Method Statement Installation, Testing and Commissioning of Fire Fighting System
Method Statement Installation, Testing and Commissioning of Fire Fighting System
Method Statement Installation, Testing and Commissioning of Fire Fighting System
2018
PAINT
FACTORY Ref/Rev. No.: 1576/ 0
Method statement
For The
Project:
HEMPEL PAINT FACTORY
Initial Release
0 30.09.2018
( Issued for Approval )
REV DATE DESCRIPTION Prepared by Checked by Approved by
HEMPEL Date: 30.09.2018
PAINT
FACTORY Ref/Rev. No.: 1576/ 0
TABLE OF CONTENTS
SECTION DESCRIPTION PAGES.
1.0 OBJECTIVE 3
3.0 REFERENCES 3
12.0 ATTACHMENTS 14
HEMPEL Date: 30.09.2018
PAINT
FACTORY Ref/Rev. No.: 1576/ 0
1 OBJECTIVE
The objective of this method statement is to establish the necessary guidelines for
installation, testing & commissioning of fire fighting system in accordance with the contract
requirements.
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
firefighting system for Hempel Paint Factory.
3 REFERENCES
4 RESPONSIBILITY / SUPERVISION
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.
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.
HEMPEL Date: 30.09.2018
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FACTORY Ref/Rev. No.: 1576/ 0
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 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.
4.5 Foreman
6 MATERIAL HANDLING
a. QA/QC Inspector will be responsible on checking and receiving all the materials delivered
at site prior to storage area.
b. All Materials delivered to site must have all relevant supporting documents as per
approved standard.
c. All Material will be stored at Main Storage Area and/or Client assigned storage area. It will
deliver at site as when required. This case the materials will be free from any foreign
materials and it will not be exposed to bad weather condition. In case inspection required,
all materials are available at site and storage area.
d. Site Supervisor will be responsible on overlook of all materials while inside storage area
and keep always the area clean so that the materials will be free from any damages and
prevent any accident on storage area as well.
a. Before any work activities commence, Co-ordinate with the contractor for daily work
permit approval.
b. Inform immediately the contractor of work co-ordination to the other contractor for
proper execution of the activities.
c. Ensure that all activities are in compliance with the other Contractor H & S POLICY.
a. Work permits shall be obtained prior to any activities being carried-out and work shall
commence in accordance to the work permit submitted.
b. Safety Officer will check and advised the Site Engineer to ensure the activities
indicated on the work permit will be done with respect to safety of all personnel,
workers and property.
c. Permits must be obtained before commencing any activities as follows:
a. All communication on site will be by means of telephone expect inside production and
testing area (i.e. Phones are not allowed inside the Production area).
b. Every Engineer at site will carry mobile phone for immediate verbal communication
and site co-ordination
8 WORK PROCEDURE
8.1.1 .1 Clean the surface of the pipe with cotton rag to remove any dust or grease on the
pipes.
8.1.2 After cleaning, paint the pipes with Red Oxide Primer. Please ensure both sides (top
& bottom) are painted evenly.
8.1.3 Wait for 12 hrs before applying Synthetic Enamel Gloss
8.1.4 Apply first coat of Synthetic Enamel Gloss paint. Please ensure both sides (top &
bottom) are painted evenly.
8.1.5 Put the painted pipes in a good ventilation condition for 24 hours for the paint dry.
8.1.6 After the paint dried, apply the Coat of Synthetic Enamel Gloss for final coat. Please
ensure both sides (top & bottom) are painted evenly.
8.1.7 Allow the surface to dry within 24 hrs. Before install the pipes.
HEMPEL Date: 30.09.2018
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FACTORY Ref/Rev. No.: 1576/ 0
8.3.1 Remove fitting from storage and check to see if it is as per approved standards and the
correct fitting as per the task in hand.
8.3.2 Apply shellac tape to the male end of the thread.
8.3.3 Check and clean if required the female end of the thread and apply lubrication grease as to
ease the male entry.
8.3.4 Once hand tight apply one wrench to the pipe and one to the female fitting.
8.3.5 Hold the male end wrench secure and one hold while you turn female fitting wrench
clockwise with the other hand.
8.3.6 Tighten till there is approximately 2 threads showing this allows for a good seal and no future
leakage or cracking by over tightening.
HEMPEL Date: 30.09.2018
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8.4.1 Remove one nut and bolt from housings. Loosen the other nut until it is flush with the end of
the bolt. Remove the gasket from the housings.
8.4.2 Check suitability of gasket for intended service and apply a thin Coat of silicone or other
compatible pipe lubricant to gasket lips and outside of the gasket. Apply lubricant to inside of
housing.
8.4.3 Insert and push the gasket over one of the grooved ends of the two pipes to be joined.
8.4.4 Align and bring the pipe ends together and slide gasket into position central between the
grooves on each pipe.
8.4.5 Place housings over gasket and apply pressure by hands to engage the keys into the
grooves. Insert bolts and apply nuts finger tight.
8.4.6 Tighten nuts alternately and equally until housing bolts pads are firmly together, metal-to-
metal.
8.5.1 Cut or drill hole in pipe, hole diameter for each mechanical branch outlet is listed on the chart
pertaining to the product. Holes must be drilled on the centre-line of the pipe. Remove the cut
piece and cutting chips. Make sure that the pipe surface within 7/8" of the hole is clean,
smooth and free of indentations or projections which would affect proper sealing.
