwise to back die head off.
h) Swing dies head to UP position.
i) After threading provide jute for the assembling of elbow and pipe.

7.3.2 Welded (65mm & above shall be Welded type)

a) Preparation of Materials and Execution of Works
• General

+974 44649206 : ‫ فاكس‬- +974 46491724 :‫ تليفون‬. ‫ – الدوحة – قطر‬37269 ‫ ب‬.‫ ص‬- 41292 : ‫ سجل تجارى‬a g e |
C.R. No.: 41292 – P.O. Box: 37269 DOHA–QATAR Tel:+974 44649172 – Fax:+974 44649206
MechaTronics ‫ميكاترونيكس‬
Electromechanical Contractor ‫لمقاولتا الكهرباء‬
W.L.L ‫م‬.‫م‬.‫والميكانيكاذ‬
Qatar, Doha P.O. Box 37269 C.R. No. 41292 41292 .‫تا‬.‫ س‬37269 .‫ب‬.‫ ص‬،‫ الدوحة‬،‫قطر‬
Tel.+(974) 44649172 Fax. +(974) 44649206 44649206 :‫ ف‬+974 44649172 : ‫تا‬
+974

• Pipe Joint Preparation

• Pipe to Pipe Fit Up
• 45° Elbow to Pipe Fit Up
• 90° Elbow to Pipe Fit Up
• Tee to Pipe Fit Up
• Flange to Pipe Fit Up

b) Welding Procedure Qualification Test Requirements

• Welding Process
• Base Metals
• Filler Metals
• Position of Groove & Weld Progression
• Temperature Requirements
• Post weld Heat Treatment
• Type of Gas
• Electrical Characteristics
• Travel Speed & Passes
• Laboratory Test Results

c) 3.1 General
• Check all pipes and fittings to be used for joint are free from defects, dents or deformities and
are straight. Remove pipes and fittings with defects and replace with acceptable materials.
• Remove foreign matter or dirt from inside of the pipe and fittings before fit up.
• For longer work breaks, place suitable stoppers to prevent debris, earth or water from
entering pipe open ends.
• Welding electrodes shall be stored and handled as per Manufacturer’s instructions.

d) Pipe Joint Preparation

• Cut the pipes to the required length using an appropriate pipe cutter, or profile cutter (Oxy-
Acetylene), allowing for provision of pipe fitting later. Works shall be carried out in accordance
with the approved shop drawings.
• The pipes shall be checked by the assigned foreman for its square ness and straightness,
after being cut to the correct angle and site requirements, as per sample of welding details in
Appendix A (pages from 9:15)

7.3.3 Pipes Hunger Installation:

a) Identify the actual location of the hanger based on the approved shop drawing. Mark the
position for installing the drop in anchor.
b) Install drop in anchor
c) Install the pipe either by screw fitting or welding.
d) Install Hanger Rod based on the pipe size. Install the hanger rod to the drop in anchor.
e) Install the Hanger to the pipe and the hanger rod.
f) Tightening the bolts and nut that hold the hanger rod and hanger evenly.

7.3.4 Valve Screw Connection installation

g) Confirm the valve size and location based on the shop drawings. Ensure that the selected
valve is screw type.
h) Fabricate Pipe to the required length and thread it accordingly.
i) Place the valve between the pipes and make sure the threads are free of dust.
j) Guide one of the pipe ends into the valve’s thread, slowly run pipe in clock-wise direction.
k) Hold the valve firmly by a spanner on the flat nearest joint and then rotate the pipe with a
plumbing wrench. Rotate the pipe until the end of the spindle operating joint. Repeat the above
steps for the other pipe.

