METHOD STATEMENT FOR INSTALLATION, TESTING & COMMISSIONING OF SPRINKLER SYSTEM
1.0 PURPOSE
This method statement is applicable for the Installation, Testing & Commissioning of Fire fighting Sprinkler System for the project as mentioned in the Specifications & Approved Shop Drawings.
2.0 SCOPE
This method Statement shall cover the Supply, Installation, Testing & Commissioning of Sprinkler System in line with project requirements as indicated in the Approved Shop Drawings, specifications & manufacturer’s instructions.
3.0 REFERENCE
3.2 Specifications
3.3 Project Quality Plan
3.4 Project HSE Plan
3.5 Material Approval
4.0 DEFINITIONS
PSP : Project Safety Plan
QCP : Quality Control Procedure
HSE : Health, Safety and Environment
MS : Method Statement
ITP : Inspection Test Plan
QA/QC : Quality Assurance / Quality Control Engineer.
WIR : Work Inspection Request
MIR : Material Inspection Request
UPVC Class E : Ultra polyvinyl chloride
UPVC : Ultra polyvinyl chloride
HDPE : High density polyethylene
PEX PIPE : Cross-linked Polyethylene
G.I. Pipe : Galvanized Iron Pipe
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
Ø 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.
Ø 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
Ø
Construction Manager is responsible to
supervise and control the work on site.
Ø
Coordinating with QA/QC Engineers, Site
Team & Foremen for all activities on site.
Ø Control and sign all WIRs before issuing to Consultant approval.
5.3 Site Engineer
Ø The method of statement to the system
shall be implemented according to the Consultant project specifications and
approved shop drawings.
Ø Provision of all necessary information
and distribution of responsibilities to his Construction team.
Ø The work progress shall be monitored
in accordance with the planned work program and he will provide reports to his
superiors.
Ø The constant coordination with the
Safety Engineer to ensure that the works are carried out in safe working
atmosphere.
Ø The constant coordination with the
QA/QC Engineer for any works to be carried out and initiate for the Inspection
for the finished works.
Ø He will ensure the implementation of
any request that might be raised by the Consultant.
Ø Efficient daily progress shall be
obtained for all the equipment and manpower.
Ø He will engage in the work and check
the same against the daily report received from the Foremen.
Ø 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):
Ø The monitoring of executions of works
at site and should be as per the approved shop drawings and project
specifications.
Ø Ensure WIRs and MIRs are being raised
for activities in timely manner and inspected by the Consultant.
Ø He will follow and carries out all the
relevant tests as per project specifications.
Ø Obtain the required clearance prior to
Consultant’s inspections.
Ø Should acquire any necessary civil works
clearances and coordination.
Ø QA/QC Engineer will assist the
Consultant Engineer/ Inspector during Inspection.
Ø Check & ensure work is completed
prior to offer consultant for inspection.
Ø Coordination with site construction
team.
Ø He will assist the Consultant Engineer/
Inspector during the inspection.
Ø Ensure all works have been completed prior to raise inspection to the consultant.
5.5 Site Foreman
Ø The carrying-out of work and the
proper distribution of all the available resources in coordination with the
Site Engineer on a daily basis.
Ø Daily reports of the works are
achieved and coordinated for the future planning with the Site Engineer.
Ø Incorporate all the QA/QC and Safety
requirements as requested by the concerned Engineer.
Ø Meeting with any type of unforeseen incident or requirement and reporting the same to the Site Engineer immediately.
5.6 Safety Officer
Ø The implementation of all safety
measures in accordance with the HSE plan and that the whole work force is aware
of its proper implementation.
Ø The implementation of safety measures
is adequate to maintain a safe working environment on the work activity.
Ø Inspection of all the site activities
and training personnel in accident prevention and its proper reporting to the
Construction Manager and the Project Manager.
Ø The site is maintained in a clean and
tidy manner.
Ø Ensure only trained persons shall
operate the power tools.
Ø Ensure all concerned personals shall
use PPE and all other items as required.
Ø Ensure adequate lighting is provided
in the working area at night time.
Ø Ensure high risk elevated areas are
provided are barricade, tape, safety nets and provided with ladders.
Ø Ensure service area/inspection area
openings are provided with barricade, tape, and safety nets.
