PROJECT NAME

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METHOD STATEMENT FOR REV. No. 0
Date :
INSTALLATION AND TESTING OF DOMESTIC COLD / HOT WATER SUPPLY Page 1 of 17
PIPING AND ACCESSORIES ( A/G & B/G)

METHOD STATEMENT FOR

INSTALLATION AND TESTING OF DOMESTIC COLD / HOT WATER

SUPPLY PIPING AND ACCESSORIES ( A/G & B/G)
 PROJECT NAME
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METHOD STATEMENT FOR REV. No. 0
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PIPING AND ACCESSORIES ( A/G & B/G)

REVISION RECORD

This cover page is a record of all revisions of the document identified above by number and title. All previous cover pages
are hereby superseded and are to be destroyed.

Rev. No. By Chkd. Approvals Description and Page Numbers of Revisions

Date

CONTENTS

1.0 PURPOSE

2.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 RESPONSIBILITIES

6.0 EQUIPMENT

7.0 PROCEDURE

8.0 ATTACHMENTS
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PIPING AND ACCESSORIES ( A/G & B/G)

1.0 PURPOSE

This method statement is applicable for Installation & testing of Domestic Cold and Hot water supply
Piping system and its accessories ( Above & Below Ground) in all areas for the project.

2.0 SCOPE
Supply , installation & testing of Domestic Cold and Hot water supply Piping system and its
accessories (Above ground & Below Ground) for all applications in line with project requirments.

3.0 REFERENCES

 Latest Approved shop drawings for the water supply system.

 Specifications
 Project Quality Plan
 Material Submittal Approvals

4.0 DEFINITIONS:

 PQP : Project Quality Plan

 PSP : Project Safety Plan
 HSE : Health, Safety and Environment
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PIPING AND ACCESSORIES ( A/G & B/G)

 MS : Method Statement
 ITP : Inspection Test Plan
 QA/QC : Quality Assurance / Quality Control Engineer.
 WIR : Inspection Request
 MIR : Material Request
 PP-R pipe : Polypropylene random copolymer (PP-R), PN-20 to DIN 8077 and
8078 for sizes up to 4" diameter for above grade.
 PEX Pipe : polyethylene cold and hot water pipe installed inside the Toilets DIN16892/93.
 PE 100 pipes : Polyethylene SDR 11 Domestic cold water pipes for below grade installation.
 PRV : Pressure Reducing Valve.

5.0 RESPONSIBILITIES:
Responsibilities for ensuring that the steps in this procedure shall be carried out are specified at relevant
steps in the procedure:
 Project Manager
 Construction manager
 QA/QC Engineer
 Site Engineer
 HSE officer
 SK

5.1 Project Manager

The work progress shall be carried out as per planned program and all the equipment’s required to
execute the works shall be available and in good condition as per project planned.

Specific attention is paid to all safety measures and quality control in coordination with Safety Engineer
and QA/QC Engineer and in line with PSP and PQP.

5.2 Construction Manager

Construction Manager is responsible to supervise and control the work on site.

5.3 Site Engineer

The method of statement to the system shall be implemented according to the Consultant project
specifications and approved shop drawings.

Provision of all necessary information and distribution of responsibilities to his Construction team.

The work progress shall be monitored in accordance with the planned work program and he will provide
reports to his superiors.

The constant coordination with the Safety Engineer to ensure that the works are carried out in safe
working atmosphere.
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PIPING AND ACCESSORIES ( A/G & B/G)

The constant coordination with the QA/QC Engineer for any works to be carried out and initiate for the
Inspection for the finished works.

He will ensure the implementation of any request that might be raised by the Consultant.

Efficient daily progress shall be obtained for all the equipment and manpower.

He will engage in the work and check the same against the daily report received from the Foremen.

The passage of all the revised information to the Foremen and ensure that it’s being carried out properly.