7.3.5 Valve with Flanged End Connection Installation

a) Confirm the valve size and location based on the shop drawings. Ensure that the selected valve is
flanged type.
b) Place the valve between the pipe flanges. Make sure the flange and adjacent pipe work are clean
of dirt.
c) Select the gasket size according to the valve size and associated pipe size based on approved

+974 44649206 : ‫ فاكس‬- +974 46491724 :‫ تليفون‬. ‫ – الدوحة – قطر‬37269 ‫ ب‬.‫ ص‬- 41292 : ‫ سجل تجارى‬a g e |
C.R. No.: 41292 – P.O. Box: 37269 DOHA–QATAR Tel:+974 44649172 – Fax:+974 44649206
MechaTronics ‫ميكاترونيكس‬
Electromechanical Contractor ‫لمقاولتا الكهرباء‬
W.L.L ‫م‬.‫م‬.‫والميكانيكاذ‬
Qatar, Doha P.O. Box 37269 C.R. No. 41292 41292 .‫تا‬.‫ س‬37269 .‫ب‬.‫ ص‬،‫ الدوحة‬،‫قطر‬
Tel.+(974) 44649172 Fax. +(974) 44649206 44649206 :‫ ف‬+974 44649172 : ‫تا‬
+974

shop drawings so that it can match the pipe work flange.

d) Connecting the valve with the pipe flange. The pipe flange shall be square with the associated
pipeline.
e) When the valve is in proper position, install the bolts into the holes. Tightening the nuts one by
one evenly. Repeat the above steps for the other joint.

7.4 Erection of Pipes

a) Complete painting of pipes as per the painting procedure.
b) Start the sample installation and get it approved.
c) Start marking the routing of the piping as per the approved and coordinated drawings.
d) Start fabrication of the pipes (Welded for sizes 21/2’’ and above & Threading for 2” and below)
e) Start drilling and fixing the supports as per the prescribed marking.
f) Start hanging the pipes with proper hangers & supports.
g) Join all the fabricated pipes and prepare it for pressure testing.
h) Pressurize the piping as per testing procedure.
i) After completing the pressure testing, start fixing the equipment (Sprinklers, Cabinets etc.) and
do the final touch-up of painting.

8. TESTING & COMMISSIONING PROCEDURE

8.1 Test Instruments

The followings test instruments shall be used to perform the required tests:

1. Pressure Gauges
2. Manifolds
3. Pressure Pump (for pressure test)

8.2 Pipe Installation Hydrostatic Test

Safety will be a major factor during pressure testing to ensure a safe working environment for all the site
personnel and to safeguard plant and equipment. Prior to commencement of test, toolbox talk will be
given to all personnel identifying the potential dangers of pressure testing and to make everyone aware
that testing is ongoing in the area.
A. Testing Procedure:
a) Test limits will be indicated on drawings. Test may comprise a complete system or a section of
piping within a system. Test limits shall be at flanged or similar mechanical joints.
b) All in - line instruments (pressure gauges, etc.) shall be removed during testing. Temporary
spreads/blinds will be installed where necessary at the test limits points.
c) All test equipment (Pump compressors, manifolds, gauges etc.) will be inspected prior to use to
make sure they comply with the site safety requirements. All gauges shall have a valid calibration
certificate available for inspection. Generally, one pressure gauge will be provided per test, located at
the manifold.
d) Before testing commences, the client will be advised twenty four hours in advance, by request
for inspection (RFI) of the intention to proceed with such testing and the intended location of any
such test. Testing will be coordinated through the main contractor so as not to affect construction
schedules of other contractors at site.

+974 44649206 : ‫ فاكس‬- +974 46491724 :‫ تليفون‬. ‫ – الدوحة – قطر‬37269 ‫ ب‬.‫ ص‬- 41292 : ‫ سجل تجارى‬a g e |
C.R. No.: 41292 – P.O. Box: 37269 DOHA–QATAR Tel:+974 44649172 – Fax:+974 44649206
MechaTronics ‫ميكاترونيكس‬
Electromechanical Contractor ‫لمقاولتا الكهرباء‬
W.L.L ‫م‬.‫م‬.‫والميكانيكاذ‬
Qatar, Doha P.O. Box 37269 C.R. No. 41292 41292 .‫تا‬.‫ س‬37269 .‫ب‬.‫ ص‬،‫ الدوحة‬،‫قطر‬
Tel.+(974) 44649172 Fax. +(974) 44649206 44649206 :‫ ف‬+974 44649172 : ‫تا‬
+974