Ø Ensure safe access to site work at all times.
5.7 Store Keeper (SK)
Ø 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.
Ø One who will acknowledge the receiving of materials at site in coordination with QA/QC & concerned Engineer.
6.0 EQUIPMENTS
a. Tool Box.
b. Measuring Tape.
c. Hack Saw Blade
d. Spirit Level
e. Electric Drill Machine
f. Step Ladders
g. Threading Machine
h. Solvent Cement
i. Electric welding machine. (if required)
j. Torque Wrench
k. Pipe Cutting Machine
l. Grinding Machine
m. Pressure Gauge
n. Hammer
o. Water Level Marker
p. Mobile Scaffolds
q. Staging Platforms
7.0 PROCEDURE
Work Sequence/Procedure
7.1 General Requirements
Ø All the materials received at site
shall be as per the approved technical material submittal for Wet Pipe
Sprinkler System and to be inspected upon receipt & approved by the
engineer prior in proceeding with the installation through MIR. Any
discrepancies, damages etc., should be reported to the supplier for
rectification or replacement & to be removed from site immediately.
Ø All construction/inspection/testing
works shall be carried out in accordance with the specifications & to be
done by qualified Mechanical Engineers and shall be checked and approved by MEP
Subcontractor Construction Manager along with QA/QC Engineer.
Ø Contractor has to clarify the procedure for material delivery to the site through consultant Engineer at site.
7.2 Material Transport/ Delivery
Ø During transportation ensure that the
equipment & its components (if any) are delivered in a shipping package and
or shall be at least in a box covered with plastic. Extra care in unloading the
equipment is required to avoid scratching or denting.
Ø Where ever possible the loading and
offloading of the Sprinkler Equipment shall be carried out by hand.
Ø Equipment shall not be dropped onto
hard surfaces & should not be dragged along the ground.
Ø All the received units shall be checked & inspected to ensure that it is complying with the approved material submittals prior to site storage.
7.3 Storage on Site Store
Ø To ensure that deterioration of the
Sprinkler Equipment does not occur during storage, it is recommended to store
the equipment in sheltered conditions that are protected from weather elements
and accidental damage.
Ø Sprinkler Equipment shall be protected
with plastic/ tarpaulin or shall not be removed from the shipping package
unless otherwise instructed to do so.
Ø All packages for the equipment reaching the site shall be identified as per package list.
7.4 Sequence of Installation for
the Sprinkler System
7.4.1 Safety
Ø All site safety rules &
regulations shall be complied with.
Ø Supervisors will deliver tool box
talks, relevant to these activities to all operatives involved in the
installation, testing & commissioning and shall be recorded.
Ø All operatives will be equipped with
minimum personnel protective equipment; hard hat, coveralls, safety boots,
safety glasses.
Ø The persons using cleaning fluid and
solvent cement have to wear hand gloves.
Ø Ensure only qualified personnel shall
install, test & commissioned the equipment.
Ø During Testing & Commissioning,
display warning sign boards necessarily provided and barricade the area
whenever necessary.
Ø Ensure that all operatives fully understand the method of these activities.
7.4.2 Pre- Installation Procedure
Ø Before commencement of installation
activity, the supervisor must ensure that:
Ø Delivered Sprinkler Equipment shall
have been inspected & approved via MIR by the consultant prior to
installation at site.
Ø All Installations & Pressure
Testing of Fire Fighting Pipe works have been completed & approved by the
consultant.
Ø Relevant documents or certificates
shall be presented at the time of inspection if required by the Consultant.
Ø Permission to start or Civil
Clearances prior to installation has been given by the main contractor.
Ø All relevant Shop drawings for the
installation of the equipment shall be available & approved by the
consultant. No installation shall be done without Approved Shop Drawings.
Ø Installation activities shall only
commence when all associated works by the Civil such as clearing of work place,
water proofing, etc. have been verified & completed.
Ø Safe access shall be provided by the
Main Contractor thru Work Permit in coordination with the Safety in charge at
site.
Ø Inspect the relevant area for any
possible clashes with other services.
Ø Check for other services, making sure that there is no interference between each service & adequate access to work and for future maintenance can be maintained.
