CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.

PROJECT ID: PA 2020 C 009 G

Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

Method Statement for Installation of Refrigeration Pipes & Fittings

Project Owner: Ashghal (Public Works Authority)

Project Engineer /Consultant: Khatib & Alami, CEC Consolidated Engineering Company
Project Contractor Al Jaber Engineering WLL

Revision Date Purpose

00 19/01/2023 For Review & Approval

Description Name Position Signature

Prepared By: Joseph Stalin Sr. Mechanical Engineer

Ayman Ashour
Reviewed By: Construction Manager
Faris

Reviewed By: Mahir Mohammed QA/QC Engineer

Approved By: Muin Alawna Project Manager

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

List of Acronym and Abbreviation

Abbreviation Expanded
AJE Al Jaber Engineering Company WLL

K&A CEC Khatib & Alami Consolidated Engineering Company

PWA Public Works Authority (ASHGHAL)

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

Table of Contents

1. PURPOSE.........................................................................................4
2. SCOPE OF WORKS..........................................................................4
3 REFERENCE.....................................................................................5
4 DEFINITION.......................................................................................6
5 PRELIMENARIES.............................................................................6
6 RESOURCES....................................................................................7
7 RESPONSIBILITIES..........................................................................7
8 PERMITS and LICENSE...................................................................9
9 WORK SEQUENCE........................................................................10
10 QUALITY CONTROL AND QUALITY ASSURANCE.....................27
11 HEALTH SAFTEY AND ENVIORNMENT.......................................27
12 ATTACHMENTS..............................................................................28

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

1. PURPOSE
The purpose of this Method Statement is to outline the general requirements which
should be taken into consideration when Installation of Refrigeration pipes and fittings
for the installation procedure in accordance with Project specification, manufacturer
recommendation & QCS2014 requirement.

2. SCOPE OF WORKS
The purpose of this Method Statement is to define the procedures and methodologies
required to deliver the Works in compliance with the project specification & QCS 2014
requirement.

Supply of Refrigeration Pipes and fittings as per technical specification.

Sequence of the Works for this method statement identifies the specific steps &
arrangements which shall be followed during the construction activities as follows:

 Inspection of Refrigeration Pipes & Fittings.

 Loading, Unloading & Handling of pipes
 Storage of Materials
 Installation
 Commissioning

3 REFERENCE
3.1 Project Specification, Section 20-Part 2, Part 3 & Section 8 Part 3
3.2 Project Approved material submittal.
3.3 HSE Plan (C823-3-DOC-OPP-OTH-OO6) rev – 03
3.4 Project emergency procedure ref no (C823-3-DOC-OPP-OTH-014)
3.5 Lifting procedure reference (C823-3-DOC-OPP-OTH-040)
3.6 Welding & PTW procedure reference (C823-3-DOC-OPP-OTH-040)
3.7 QCS 2014 (section 20, part 2)
3.8 Material submittal C823-3-DOC-MAT-MEC-036
3.9 IFC Drawings
3.10Approved shop drawing

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

4 DEFINITION
4.1 Client-PWA - ASHGHAL (Public Works Authority)
4.2 SC - Khatib & Alami CEC
4.3 AJE - Al Jaber Engineering W.L.L.
4.4 QCS - Qatar Construction Specifications
4.5 HSE - Health, Safety & Environment
4.6 PQP - Project Quality Plan
4.7 ITP - Inspection Test Plan
4.8 PPE - Personal Protective Equipment
4.9 TDP - Traffic Diversion Plan

5 PRELIMINARIES

5.1 Survey Works

5.1.1 Well experienced & professional survey personnel will be engaged for commencing
the works.
5.1.2 Accurate survey data will be provided using the survey instruments such as total
station, survey instrument. Calculated and set out of all survey lines and points will
be provided on site before proceeding the work.
5.1.3 According to existing benchmark referred from the Qatar National Height Datum &
QND 95 Grid system, a temporary bench mark will be established. Then the survey
team will make a complete survey record and take levels of the site upon which the
setting out for the works is based.