5.4 QA/QC Engineer (MEP):

The monitoring of executions of works at site and should be as per the approved shop drawings and
project specifications.

Ensure WIRs and MIRs are being raised for activities in timely manner and inspected by the Consultant.

He will follow and carried out all the relevant tests as per project specifications.

Obtain the required clearance prior to Consultant’s inspections.

Should acquire any necessary civil works clearances and coordination.

5.5 Site Foreman

The carrying-out of work and the proper distribution of all the available resources in coordination with
the Site Engineer on a daily basis.

Daily reports of the works are achieved and coordinated for the future planning with the Site Engineer.

Incorporate all the QA/QC and Safety requirements as requested by the concerned Engineer.

Meeting with any type of unforeseen incident or requirement and reporting the same to the Site Engineer
immediately.

5.6 Safety Officer

The implementation of all safety measures in accordance with the HSE plan and that the whole work
force is aware of its proper implementation.

The implementation of safety measures is adequate to maintain a safe working environment on the work
activity.

Inspection of all the site activities and training personnel in accident prevention and its proper reporting to
the Construction Manager and the Project Manager.

The site is maintained in a clean and tidy manner.

Ensure only trained persons shall operate the power tools.

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PIPING AND ACCESSORIES ( A/G & B/G)

Ensure all concerned personals shall use PPE and all other items as required.

Ensure adequate lighting is provided in the working area at night time.

Ensure high risk elevated areas are provided are barricade, tape, safety nets and provided with ladders.

Ensure service area/inspection area openings are provided with barricade, tape, and safety nets.

Ensure safe access to site work at all times.

5.7 Store Keeper (SK)

Responsible for overall Store operations in making sure to store the material delivery to the site and keep
it in suitable area that will keep the material in safe from rusty and damage.

6.0 EQUIPMENT

Following tools shall be arranged before starting the job.

 Tool box  Anchor punch  Pipe wrench

 Measuring tape  Marking line-dori  Electro fusion machine for

 Test Plug  Manual Pump PE Pipes( HDPE)

 Marker  Screw driver (flat & star  PP-R cutter

set)

 Wood-saw  Fix spanner (4mm to 32  Testing pump

mm)

 Half round file  Adjustable spanner  Steel cutter plier

 Hack-saw frame  Monkey plier  Teflon tape.

 Hilti drill machine  Electrical plier  Scaffolding/Ladder

 Fusion machine for
PPR pipes

7.0 PROCEDURE

7.1 Work Sequence

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PIPING AND ACCESSORIES ( A/G & B/G)

stored properly as per manufacturer’s recommendations.

 MIR shall be raised for the inspection of All pipes and fittings received at site to the Consultant
Engineer.
 Work shall be carried out by the site staff under strict supervision and guidance of the
concerned Supervisors / Foremen / Engineers.
 The MEP QA/QC Engineer shall check all the installations as per the Installation Check list.
 WIR shall be prepared by MEP QA/QC Engineer and will be submitted to Consultant for their
inspection and approval.
 MEP QA/QC Engineer shall coordinate with other contractors and arrange inspection for
installation to the CONSULTANT Engineer.

7.2 Material Storage & Handling

All pipes shall be stored properly with end caps. The pipes shall be stored on a flat dry level surface
free from sharp projections, stones or other objects likely to cause point loading or pipe deformation.
Timber supports spaced 1.5m apart along the pipe can be used to support the pipes.

7.3 Sequence of the Installation

a. Ensure that all piping are installed as per approved material submittal and approved shop draings.
b. Mark routing of pipe work according to approved shop drawing.
c. Install fittings for changes in direction and branch connections with appropriate branches, bends and
long sweep bends.
d. Check below the sequence of installation for all water supply pipe works.