8.5.2 Remove one nut and bolt from assembled housings. Loosen the other nut until it is flush with
the end of bolt, Remove the tape and lift the gasket.
8.5.3 Apply a thin coat of silicone or other suitable pipe lubricant to all surfaces of the gasket.
Reposition the gasket into the housing using alignment tabs on the sides for proper
positioning.
8.5.4 Rotate the lower housing approximately 90 degrees away from the upper or outlet section.
Place the upper on to the surface of the pipe in line with the outlet hole prepared per
instructions and rotate the lower section around the pipe and close the two halves.
8.5.5 Insert bolt in its hole and finger tightens both nuts, making sure that the locating collar is in
the outlet hole. Also make sure that the positioning lugs are aligned properly.
8.5.6 Tighten nuts uniformly until the gasket pocket area of the upper housing is in
complete contact with pipe surface and the assembly is rigid. Nuts must be tightened
with even gaps between bolt pads.
HEMPEL Date: 30.09.2018
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8.6.1 Open the Flange Adapter and place hinged flange around the grooved pipe end with
the circular key section locating into the groove.
8.6.2 Insert a standard bolt through the mating holes of the Flange to secure the Flange in
the groove.
8.6.3 Check suitability of gasket for the intended service and apply a thin coat of silicone
or other compatible lubricant to gasket lips and outside of the gasket.
8.6.4 Press the gasket into cavity between the pipe outside diameter and Flange recess.
8.6.5 Insert a standard Flange bolt in the hinge hole opposite the lock-bolt and direct the
two bolt assembly to mate with the Flange of the device to be joined.
8.6.6 Add the remaining standard Flange bolts and tighten all nuts evenly until faces
contact firmly or bolts attain recommended joint torque values.
8.7.1 Identify the actual location of the hanger based on the approved shop drawing. Mark
the position for installing the drop in anchor.
8.7.2 Install drop in anchor in case of rigid ceiling and use Site Fabricated supports made
of L-angles in case the ceiling is not rigid
8.7.3 Install the pipe either by screw fitting or welding.
8.7.4 Install Hanger Rod based on the pipe size. Install the hanger rod to the drop in
anchor.
8.7.5 Install the Hanger to the pipe and the hanger rod.
8.7.6 Tightening the bolts and nut that hold the hanger rod and hanger evenly
8.8.1 Identify the actual location of the hanger based on the approved shop drawing. Mark
the position for installing the drop in anchor.
8.8.2 Check the hanger size to confirm the depth of the hole to be drilled based on
approved shop drawings and manufacturer’s specification. Adjust depth gauge so
anchor will be flush with the base material surface.
8.8.3 Check the hanger size to select the right drill bit. Then drill the hole according to the
manufacturer’s specification on the marked position.
8.8.4 Clean the drilled hole to ensure it is free of dust.
8.8.5 Insert the drop in anchor into the hole.
8.8.6 Hammering down the conical plug inside the anchor with setting punch.
8.8.7 Install the hanger rod into the drop in anchor.
8.12.1 Installation of fire water sectional tank shall be in accordance to approved material
submittal, approved drawing, manufacturer’s instruction and NFPA Standard.
8.12.2 Prior to installation ensure the plinth is constructed as per approved drawing and
epoxy coated.
8.12.3 Pre-Fabricated Galvanised Panels shall be assembled by an approved supplier using
bolts & Nut.
8.12.4 No Site welding is allowed over the prefabricated G.I panels.
8.12.5 Ensure the Fire Tank Outlets are placed at the designated location as in the approved
drawing.
8.12.6 After completion of Installation, water test for the tank should be carried out by
gradually filling the tank to the effective capacity (in accordance to manufacture
standards).
8.12.7 Any Leakages shall be rectified.
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The following calibrated test instruments shall be used to perform the required test
Test Manifold
Pressure Gauge
Pressure Test Pump (Hydrostatic Pump)
Digital Multi Meter
Flow Test Meter
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, thermometers, etc.) shall be removed during
testing. Temporary spreads/blinds will be installed where necessary at the test limits
points.
c. All test equipment’s (test pumps, 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, two gauges will be
provided per test, one at the high point possible and one at the lowest point possible.
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.
e. Prior to introducing water 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. The piping shall be hydrostatic tested in a closed circuit for a period of 2 hours at
200psi (13.8 bar). At the end of 2 hours, the pressure shall not drop to +5 psi.
h. 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.(bladder tanks shall not be included in pressure test)
i. 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.
l. Test pressure results will be recorded on a pressure test certificate.
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9.1.2 FLUSHING
Before performing this test which will result in operation of alarms, notify all the
concerned personnel who may be affected.
Following Test should be carried out as a part of Commissioning.
1. Fire Pump – Functionality & Flow Test as per NFPA 20
2. Foam System- Functionality & Conductivity Test
3. Sprinkler System- Functionality Test
4. Standpipe System- Functionality & Flow Test.
10 QUALITY CONTROL
B. All inspection requested must be properly documented for future references and
to be witness and approved by main contractor QA/QC Engineer.
B) Responsible health, safety and environment officer of the project will conduct ROUTINE
HSE inspections.
C) Safe access and egress to and from the work place shall be provided by the Client.
D) Risk assessments for the installation of deluge foam system have been attached to this
method statement and related to the risks and associated hazards related to the activity.
HEMPEL Date: 30.09.2018
PAINT
FACTORY Ref/Rev. No.: 1576/ 0