5.2 Traffic Management

5.2.1 Before commencing with any work that is likely to cause disturbance to the existing
road network, diversions shall be addressed and submitted for approval in advance,
and as per the HSE Plan, for project traffic management plan refer C823-3-DOC-OPP-
OTH-007-01
5.2.2 SUEZ Team in DNSTP shall be consulted prior to commencement of any such
diversion works, if required.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

6 RESOURCES

6.1 Equipment and Tools

6.1.1 Crane
6.1.2 forklift
6.1.3 Complete tightening tools
6.1.4 Level gauge &measurement tape
6.1.5 Other hand tools and necessary PPE
6.1.6 Other lifting devices
6.1.7 Self-loader
6.1.8 Welding machine

6.2 Manpower
6.2.1 Site Engineer
6.2.2 Foreman
6.2.3 QC Inspector
6.2.4 Charge hands
6.2.5 Equipment Operators
6.2.6 Safety Officer
6.2.7 Pipe fitters
6.2.8 Lifting supervisor
6.2.9 Rigger
6.2.10 Laborers

6.3 Materials

6.3.1 Refrigeration pipes

6.3.2 Refrigeration pipe fittings

7 RESPONSIBILITIES

7.1 Project Manager

7.1.1 Responsible for controlling the Project entire activities & for the overall
coordination with the Client/Consultant.
7.1.2 Coordinating and following up the planning, progress, resource in adherence
with Quality and HSE requirements.
7.1.3 Monitor the Project progress and financial performance and advice concern of
the corrective and preventive action in case of slippage or violation

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

7.2 Construction Manager

7.2.1 Organize the site so that work is carried out to the required specifications with a
minimum risk to men, equipment and materials.
7.2.2 Adhere to the Project Specific Quality Management Program and HSE
Requirements.

7.3 Sr. Mechanical Engineer

7.3.1 Analyzing problems and coming up with designs to solve them.

7.3.2 Networking and collaborating with other engineers and professionals.
7.3.3 Allocating resources and time effectively.
7.3.4 Attending meetings and providing input and updates.
7.3.5 Analyzing data to write up reports.
7.3.6 Communicating with staff, and clients.

7.4 QA/QC Engineer

7.4.1 Identify the Projects Specific Quality Requirements, Develop the Project Specific
Quality Assurance Program (Project Quality Plan), Inspection and Test Plan (ITP),
Operational and Control procedures, Mechanism and Forms and ensure
effective implementation of the same.
7.4.2 Resolving day to day Quality issues with Client/Consultant Representative,
Responsible for initiating on site quality control inspections.
7.4.3 Ensure compliance with applicable Standards as well as relevant statutory
requirements.
7.4.4 Monitoring & evaluate the performance in terms of Quality requirements for
Sub-Contractor.

7.5 QA/QC Inspector

7.5.1 Responsible for the work entire Quality Assurance, Quality Control & inspection
programs.
7.5.2 Produce all Quality related documents & necessary quality reports as requested.
7.5.3 Provide written procedures & to coordinate in formalizing the Method
Statements with the Construction Manager/Site Engineers to describe the job
specific work for each stage of activity.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

7.6 OHSE Engineer

7.6.1 Responsible for entire HSE matters and preparing Risk Assessment (RA) in line
with Method statements for particular activity.
7.6.2 Liaison with Client/Consultant Representative for HSE issues.
7.6.3 Monitoring the HSE requirements as per Project Specifications and Consultant
requirements.

7.7 OHSE Officer

7.7.1 Ensure that all workers have a safe place of work, advice safe system of work
and provide adequate instructions, training and supervision to enable
employees to work in safety.
7.7.2 Carry out site survey on daily basis to ensure that the HSE Methods of working
are in operation & that all regulations are being observed.
7.7.3 Report, determine & analyze the cause of any accident or dangerous occurrence
and recommend measures for preventing recurrence

7.8 Chief Surveyor/Surveyor

7.8.1 Chief Surveyor: Chief surveyor will be in-charge of the Topographic survey. He
will lead the survey team and will coordinate with all the concerned parties and
ensure survey works is in time and with proper quality.
7.8.2 Surveyors: The surveyor will be responsible for all survey work and will report to
chief surveyor.

7.9 Site engineer

7.9.1 Adheres to the Project specific method statements, procedures, inspection

programs & HSE instructions to get the activities performed to Engineer’s
Representative satisfaction with full coordination with the HSE & Quality
personnel.