7.4. Sleeves and Puddle Flange Installation:

7.4.1 Sleeves installation procedure:
 As per approved shop drawings and Invert Level, mark the centre and invert level of Sleeve on
reinforcement /steel bars for water walls.
 Steel fixing contractor to bend and clear the exact area for installing Sleeve.
 Once the location is clear, position the Sleeve in the steel area.
 Once the Sleeve is in proper location recheck the level and alignment.
 Tie the sleeves with suitable wires with steel to avoid any misalignment while concreting.
 Clearance for civil contractor to close the shutter with exact holes matching with Sleeve to
proceed with concrete pouring.
 All the work to be inspected at all stages by consultant engineer as per attached in the check
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list.
7.4.2 Procedure Installation of Puddle flange for the water wall:
 As per approved shop drawings and Invert Level, mark the Centre and invert level of Puddle
flange on reinforcement /steel bars for water walls.
 Steel fixing contractor to bend and clear the exact area for installing puddle flange.
 Once the location is clear, position the puddle flange in the steel area.
 Once the puddle flange is in proper location recheck the level and alignment.
 Clearance for civil contractor to close the shutter with exact holes matching with puddle flange
to proceed with concrete pouring.
 All the work to be inspected at all stages by consultant engineer as per attached in the check
list.
 The puddle flange to be applied by two coats bitumine as specified before installation.

7.5 Pipes & Fittings Installation Procedure

7.5.1. Domestic cold water below grade (PE 100 SDR 11 pipes).
 Make sure civil clearance is available for laying the pipe line in trench.
 Below ground water supply pipes shall be PE-100.
 Mark routing of pipe work according to approved shop drawing.
 Install any supports or spacers as required or as per the approved shop drawings and
specifications.
 Lay the pipe according to the approved shop drawing.
 Install fittings for changes in direction and branch connections with appropriate branches,
bends and long sweep bends.
 Reducing the size of piping in direction of flow shall be avoided.
 Provide thrust blocks for buried water mains, at every change in direction of the pipe, to resist
the thrust due to the test pressure and unexpected surge during operation.Thrust blocks shall be
poured against undisturbed soil.
 Pipes shall be joined using electrofusion process as mentioned in point 7.5.1.2.
 Plug all open ends of the pipe work.
 Flush all fluid-carrying systems after completion with a stream of water or appropriate fluid at
the highest obtainable pressure and velocity. Discharge the flushing fluid through all strainers
and out through line sized valves with hose ends. Clean all strainers. Repeat flushing operation
to the approval of the CONSULTANT until the water is running clear, colourless and
odourless.
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PIPING AND ACCESSORIES ( A/G & B/G)

7.5.1.1 Pipe Jointing For Below Grade Pipes

Below grade PE 100 pipes shall be joined using the electro fusion welding PN-16 as follow:

7.5.1.2 Steps of the electrofusion weld process:

1. Preparations
Good preparation consist of making sure the electrofusion control box works properly. The inserted
pipe or fitting must completely cover the resistance wires at the surface of the coupler for a good
heat exchange. In order to utilize the fusion and cold zones in the pipe or fitting must be inserted to
the correct depth.

2. Cutting the pipe square

The pipe ends must be cut square to ensure that the resistance wire in the coupler is completely
covered by the pipe or fitting.

3. Mark surface for scraping

The insertion depth +10 mm must be marked to ensure the oxidized layer will be removed from the
full welding zone.

4. Scrape pipe and mark insertion depth

The full outer surface of the pipe that will be covered by the coupler, must be scraped (approx. 0,2
mm deep) to remove any surface 'oxidation'. The insertion depth should be marked again to
safeguard full insertion.

5. Clean electrofusion coupler

Before assembling the pipes into the coupler ensures that all surfaces are clean and dry.

6. Insert pipe/fitting until marked line

Ensure that the pipe is pushed into the coupler as straight as possible and up to the marked insertion
depth. This will ensure that all the wires are covered with PE100 during the fusion cycle.