e) Prior to introducing pressure into the system, all piping installations shall be checked
thoroughly for tightness.
f) Testing shall be in accordance with the project specifications and guidelines in NFPA 13
g) Chilled water and condenser water piping shall be hydrostatically tested to a pressure of 150 psi
or 1-1/2 times design pressure, whichever is higher.
h) Test shall be performed for a minimum period of 24 hours with no fluctuation in pressure.
i) Pressure testing shall be performed prior to installation of thermal insulation and with all joints
fully exposed to inspection.
j) Underground and other piping that will be covered by subsequent construction shall not be
covered prior to the approval by MDAD of successful testing.
k) Equipment shall be omitted from tests and bypass arrangements shall be tested. Temporary
spades/blinds will be installed where necessary at the test limit points.
l) Prior to testing, a demarcation area will be taped off and warning signs placed prominently,
stating that hydrostatic testing is in progress.
j) These demarcation areas will be on entry areas for all personnel with the exception of testing
inspectors and test personnel. The demarcation area limits may vary greatly in relation to
hydrostatic testing that is in progress.
k) Pressurizing of the system will proceed on an incremental basis in the interest of safety.
I) Test pressure results will be assessed on a test-by test basis to be agreed on the site and shall be
carried out without environmental contamination.
m) When all aspects of testing are completed, the demarcation area will be removed and all barriers and
signs stored in a safe / tidy manner.

9. QUALITY CONTROL

• In process, works shall be monitored for quality of workmanship and it should be in accordance to
approved shop drawings, specifications, code and standard.
® All inspection requested must be properly documented for future references and to be witness and
approved by main contractor qa/qc engineer.

10. HEALTH, SAFETY AND ENVIRONMENT

Implementation of Health, Safety and Environment mechanisms must be check thoroughly as per
contract agreement and the approved Health and Safety Manual.
• Responsible Health, Safety and Environment Officer of the project will conduct routine HSE
inspections.
• Safe access and egress to and from the work place shall be provided by the main contractor.
• Risk assessments for the installation of Fire Fighting System have been attached to this
method statement and related to the risks and associated hazards related to the activity.

11. ATTACHMENTS
 APPENCIX 1 RISK ASSESSMENT SHEET
 APPENCIX 2 MATERIAL DELIVERD INSPECTION REQUEST
 APPENCIX 3 SITE INSPECTION REQUEST

+974 44649206 : ‫ فاكس‬- +974 46491724 :‫ تليفون‬. ‫ – الدوحة – قطر‬37269 ‫ ب‬.‫ ص‬- 41292 : ‫ سجل تجارى‬a g e |
C.R. No.: 41292 – P.O. Box: 37269 DOHA–QATAR Tel:+974 44649172 – Fax:+974 44649206
MechaTronics ‫ميكاترونيكس‬
Electromechanical Contractor ‫لمقاولتا الكهرباء‬
W.L.L ‫م‬.‫م‬.‫والميكانيكاذ‬
Qatar, Doha P.O. Box 37269 C.R. No. 41292 41292 .‫تا‬.‫ س‬37269 .‫ب‬.‫ ص‬،‫ الدوحة‬،‫قطر‬
Tel.+(974) 44649172 Fax. +(974) 44649206 44649206 :‫ ف‬+974 44649172 : ‫تا‬
+974

APPENDIX A

+974 44649206 : ‫ فاكس‬- +974 46491724 :‫ تليفون‬. ‫ – الدوحة – قطر‬37269 ‫ ب‬.‫ ص‬- 41292 : ‫ سجل تجارى‬a g e |
C.R. No.: 41292 – P.O. Box: 37269 DOHA–QATAR Tel:+974 44649172 – Fax:+974 44649206