8 PERMITS and LICENSE

8.1 Obtained relevant permit/license shall be approved if required and available at

site prior to start any activities. All drivers, operators shall have valid driving-
operating licenses/permits. Licenses/permits should be obtained, from relevant
concerned department/authorities.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9 WORK SEQUENCE
9.1 General Requirement

9.1.1 All works shall be carried out as per approved Drawings and Material Submittal
approval from client.
9.1.2 All activities shall be carried out as per approved Method Statement and
Projects Specifications.
9.1.3 All pre-requisite inspection must obtain clearance approval prior to any work
execution.
9.1.4 Access way shall be provided to client/consultant personnel for easy passage
through working area.
9.1.5 All necessary work permits shall be obtained from the authorities, prior to the
commencement of any activity at site and shall remain valid throughout the
entire duration of the operation.
9.1.6 All Survey Instruments should have valid Calibration Certificates.
9.1.7 Level and setting-out points shall be set-up and marked by the assigned Site
Surveyor as per approved shop drawings.
9.1.8 Ensure that persons involved with the works are adequately trained & equipped
with the required PPE against the work hazards.
9.1.9 Ensure that all the Driver’s / Operator’s should carry valid license.
9.1.10Warning signs & traffic cones should be set all around the site work area as
necessary.
9.1.11 Ensure that Flag man are available with each individual Equipment’s.
9.1.12All works to confirm to manufacturer recommendation.

9.2 Work Methodology

9.2.1 Inspection of Materials

9.2.1.1 Upon receipt of materials on site, the storekeeper and site Engineer or any
representative will have to check to ensure that the materials delivered and
their respective quantities are correct.
9.2.1.2 Refrigeration pipes and fittings should be carefully inspected at the storage
area. Each batch should be visually checked to ensure that each pipe has not
been damaged externally or internally during transportation/handling.
9.2.1.3 A material inspection request shall be issued and all materials must be
inspected and verified by the engineer.
9.2.1.4 When approved, the materials will be considered correct with respect to their
approved samples, catalogues and technical reports.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.2.1.5 Refrigeration pipes and fittings shall be from approved manufacturer.

9.2.1.6 Refrigeration pipes and fittings shall be inspected and approved by the
Consultant prior to laying & Installation.
9.2.1.7 Inspection procedures and tests for Refrigeration pipes and fittings shall be
carried out in accordance with QCS 2014

9.2.2 Loading, Unloading, Receiving & Handling of Materials

9.2.2.1 It is essential to maintain control during loading & unloading of the materials.
Use the necessary equipment such as crane/self-loader, sling belt and
competent people for loading & unloading the pipes as per QCS 2014 section 8
part 3 clause 3.1.5
9.2.2.2 Refrigerant pipes and fittings should never be dragged or rolled along the
ground.
9.2.2.3 Materials should never be dropped on hard or uneven surfaces.
9.2.2.4 Materials loading/unloading and handling will be as per manufacturer’s
recommendation.
9.2.2.5 Suitable lifting equipment i.e. crane or forklift shall be used to shift the pipes
from stored place to installation site. All necessary safety precautions as per
established safety procedure shall be implemented during shifting and
installation.

9.2.3 Storage of Materials

9.2.3.1 The storage surface as per QCS 2014 section 8 part 3 clause 3.1.5 must be in
level and free of stones.
9.2.3.2 Storage areas should be as well protected as possible, absorption of oil;
solvents and other chemicals must be avoided at all costs.
9.2.3.3 Pipes stacking shall be as per the manufacturer’s recommendation.

9.3 Installation Procedure

9.3.1 Site Preparation

9.3.1.1 Access and ingress shall be ensured by clearing the area from unnecessary and
not relevant materials. Access and ingress shall be ensured by stacking
materials relevant to the task according to the work schedule.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.3.2 Pre-Installation

9.3.2.1 All relevant documentation approved shop drawings, and material applicable to
a particular section of work will be checked by site engineer prior to work.
9.3.2.2 Ensure that the material received is in compliance with the project
specifications/authorities regulations and is approved.
9.3.2.3 Ensure that all required materials and accessories are delivered, inspected &
approved by consultant and are readily available at the site to carry out the
work.
9.3.2.4 All relevant documentation (Including MST & RA are approved, obtain necessary
work permits, fill up STARRT Cards after the completion of the daily toolbox
talk), will be checked by site engineer prior to the commencement of work.
9.3.2.5 The site engineer/Site supervisor will give necessary instructions to tradesman
(Mechanical/HVAC) & provide necessary.
9.3.2.6 The site engineer/site foreman will check that proper tools and equipment’s
are available to carry out the work and are in compliance with contract
specifications.
9.3.2.7 The site engineer will explain to his team about HSE precautions to be observed.
9.3.2.8 Ensure to remove scales and dirt inside and outside of the pipes. Prepare the
piping connection to equipment with flanges or unions.
9.3.2.9 Ensure proper storing/handling of the copper piping without damaging the
surface.
9.3.2.10Before starting the installation, ensure that area has been surveyed &
coordinated.
9.3.2.11Confirm that appropriate openings required through walls, beams, and slabs are
available.

