PAT ENGINEERING ENTERPRISES CO. WLL.

Method Statement

FOR

HOT WATER BOILER, CALORIFIER, HEAT

EXCHANGER & HOT WATER
SYSTEM PRIMARY PIPING
AT AL BANDARI HOTEL TOWER

Method Statement No: PAT / MS / HWB/ 001

Issued by:
Rev.No. Date Description
Prepared Checked Approved

For Approval LLOYD ANIL ELECTROWATT

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TABLE OF CONTENTS

TITLE

1. SCOPE OF WORK
1.1 General description
1.2 Plant and equipment
1.3 Materials
1.4 Site planning & preparation
2. WORK METHODOLOGY
2.1 Work methodology of system
2.2 Implementation of work
2.3 Equipment tagging & identification
2.4 Flushing and testing
2.5 Pipe Welding
2.6 Pipe Supporting & Installation Work
2.7 Insulation & Cladding of piping.
2.8 Organisation, Responsibilities & Supervision
2.9 Work Force

3. HEALTH & SAFETY

3.1 Risk Assessment
3.2 Protective & Safety Equipment
3.3 Information to personnel
3.4 Emergency Procedures
3.5 Permit Requirements

4. ENVIRONMENTAL ISSUES
4.1 Environmental Impact assessment
4.2 E S&H Contractor Requirements
4.3 Contractual Requirements
4.4 Emergency Procedures

5. QUALITY ASSURANCE
5.1 Contractual Requirements.
5.2 Critical works.
5.3 Inspection & Testing.
5.4 Follow up & Evaluation

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TITLE

SYSTEM PIPING WORK INSTALLATION

1. SCOPE OF WORK

1.1 General Description

This Method Statement details the procedure to be carried out during

the installation of Primary piping installation work & Chimney
Installation.

1.2 Plant and Equipment

S. Quantit
Item Description Purpose
No. y
1 Welding Machine As Req. For Welding
2 Hand Grinding M/c As Req. For Grinding
3 Drilling M/c As Req. For Drilling
4 Slings, shackle, ropes For erection
5 Chain Block For Erection
6 Hand tools, elec. drill For fixing/installation
Spirit level, measuring For fixing &
7
tape, tri-square, etc. measurement purpose
8 Threading tools For Threading if req.
For installation work at
9 Ladder & Scaffolding height more than 2
mtrs.

Ladders and scaffolding shall be approved by ES&H Staff.

1.3 Materials

 Seamless Sch. 40 Pipes & fittings for primary & return lines.
 Seamless Sch. 40 Pipes & fittings for supply & return lines.
 Insulation & cladding material
 Holding clamp
 Ball Valves.

Delivery, Handling & Storage

System equipment and accessories shall be packed for protection against

damage during handling, transport, warehousing and installation. The
equipment or any of its accessories found damaged shall be removed from
site and send for repair or replace at no additional cost if proven that the
damage was caused by packing, storage or handling deficiencies.

System equipment Boiler, Calorifier shall be transported by suitable

forklift with proper forklift movement plan. Loading and unloading shall be
done carefully to avoid damage.
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System equipments shall be kept under shaded area and under no

circumstances, exposed to direct sunlight for prolonged period of time.

Protection shall be taken care of for the HWS equipment and accessories
during post-installation until pre-operation and commissioning to ensure
damage-free HWS equipment while other trade activities are being carried
out.

Fork lift and Tower crane shall be used to unload the boiler & Accessories.
Nylon slings shall be used for lifting the equipment.

All material handling operations shall be supervised by store supervisor

and carried on by qualified manpower.

Engineer shall be responsible for requisition and transportation of crane

and its accessories from Lay down Area/ Store to the Site. Small
components shall be transported on pick-ups and manually handled.

1.4 Site Planning & Preparation

1.4.1 Site Management plan and Access route

1. Safe lifting plan as per the approved method statement on rigging shall
be followed.
2. The Site Engineer shall be responsible for the installation as well as for
the co-ordination and interfacing with other trade activities during the
installation works.
3. The equipment tools and consumable required shall be planned and
arranged at the Site before commencing the installation.
4. Site Safety and Personal Protective Equipment shall be planned and
arranged in advance.
5. STARRT talks shall be conducted at every morning before start of any
job.
6. The Site Engineer and the Supervisor shall supervise and control all the
work at the Site.