7. Prevent misalignment and movement

Misalignment will cause extra load on the fusion zone causing additional PE100 to melt resulting in
the outpouring of PE100 pipe or wire movement. The movement of the pipe can cause melted
PE100 to flow out of the joint. This can result in wire movement and possibly a short circuit and
thus a bad weld or fire hazard.

8. Welding electrofusion coupler and cooling down

Commence welding after connecting the control box to the coupler by pressing the start button.
Control boxes adapt the welding time to the ambient temperature. The joint assembly should not be
disturbed during the fusion cycle and for the specified cooling time afterwards.

7.5.2 Installation of Domestic Hot & Cold Water Piping (Above Grade) – PP-R (PN-20):

 Ensure only approved drawings are used for installation.

 Mark the pipe routing on the soffit of slab or as required, duly coordinated with other services
and as per approved layout drawings.
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PIPING AND ACCESSORIES ( A/G & B/G)

 Install hangers and supports with approved material.

 The spacing of the supports for the vertical and horizontal pipes shall be in accordance with the
approved details drawings and standards as applicable.
 The pipes shall be installed at designated levels as per the coordinated layout.
 The pipes are cut to required length, and all sharp edges and burrs shall be removed.
 All safety measures to be taken for fusion welding of PPR.
 Use proper size of fusion weld bushes for jointing of PPR pipes and fittings while joining.
 Ensure manufacture’s recommended timing for heating and hand pressing.
 All valves shall be installed in an easily accessible location and adequate space shall be
available for maintenance.
 Ensure that Air vents installed on all high points required for efficient operation and venting of
system whether indicated on the drawings.
 PRVs will be installed as per manufacturer’s instructions at locations approved on approved
shop drawings.
 Isolating valves shall be installed at all low points.
 Make sure that water hammer arrestor installed in all open circuit water system, in each branch
connection and in each vertical branch on pipe run. It must be selected for Maximum working
pressure 125 psi and Maximum temperature 300o F, and as per approved shop drawings.
 Make sure that the water meter installed as per manufacturer recommendation and as per
approved shop drawings.
 Ensure that the Backflow preventers installed in horizontal or vertical position as per approved
shop drawings.
 All pipe joints shall be left exposed until satisfactory completion of hydrostatic pressure testing
as per point #. 7.6.
 The pipe work, valves etc., shall be identified as per specifications and manufacturer
recommendations.
 Use crimping Tools in order to install the PEX pipes in the toilets embedded in the wall as
follow:
 Cut the PEX tubing. Make sure you have a smooth and even cut. To achieve this, position the
cutter at 90 degrees to the tubing as per below photo.
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 Take the PEX crimp ring and slide it over the tubing approximately 2” past the end.

 Fully insert the PEX fitting into the PEX tubing in a way, so that the fitting’s shoulder touches
the tubing.

 Position the PEX crimp ring 1/4”-1/8” from the end of the tubing. This way the crimp ring will
be right above the PEX fitting’s barbs.

 Open the PEX crimp tool’s jaws. Position the PEX crimp tool over the crimp ring evenly, at
90-degrees to the tubing. Make sure that jaws of the tool are cantered over the crimp ring and it
stays in place; Close the crimp tool’s jaws completely till the connection complete.

 Check the connection with a go-no-go gauge, to make sure that it was properly done.

 Then connect the pipe to the brass fittings as per approved shop drawings and specification.
 Make sure the installation of the PEX pipes to the Domestic Water heater done as per approved
shop drawings and as per manufacturer recommendations.