9.4 INSTALLATION

9.4.1 Supports & Hangers

9.4.1.1 Install supports or brackets for refrigerant piping as per project requirement,
approved shop drawing, and site condition for individual case (i.e.; Slab & Walls
etc.)
9.4.1.2 Refrigerant piping supports shall be installed with maximum horizontal &
vertical spacing as specified, and the allowable minimum pipe elevation from
the finish floor level.
9.4.1.3 Riser support for vertical refrigerant piping shall be as per the detail shown on
the approved shop drawing.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.4.1.4 As indicated on approved construction drawings where more than one pipe can
be supported on one hanger, the size of the hanger will be assessed on the sum
of the maximum widths and weight of filled pipes.
9.4.1.5 Supports are to be fixed at the correct levels and check the bracket material is
compatible with the installation.
9.4.1.6 Install hangers to provide a minimum of 13mm space between the finished
covering and adjacent work.
9.4.1.7 Provide trapeze hangers where several pipes can be installed in parallel and at
the same elevation.
9.4.1.8 In line equipment is to be independently supported from the main structure.

9.4.2 JOINTING METHOD OF COPPER TUBES & SOLDER FITTINGS

9.4.2.1 Cut tube square to required length with the cutter or fine hacksaw (32 tooth
blade is recommended) & remove burr with file or scraper.

9.4.2.2 Clean outside end of copper tube thoroughly with sand cloth or sandpaper
equal depth of fitting. Leave no dark spots.

9.4.2.3 Clean inside of fitting carefully with wire brush, sand cloth or sand paper.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.4.2.4 Apply heat uniformly around the fitting with torch. When brazing rod melts
upon contact with heated fittings, the proper brazing temperature has been
reached. Remove flame and feed brazing rod slightly off center at the bottom of
the joint. Proceed across the bottom of the fitting and up to the top center
position. Return to the starting point, and then proceed up the incomplete side
to the top, again overlapping the filler metal. Wipe off surplus brazing alloy with
a piece of cloth.

9.4.3 Refrigerant pipe installation

9.4.3.1 Establish the reference level/datum point from where measurement will be
made to the position of the service.
9.4.3.2 Clean the surfaces, Ream pipe, and tube ends and burrs inside the pipe ends.
9.4.3.3 Proper tools are to be used for making cutting the refrigerant pipe at the site.
9.4.3.4 Installation of all refrigerant piping connections/ specialties shall be in
accordance with the manufactures recommendation.
9.4.3.5 Route piping in an orderly manner and maintain gradient. Route piping parallel
and perpendicular to the wall.
9.4.3.6 Group piping whenever practical at common elevation, without stressing pipe,
joints.
9.4.3.7 Provide clearance in hangers and from the structure and other equipment for
the installation of insulation and access to fittings.
9.4.3.8 Install piping to be short and direct as possible, with a minimum number of
joints, elbows and fittings.
9.4.3.9 Pipe must be cut accurately to measurements. Pipes must be installed as to
permit free expansion and contraction without damage to joints & hangers.
9.4.3.10 All due consideration and allowances shall be taken to keep pipework clean &
dry during the installation works. Ensuring that all pipework’s unfinished ends
are capped off at all times
9.4.3.11 Arrange piping to allow inspection and service of compressor and other
equipment. Installed piping must not interfere with the operation or