1.4.2 Co-ordination with other Contractors

1. The Interface coordinator shall be responsible for the co-ordination and

interfacing with other contractors during the installation works.
2. After the routes for the delivery of materials are determined,
Electrowatt will notify other Contractors affected by the traffic route of
materials and equipment in advance to avoid any disturbance of their
job schedule.
3. At work front, if there is any interface with other contractors, they shall
be informed well in advance and necessary precautions shall be taken
care of.

1.4.3 Traffic Management

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Contractor will check and finalize timing for transportation of material to
various locations.

1.4.4 Permits and Certificates

The following Work Permits shall be obtained prior to commence the

installation of equipment and accessories:
 Hot Work Permit
 Lifting Work Permit

1.4.5 Lay-down Areas

Mark and barricade letdown area to restrict the access for the following
items:
1. Equipment & Vehicles
2. Steel Structure, Cables and Other Materials & Equipment components.

The site storage will be made on sufficiently firm flat ground and laid on
timbers. The Equipments shall be always protected from dust, moisture
and sun by covering it with tarpaulin or polythene sheets.

1.4.6 Communication

1. Toolbox Talks
2. Staff Meetings
3. STARRT Talks
4. Supervisor Instructions
5. Communication at Site shall be by cellular phones. Supervisory
personnel shall utilize their own cell phone. However, no cell phone
shall be allowed in close proximity of lift operations. In case of
emergency, announcement will be made through portable public
address system or Air horn to evacuate people to designated areas.

2. Work Methodology

2.1 Methodology for System

2.1.1 Preparation

a) Engineering and designing:

This is the first stage of the project. At this stage, design and selection of
plant and equipment and implementation schedule will be done based on
the data furnished by the client.

b) Drawing submittals and approvals

This is the second stage in the project. In this phase site selection will be
done based on the safety distances required, traffic movement of the
vehicles and on the other factors. A site layout and shop drawing will be
prepared showing the location of the boiler, and piping from boiler to
Heat exchanger Calorifier area of utilization. A schematic drawing for the
system also will be made. These drawings will be submitted to M/s
consultant for the approvals.
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c) Materials submittals and approvals

Materials submittals will be prepared for all materials proposed to use for
the Project. These materials submittals will be submitted to M/s
consultant for the approvals.

d) Materials Procurement and Delivery

Based on the approvals from consultant materials will be procured from
the suppliers by placing purchase order and the same will be delivered to
the project site. All the deliveries will be documented through delivery
notes.

2.2 Implementation of work

Method statement for welding of piping will follow the piping activities. All
piping work will be pressure tested before painting / installing any
instruments as per the pressure testing procedure. All the plant and
equipment procured as per the approved materials submittal and as per
the implementation schedule. Foundations will be kept ready for plant and
equipment before they arrive in the site. As soon as the plant and
equipment are arrived in site, it will be erected with the required
resources. Piping will be completed prior to the plant and equipment
reach in the site and it will be hooked to the plant & equipment as soon as
they are erected or if equipment arrival coincides with the construction
schedule the piping will follow the completion of equipment installation.
boiler & Accessories will be installed as per the manufacturer’s installation
manual and will be checked, inspected by consultant for record. After
completion of all activities a final inspection will be conducted and
recorded.

2.3 Equipment Tagging & Identification

Provide proper tag numbers for the equipment as per project

specification. This nameplate must be permanently fastened to
equipment which is accessible & visible. pipeline will mark by paint or
stickers on cladding sheet with line specification and arrow mark. Use
numbers, letters and terms indicated for proper identification, operation
and maintenance of mechanical system and equipment.

2.4FLUSHING & TESTING

2.4.1 Flushing
Before the test shall commence, flushing of the pipes with inert gas /
compress air will be carried out to ensure that no sand, debris and other
foreign materials remain inside the pipe. Compress air will be applied at
some desired pressure from one end of pipeline. Other end will remain
open to release all foreign particles in pipeline. The same procedure is
repeated till there is no trace out of debris and foreign materials

2.4.2 Testing
Check the system for proper installation in accordance with the relative
drawing and design specification. A calibrated pressure gauge to read not
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more than 4 times the working pressure will be used. The system shall be
tested with Water with pressure regulator and a gauge manifold to
provide the proper test pressure desired and to prevent over pressurizing
the system.

All the lines in the system will be pressurized using water at a pressure of
1.5 times of working Pressure of supply piping. Considering return supply
line maximum pressure of 6 bar all line will be hydro tested at pressure of
10 Bar. The pressure will be hold for a period of Minimum 40 Min.