7.4.3 Installation Procedure for
the Sprinkler System
7.4.3.1General Notes on the System:
* A wet
sprinkler system is used for Fire Protection purposes and it is an integral
part of the Installation of Fire Fighting System & Accessories as mentioned
in the Approved Method Statement. The system is designed in accordance to the
Fire Protection Engineering Standards. The system is a portion of the
aboveground network of specially sized and pipes are hydraulically designed
which will be installed inside the building, structure or areas as indicated in
the Approved
Fire
Fighting System Approved Shop Drawings for which sprinklers are installed &
fix in a systematic pattern. The valve controlling the each system is located
in the system riser or its supply piping. Each sprinkler riser includes a
device for actuating an alarm when the system is in operation. The system is
actually activated by heat from fire and discharges water over the fire area.
** The
sprinkler is fire suppression & control device that operates automatically
when heatactivated element is heated to its thermal rating or above, allowing
water to discharge over a specified area. The characteristics of a sprinkler
that define its ability to control or extinguish a fire are thermal
sensitivity, temperature rating, orifice size, and installation orientation
& water distribution characteristics.
*** The sprinkler system is designed as per NFPA 13 “Standard for the Installation of Sprinklers”. The location & spacing of sprinklers and pipe sizes are designed in conformance with the applicable clauses of NFPA 13. This standard provides the minimum requirements for the design & installation of automatic Fire Sprinkler Systems and exposure protection sprinkler systems, including the character and adequacy of water supplies and selection of sprinklers, fittings, piping, valves & all materials and accessories.
7.4.3.2 Installation Procedure:
Refer to
Approved Method Statement in which the Installation Procedures for Sprinkler Pipes,
Valves & other Accessories have been discussed. However, Installation
procedure for Sprinkler Heads, Butterfly Valves, & Flow Switches are as
follows:
7.4.3.2.1 Sprinkler Heads:
Ø Prior to installation, ensure that all
the Sprinkler Equipment is equipped with associated appurtenances as per
manufacturer standard & supply according to the approved material
submittal.
Ø All Sprinkler Equipment shall be
covered & protected for moisture, corrosion, dust & any deterioration
before & after the installation.
Ø Ensure that the installations (with or
without ceiling) whichever is applicable shall be on the exact locations as
mentioned on the Approved Shop drawings.
Ø Mark the final location of the
Sprinkler System. It is much recommended to check physically & measure the
actual dimensions on site.
Ø Installation
of sprinkler heads shall be as per manufacturer’s instructions and requirements of NFPA-13.
Ø Make sure hangers & supports are
aligned & secured.
Ø Pipe sizes shall be as per the
approved & shall be initially tested.
Ø Hand tight the sprinkler heads into
the fittings to avoid mechanical damage and gradually tighten it with
appropriate size & type of wrench.
Ø A nominal clearance
of 3/8” to 1” from the finished ceiling line. Adjustment can be made through the push-on Escutcheon
plate to compensate for the variation in the fittings.
Ø To install the Escutcheon plate, align
and press it over the Sprinkler body, until the outer edge of the Escutcheon
meets the mounting surface.
Ø Ensure that the concealed pendant sprinklers are installed and inspected prior to fixing of the cover.
7.4.3.2.2 Installation Procedure of
Butterfly Valves:
Ø Install butterfly valves as per the
approved drawings. Ensure that it is readily accessible for operation &
maintenance.
Ø Ensure valve disc does not interface
with the operation of other system components adjacent to the butterfly valve.
Ø If the valve is hard to close, it may
be due to debris lodge in the sealing area. This can be corrected by
backing-off the hand wheel and closing it again several times if necessary.
Don’t force the valve to seat by applying a wrench to hand wheel. This may distort the valve components or
scratch the sealing surfaces.
Ø The inlet & outlet piping of the
valve shall be properly supported to prevent excessive stress to the valve
body. Do not use the valve body to support pipeline position as it may result
in distortion of the valve body.
Ø Fire alarm provision has to be provided on the valve to connect with the fire alarm panel.
7.4.3.2.3 Installation Procedure of
Flow Switches
Ø Install the flow switch as per the
approved drawings. Ensure that it is readily accessible for operation,
inspection & maintenance.
Ø Mount the flow switch either on
horizontal or vertical pipes. On horizontal pipe, it shall be installed on the
top portion of the pipe for easier accessibility and service.