7.5.3. Installation and Insulation of Cold Water Piping (in the Roof Area):
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 Ensure all installation for the pipes in the roof as per approved shop drawings.
 Ensure civil clearance for all work in the roof area before starting the installation.
 Ensure that pipes runs with no clashes with other services.
 Make sure that Cold water services pipework installed on roof shall be insulated with
preformed sections of aluminium foil faced rigid fibre glass insulation, minimum density 2 inch
65 Kg/M3, and covered with Aluglass Cloth backing (18u / FR Glue / 8x8 Mesh Aluglass
Cloth), combined with a high performance flame retardant solvent acrylic adhesive, protected
by an easy-release silicone release paper.
 Expansion loop and Expansion compensators shall be used for the network as per thermal
expansion.
 All insulated pipework installed on roof, within plant room and wherever exposed to view shall
be cladded with plain aluminium sheets at least 0.7mm thick.
 Insulation thickness shall be as follows:
Pipe Size Insulation
MM thickness (MM)
Up to 28 25
35 to 50 40
Above 50 50

7.6 Hydrostatic Test:

 Upon completion of installation, the open ended pipes shall suitably be plugged or blanked-off.
 All the joints shall be left uncovered until satisfactory completion of testing.
 Connect a calibrated pressure gauge to the pipe work at a suitable location.
 Check and ensure all drain valves are closed and in-line valves are open.
 Fill the section of pipe work under test with clean water.
 Subject the Cold & Hot Water piping to hydro test at 10 Bar Pressure for 24 hours of 1.5 times
of the working pressure, whichever the highest by using a mechanical hand pump.
 After pressurizing the pipe work to the required pressure, a holding time of 2 hours shall be
allowed.
 Inspect all joints, valves, fittings etc. for leaks, if there is a drop in pressure.
 Repair leaks and defects, if any, with new material as required and retest the pipe work until
satisfactory results are obtained.
 Consultant/Consultant shall be notified at least 24 hours in advance to witness the test by
submission of work inspection request.
 Only calibrated pressure gauge shall be used for pressure testing.
 All underground piping shall be tested in accordance with the manufacturer's test pressures,
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before back filling can commence the same to be available during the said testing.

7.7 Testing and Commisssiong of the Water supply system

 After the piping network is finally approved the flushing and disinfection shall be done.
 Where pressure testing is specified in the contract documents this shall be undertaken using
water pressure in accordance with the approved Specifications, provide and complete a signed
record sheet for each pressure test for the contractors and consultant.
 Flush out all pipe work with clean water before commissioning.
 Check all isolating valves and float-operated valves for effective operation.
 Visually check all stem glands for leaks on all types of valves and drain cocks.
 Visually check for leaks, any pipe joints which were not subjected to a pressure test.
 Check that all pipeline strainers and outlets strainers are free of deposition before completing
the commissioning procedure.
 Prior to the handover of the work, complete any commissioning check list document issued
under the contract or provided by an equipment manufacturer and hand over to the main
contractor.
 The samples will be taken and tested from the third party as per Consultant requirement.

7.8 Commissioning and Testing of Water Tanks

 All tanks operating at atmospheric pressure shall be tested under "tank full" conditions for
tightness and structural soundness.
 All cold water tanks shall be subject to a standing leak test for twenty four hours, during which
time all joints shall be carefully examined. Any defects shall be rectified immediately and the
test repeated as per manufacturer recommendation in the commissioning stage.

7.9 Domestic Water Piping / Water Tank Sterilization

 On completion of the potable cold water supply services system, including any parts of the
existing service they shall be sterilized by the application of chlorine.
 The minimum requirements prior to chlorination shall be to flush the pipework thoroughly to
remove dirt.
 Chlorine solution with at least 50 PPM (50 mgtl) of chlorine shall then be added to the storage
tanks and water drawn from all draw-off points until chlorine is detected at each outlet point.
 The mains are then to be allowed to stand for a period of 24 hours, after which the outlets are to
be tested for chlorine. If chlorine is found to be present, all the above shall be repeated until
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residual chlorine is not detected.

 After this, the system is to be completely flushed with clean water and precautions taken to
avoid subsequent contamination of the installation.
 Samples to be sent to third party to check the water quality inside tank and network.

8.0 ATTACHMENTS

8.1 Inspection & Test Plan

8.2 Check Sheets

8.3 Rik Assessment