Authorized personnel shall be in control and present during the testing to

ensure proper set up and use of test equipment.

Testing Procedure
 Flush the line with compressed Air
 Fill the complete line with water by using a manual pump.
 By venting remove all air bubbles present in the line.
 Start the test by raising the pressure incrementally by manual Hydro
pump.
 After reaching pressure to 1 bar then hold the line to check the
leakage/pressure drop for 1/2 Hr.
 Gradually raised the pressure till 5 bar and again hold for 20 minutes.
 Again hold the pressure at 10 bar which is maximum working pressure
of line for 1 Hr.
 Increase the pressure till 15 bars which is 1.5 times the MAWP and hold
it for 20 Minutes.
 During holding periods, the gauge shall be monitored also for sudden
changes in pressure.
 Any repairs other than tightening of nuts require depressurization.
 If the pressure has not fallen the water shall be slowly drained in
sewage area.
 After completion of test flush the entire system by compressed air.
 Repeat this flushing with dry air till all the line is completely dry.
 Hydro testing will be offered to client for inspection and approval. The
entire Hydro testing will be documented in the format. The
documentation of the Hydro testing to be approved by
client/representative will be kept in the records.

2.5 PIPE WELDING

2.5.1 Welding Precaution :
Before commencement of any welding the following works are required to
be carried out.
a) The material to be used has an approved material submittal.
b) Approved Material inspection Report is available
c) WPS is Approved
d) Welding is done by Welders Qualified by third party.
e) Work area is clean and safe
f) Fire extinguisher, fire blanket is available near welding place during
welding time.

2.5.2 Welding Procedure & Responsibilities:

This Procedure is to be followed by the Pipe Fabricator and Welder
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 Measure length of pipe required, making due allowance for any

pipefitting to be used.
 Cut the Pipe to the measured length ensuring that the ends are cut
square.
 Prepare the end of the pipe to the pipe to be welded to the right
angle of level and the size of the ‘V’bel and root face in accordance
with procedure specification.
 The surfaces to be welded shall be smooth, uniform, and free from
laminations, tears, scale, slag, grease, paint, and other deleterious
materials that might adversely affect the welding.
 Power Tools or Hand Tools will be used for cleaning grinding or both.
 The two prepared ends to be welded pipe to pipe or pipe to fitting
shall be aligned as accurately as is practical and ensuring that the
spacing between the abutting ends is in accordance with the
procedure specification used.
 The alignment of the abutting ends shall minimize any offset
between the surface caused by dimensional variation and will
equally distribute around the circumference of the pipe any such
offset. Hammering of the pipe to obtain proper line up will be kept to
a minimum.
 The two prepared ends shall be tack welded together in four
positions at ninety degrees.
 After tacking, the alignment shall be checked to confirm the integrity
of the alignment has been preserved during the welding process; the
tacks shall be removed by grinding.
 The welding process will commence, ensuring that the correct filler
metal, electrical current, Polarity, voltage, amperage, and number of
passes are in accordance with the welding procedure.
 All slag of foreign metal shall be removed from each pass of welding,
including the repair of any visible defects, such as cracks, cavities
etc. prior to commencing the succeeding passes.
 The removal of any such impurities will be by electronic power tools
(Grinder).
 On completion of the welding process, the welders designated
identification mark will be placed adjacent to the weld with a hard
die stamp.
 After the completion of weld, the weld will be inspected by the
QA/QC personnel for the following.
1. The weld to be visually inspected to check for inadequate
penetration, excessive undercutting, and burn-through and to
ensure the weld is free from cracks.
2. After Inspection any defects found are to rectified
2.5.3 Equipment used:
 Tungsten Electrode
 Argon (inert gas)
 Metal Arc & tig Welding Machine
 Electric torch
 Electrical Angle Grinder,
 Portable Electric Electrode Quiver,
 Welding Electrodes
 Welding Screens

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 Preheating oven

2.5.4 Weld Repair Procedure

In case of a weld joint failure during inspection, the following is a
procedure for the repairing the failures.
 The defective area will be ground out using electric grinders and if
required the welded portion will be detached from the pipes. The
welder will then clear the area and carry out the repair using the
originally qualified welding procedure specification.
 On completion of the repair, the weld will be re-inspected in the
defective area.
 The repair will be dictated on the joint no. by a letter “R” for repaired
welded
 If the weld is unrepeatable it will be cut out and replaced.
 These changes will be recorded in Weld history sheet.