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

accessibility of doors or windows and must not encroach on aisles,

passageways, and equipment.
9.4.3.12 Pipe work to properly fixed and supported using a recognized and approved
support system.
9.4.3.13 Check for above false ceiling clearances for refrigerants piping and other MEP
services, and allow sufficient ceiling space.
9.4.3.14 Care will be taken during setting out that refrigerant pipe work runs between
ceiling module lines so as to maintain maximum flexibility for any further
relocation of lightning fixtures or other services.
9.4.3.15 For all open ends check for debris and then cover with suitable material to
prevent any ingress of debris, vermin or moisture.
9.4.3.16 Supervisor to ensure that there are no dents, distortion, or buckling of
refrigerant pipework during installation
9.4.3.17 Refrigerant pipes penetrations across the wall and slab shall be sealed with
approved material as agreed with engineer. The sealant installer shall be
certified and all complete locations shall be tagged along with signature.
9.4.3.18 Provide proper sleeves including fiber glass to fill the gap with fire stop material
for refrigerant pipe work which passes through a fire rated wall or slab.
9.4.3.19 Insulation of refrigerant piping shall be as per approved material submittals as
per manufactures recommendation.
9.4.3.20 Install the gauges as per located in the approved shop drawings. It must be
installed appropriately ranged continuous-duty temperature and pressure
gauges designed for refrigeration service. Pressure gauges must be installed to
sense compressor suction and discharge pressures.
9.4.3.21 Pipe work shall be suitably identified and labeled where specified.
9.4.3.22 Connection between piping of steel and copper of brass or dissimilar metals
shall be made using dielectric fittings.

9.5 Installation of Refrigeration Piping Insulation

9.5.1 Installing Insulation on New Refrigeration Piping: the slip- on Method

9.5.1.1 The slip-on Method of installation is used when you can insulate new piping
before it goes up or as it is being connected.
9.5.1.2 Slip a particular length of insulation over the pipe as shown in fig 1

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.5.1.3 Since it is rubber insulation a closed cell rubber, is flexible in which it will follow
bends in the tubing and can be slipped right over bent tubing, 45 degrees, 90
degree and couplings as shown in fig 2

9.5.2 Guidelines for working with refrigeration piping insulation

9.5.2.1 Use good quality tools – Good adhesive brushes, sharp knives.
9.5.2.2 Process installation of insulation only when the pipes are clean, dry, and
unheated or uncooled. The surface to be insulated should be free from rust.
9.5.2.3 Never stretch insulation when sealing the joints. It is better to compress it
slightly. Use pieces of insulation that are at least as long as the section of pipe to
be insulated.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.5.2.4 Always use the insulation that is properly sized for the pipe to cover. Do not
stretch it over the pipe.
9.5.2.5 Do not crowd insulation - covered pipes. Spacing must be provided far enough
apart to allow for the free circulation of Air. Air Movement is an extra safe guard
against surface condensation of cold pipes, especially under hot, humid
conditions.
9.5.2.6 When using wall insulation, it may be necessary to cut the insulation for the
required 90 degrees as shown in fig 3. Butt the insulation against each long or
slightly longer than the section of piping to be covered.

9.5.2.7 Apply a coating of an approved contact-type adhesive to both ends to be joined,

as shown in fig.4.

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PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.5.2.8 Butt the ends together, allow the adhesive to set until it is dry to touch under
slight pressure. Join the surfaces as fig 5.

9.5.3 FABRICATING FITTING COVERS

9.5.3.1 To form a 90-degree elbow, cut through the insulation at a 45-degree angle with the
help Saw as in fig 6.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.5.3.2 Reverse the position of one of the sections in relation to the other so that an elbow
is formed, as shown in fig 7. Join the two sections using the adhesive.

9.5.3.3 Cut & open the inside wall of the elbow, taking care no damage is occurred to the
opposite wall.
9.5.3.4 The slit-open elbow should slip over the fitting, as shown in fig 8. Apply adhesive to
the seam (not to the butt ends), allow to tack dry, and fit over the fitting. Press the
seams together working from the ends toward the center of the elbow.

9.5.3.5 Finally, wet seal the but ends to the incoming lengths of insulation, as shown in fig 9.
Cut the incoming lengths so that the butt joints are in slight compression.

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PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.5.4 P- TRAP FITTINGS

9.5.4.1 When installation of insulation in wall, it is normally necessary to fabricate by cutting

the insulation covers for P-trap fittings. This can be accomplished by using either a 45
degree cutting layout or 22.5 degree cutting layout as shown in fig 10 & 11

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PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.5.4.2 After fabrication, the 180-degree cover can be slit into the pipe so that it may be
snapped around the trap and then sealed with adhesive. The insulation must be
adhered to the pipe on both sides of the P-trap with adhesive.

9.5.5 Installing insulation on existing refrigeration piping: The Snap-On method

9.5.5.1 The Snap-On method of installing insulation is used when the pipe or copper tubing
to be is insulated has already been installed and connected.
9.5.5.2 With unslit tubular insulation, use a sharp knife to cut the insulation lengthwise on
one side, as shown in fig 12.