2.5.5 Welding electrode storage and material handling procedure.

 The welding electrodes upon delivery are stored in an air-tight
container.
 The electrodes are transferred to a welding rod holding oven when
space in the oven is available.
 The oven is thermostatically controlled.
 The rods will be stored as per the manufacturer’s recommendation.
 Once transferred to the site the electrode are stored in each welding
operative’s heated quiver.
 Electrodes that are surplus will be checked before they are replaced in
the oven, operatives are instructed to take only the amount they
require to carry out the welding they are undertaking.

2.6 Methodology for Insulation & cladding of Piping

Insulation is defined as those materials or combinations of materials which
retard the flow of heat energy by performing one or more of the following
functions:
1. Conserve energy by reducing heat loss.
2. Control surface temperatures for personnel protection and comfort
3. Facilitate temperature control of a process
4. Prevent vapour flow and water condensation on cold surfaces
5. Increase operating efficiency of heating/ventilating/cooling, plumbing,
Hot water, process and power systems found in commercial and
industrial installations.
6. Prevent or reduce damage to equipment from exposure to fire or
corrosive atmospheres.

2.7.1 Procedure and Responsibility

Before starting insulation and cladding of piping following steps needs to
be complete & inspected.
 Hydro testing of piping to be complete and recorded.
 Two coats of epoxy primer coating to be painted.

2.7.2 Insulation Procedure

2.7.2.1 PREPARATION AND APPLICATION PROCEEDURE

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The proposed pipe which are to be Insulated & cladded will be clean and
remove any loose mil scale and oil and grease prior to insulation
application as per specification.

2.7.2.2 APPLICATION OF INSULATION (100 kg/m3-25mm Thick

Rockwool Pipe Sections)
Once the cleaning operation is over, the specified Rockwool Insulation
100Kg/m3-25mm thick (Aluminium faced Rockwool Pipe sections) will be
cut into sizes and wrap around the exhaust pipe and laced with
galvanized steel wire firmly.

2.7.2.3 APPLICATION OF CLADDING (Aluminium Jacketing)

Once the Insulation is completed, take site measurement and fabricate
and install Aluminium jacket 0.6mm thick Alloy 3003 -H 14 Temper ASTM
B 209 grade.

2.7.2.4 FASTENING OF ALUMINIUM JACKET

The Fabricated aluminium cladding shall be secure with self taping screws
or Pop rivets as required to secure the cladding materials.

2.7.2.5 INSULATION & CLADDING MATERIAL

Rockwool Pipe Insulation 100 kg/m3-25 mm thick (In 1 layer50) with
Aluminium facing Aluminium Jacket 0.6mm thick mill finish.

2.8 Responsibility & Supervision

The execution supervision shall be as follows:

Designation Responsibility

Manage the installation of

Project In charge Equipment and safety
requirements
ES & H Engineer ELECTROWATT Co. WLL
Check the Quality of Work and
QC Engineer /Inspector maintain necessary
documentation
ELECTROWATT/PAT supervise
& manage the installation as
Supervisor/ Foreman
per approved procedure and
safety requirements.

2.9 Work Force

Description

Riggers
Mechanical Fitters
Welder
Helper
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Safety (part time)

3. HEALTH & SAFETY

3.1 Risk Assessment

 Barriers and warning tape will be provided as appropriate. Tape will be

used as a warning of danger.
 Installation personnel shall ensure that all work facilities are safe prior
to commencing work activities; safety personnel will provide
surveillance inspections before start and during the activities to ensure
that there is no any safety violation. All lifting equipments, slings,
hooks etc. shall have valid certificates.
 Detailed system of works shall be implemented to overcome and
identify hazards:
1. Prior to commencement of work a toolbox talk will be conducted by
the Supervisor in accordance with the safety requirements and
standards.
2. Cordon off and properly secure area within the radius of installation
limits.
3. All equipments, tools and machines to be used should be fully tested
4. Installation work shall be carried out in day light hours.
5. All personnel shall be equipped with PPE and shall be used at all
times.
6. Weather conditions particularly wind speed should be monitored and
lifting/lying work shall be stopped in case the wind speed is above
the safe working limit.
For forklift, cranes, chain blocks and lifting operations, the following
requirements apply:
1. The certification of forklift, Crane by third party inspection agency
shall be submitted for approval before commencing the erection
activity.
2. Banks man/Slingers shall have adequate experience and good
communication
3. Lifting Supervisor shall have overall control of lifting operations.
4. Cell phones shall not be used during lifting operations.
5. Daily pre-operational function checklist shall be carried out by the
maintenance crew to ensure proper functioning of the crane.
6. Lift Plan shall be prepared and implemented.
7. Crane operator shall perform and record an inspection of the
equipment prior to use.
The following table described the specific activities that will be conducted
during the installation of shop/field fabricated materials and measures to
be undertaken to ensure safety during execution of the activities.