9.5.5.3 Brush coat both cut surfaces with adhesive as shown in fig 13.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.5.5.4 Test the tackiness with the back of fingernails, as shown in fig 14.

9.5.5.5 Check whether the insulation is stuck to the pipe after applying of adhesive, break
the insulation loose it by running a finger down the pipe. This is illustrated in fig 15.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

9.5.5.6 When the adhesive has air dried, apply moderate pressure to the entire joint to
assure a vapor – tight bond as shown in fig.16

9.6 PRESSURE TESTING

Refrigerant Piping ( Leak Check ) by pressure Testing:

 Pressure testing helps ensure a leak free system, a critical component to a successful
installation.
 Pressure testing process: Tighten down stop valves before pressure tested to 550 PSIG and
held for 24 hours.
 Pressure testing process : Tighten down stop valves before any pressure testing to prevent
nitrogen.
 From leaking back through condenser and containing refrigerant.
 Pressure testing shall be done in three steps:
 Step 1 – Leak check 3 minutes at 150 PSI

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

 Step 2 – Leak check after 5 minutes at 324 PSI

 Step 3 – Leak check after 24 hours at 550 PSI
 After the gauge reading reaches 550 PSI, isolate the system by first closing the gauge
manifold, then close the nitrogen cylinder valve.
 Check flared and brazed connections for leaks by applying a bubble solution to all joints.
 The bubble solution must be a solution designed for refrigerant leak testing. Common soap
solution must be never be used on refrigerant piping as those contain chemicals that could
corrode copper & brass, and cause product malfunction.
 If the pressure does not drop for 24 hours, the system passes the test.
 In this case , the pressure drop of 9.5 psi this is due to temprature diffrences, therefore
there is no leak in the refrigerant piping system.
 If the pressure drops and it is not due to ambient condition, there is a leak and it must be
found. Remove the bubble soulution with clean cloth, repair the leaks, and perform the
leak/ pressure check again.
 After the system has been throughly tested and no leaks are found, depressurize by
loosening the charging hose connector at the nitrogen cylinder regulator . When system
pressure returns to normal completely disconnect the charging hose from the cylinder, and
release the nitrogen charge from all refrigerant piping. Wipe off any remaining bubble
solution with clean cloth.

10. QUALITY CONTROL AND QUALITY ASSURANCE

Ensure relevant permit shall be prepared if required and maintained at site to

ensure all necessary checks and verification has been done prior to Concrete repair
works.

 Product training to be conduct to Execution team after approval of the product as

per manufacturer recommendation.
 Application is always done by a trained worker only on site.
 Complying with manufacturer’s instruction and recommendations for work.
 To make sure the MIR is approved by Engineer’s.
 Approved ITP to be followed for required INR for the project.
 Inspection shall be carried out as per the approved ITP
 Ensure that latest approved shop drawings and latest relevant documents are
being utilized at site.
 All surveying instruments shall have valid calibration certificates.

11. HEALTH SAFTEY AND ENVIORNMENT

The site in-charge in coordination with the Environment Manager, Health and Safety
Manager shall ensure that the toolbox talks include aspects of the environment,
particular to the work execution.

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CONSTRUCTION OF TERMINAL SEWAGE PUMPING STATION AT DOHA NORTH STW PACKAGE 3 –C823/3.
PROJECT ID: PA 2020 C 009 G
Document Title: Method Statement for Installation of Refrigeration pipes & fittings
Document reference: C823-3-DOC-MST-MEC-006 Rev: 00 Date:19-01-2023

Waste shall be minimized by incorporating the following:

 Sufficient waste collection bins shall be provided at each working zone.
 For static equipment drip trays will be provided.
 Spill kits will be made available to be used in the event of oil / chemical spill.
 HSE induction courses shall be provided to all personnel prior to site attendance.
 All manpower to use the required PPE during execution of all the works.
 Regular toolbox meeting shall be conducted to explain the nature of works and
associated risks.
 Continuous on-site supervision will be conducted to always ensure safe
environment.
 Suitable & adequate access (ingress/egress) in the work area / trench excavation
area shall be provided & inspected / maintained regularly.
 Standard scaffolding working platform shall also be provided and
inspected/maintained regularly for pipe installation involving work at heights.
 Identified risk controls / mitigation in the risk assessment shall be strictly
complied / adhere to.

12. ATTACHMENTS

 Risk Assessment (RA)

 Drawings

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