Activities Safety Measures

Transport of  Transport equipment shall drive
materials by only through designated route.
truck / trailers,  Vehicle speed should not exceed
speed limit.
 Security / Safety shall control
traffic during transport.
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Lifting /  Inspection of equipment by forklift

installation Crane Inspector prior to lifting.
 Provide warning sign of clearance
limit.
 Only licensed & certified operator
shall operate the crane.
 Qualified/Experienced riggers will
be provided.

Lifting /  Lifting gears will be properly check

installation & inspected.
 Weather condition shall be
checked during lifting, i.e. wind
velocity and direction.
 A competent person shall be
placed in charge of the lift with the
responsibility of explaining
potential hazards before actual lift
commences.

Use of Power Tools  All power tools must comply with

electrical and pneumatic
regulations applicable to the
project.
 All power tools must be plugged
into a GFCI and shall not exceed
220V AC
 Power tools designed with guards
must be equipped with those
guards during use.
 Extension cords must not show
any damage (cuts splice or
exposed internal wires on the
plug).
 Power cords/connectors will be
inspected and marked in
accordance with colour coded
inspection program.
 Only certified/trained workers will
be allowed to operate the
tools/equipment.

3.2 Protective & Safety Equipment

Members of the construction team will be issued with the following
personal protective equipment (PPE):
 Helmet
 Safety Goggles
 Gloves
 Safety Shoes
 High visibility vests

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Additional protective equipment will be issued when and as required.

3.3 Information to Personnel

Communication to personnel shall be made through:
 Safety Induction
 STARRT Programme
 Supervisors
 Notices and Memos
 Method Statements

STARRT talks shall be conducted prior to start of every new activity and for
each new location.
Weekly safety toolbox meeting will be conducted by the assigned
supervisors and/or ES&H Engineer prior to daily work activities. In addition
to the basic ES&H instructions, the following will be discussed:

Method Statement Requirements

All pertinent requirements of this Method Statement will be discussed with
the concerned personnel.

Transport of fabricated materials

Transport crews for materials will be briefed on the designated routes and
waiting areas prior to unloading as well as on safe driving practices.

Lifting and Installation

Prior to unloading and installation, the installation Foreman will brief the
crane operator, rigger, truck driver, fabricators, welders, and other crews
involved on the step by step unloading (position of the transport and
crane, and lifting, laying down, positioning and alignment) and installation.

3.4 Emergency Procedures

Contractor will provide first aid kits on site for light injuries. In the event of
an emergency, all workers will be asked to evacuate and assemble at the
designated assembly area and wait for further instruction from
supervisors. Site Evacuation plan shall be posted at work site.

3.5 Permit requirements

The hot work permit & lifting shall be obtained before commencing the
work.
PAT may require special permits for the transportation of the boiler &
equipment when required.

4. ENVIRONMENTAL ISSUES

4.1 Environmental Impact Assessment

No hazardous material or the like shall be used in the construction hence
no hazardous chemicals will be stored or used on site.

4.2 E S & H Contractor Requirements

No environmental, safety or health hazardous chemicals are involved in
the installation of clarifier equipment and associated works.

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4.3 Contractual Requirements
The waste generated from installation of Hot water piping equipment and
associated works shall be dumped at designated locations.
4.4 Emergency Procedures
No environmental emergency requirements for installation of Hot water
piping equipment and associated works.

5 QUALITY ASSURANCE
5.1 Contractual Requirements
Piping shall be installed as per the approved design in accordance with
the project specification standards and approved General Arrangement
drawings and manufacturer’s instructions.

5.2 Critical Works

1. Installation Equipments
2. Erection of Boiler / Heat Exchanger.
3. Installation of chimney.
4. Installation of Calorifier
5. Pressure Testing

5.3 Inspection & Testing

Inspection and Testing will be carried out as per ITP

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