Ø Drill the hole in the pipe, as per
product manufacturers’ recommended hole size for insertion of the vane of
the flow switch.
Ø Clean
the inside surfaces of the pipe, where the hole was made for a distance equal
to the pipe diameter on either side of the hole.
Ø Roll
the vane so that the arrow on the saddle points in the direction of the water
flow.
Ø Install
the saddle strap and tighten the bolts alternately.
Ø Ascertain
that the vane does not rub the inside surfaces of the pipe.
Ø Fire
alarm provision has to be provided to connect with the fire alarm control
panel.
Ø After
completion of installation of the entire sprinkler heads, butterfly valves
& Flow Switches & raise inspection for Consultant Approval.
Ø Once
installation has been accepted & approved by the Consultant, provide
covering material to the Installed Sprinkler Heads to avoid entry of dirt, dust
and damage.
Ø Testing & Commissioning shall commence after final approval by the consultant.
7.4.4. Testing & Commissioning
Procedures
7.4.4.1 Visual Inspection &
Testing Procedure
Ø After documentations & visual
checks, Testing shall proceed further.
Ø Ensure all pipe works has been
hydrostatically tested & completed.
Ø All supporting system has been
completed, properly installed & fixed.
Ø Ensure all instruments (if required)
to be used during the testing shall be calibrated & records shall be
available.
Ø Ensure that the all Equipment is in their proper location as mentioned on the Approved Shop Drawings.
7.4.4.1.1 Flushing Procedure
Ø All main risers including Sprinkler
& Fire Hose Reels shall be thoroughly flushed before connection of
Sprinkler Heads.
Ø Close all branch lines for initial
flushing.
Ø Fill complete system with clean water
and initially carry out the flushing manually.
Ø Refill the system with clean water
& run the pumps for 2 hours.
Ø Open Drain valves in the main lines
and drain the water.
Ø The flushing operation shall be
continued until satisfactory cleaning is ensured.
Ø Water used during the flushing shall
be drained or disposed to a safe place using flexible pipes to the nearest
drain point.
Ø Hydrostatic Testing for the Sprinkler Piping System shall commence after flushing.
7.4.4.2 Commissioning Procedure for
the Sprinkler System
Prior to
commissioning, ensure that all instruments (if any) to be used during the
commissioning shall be calibrated. Calibration certificates shall be available.
Ensure
that all installed Fire Fighting Equipment & its components have been
installed as per the approved shop drawings, manufacturers’ recommendation
& piping system have been tested for leaks. Approval for all preliminary
inspections shall be available during the commissioning stage.
Ensure
all Fire Fighting System pipe works has been completed, tested & approved
by the Consultant.
Ensure
all sprinkler heads have been installed & fix properly with the correct
alignment & spacing.
Ensure
firmness & tightness of supports prior to Commissioning of the equipment.
After
satisfactorily verification of installation & testing records & visual
checks for the Fire Fighting Equipment, commissioning shall commence.
Close
the gate valves after all the PRV station in the building.
Start
pressurizing the high pressure lines using the fire pumps up to the required
system pressure.
Adjust
the PRV to reduce the pressure after the PRV Valve to the required system
pressure.
Maintain
the pipes pressurized & re-check visually if there are any leaks for about
2 hours.
Close all
the zone control valves, landing valves inside the cabinets & lock shield
valves of the hose reels.
Open the
gate valve after the PRV valve & start pressurizing the riser pipes &
cabinets using the fire pumps.
Check
pressure in all floors by using special adapter with calibrated pressure gauge.
Record the reading.
Start
opening the zone control valves for each floor & check for any leaks for
about 2 hours.
After
pressurizing the whole system. Keep it for 24 hours for observation.
Open the
drain valves of the zone control valves floor by floor. Alarm system should
indicate fire signal in the building.
Close
the zone control valves floor by floor & alarm system should give fault
signal.
Commission the alarm check valve in the pump room by opening its drain line
& check the mechanical bell performance.
Open the lock shield valves for each hose reel & adjust its pressure to 3-4 bar through the PRV using special nozzles with pressure gauge. The water flow should be at least 6 meters. (Hose reel should be open outside the building to avoid any damages to other services).
8.0. ATTACHMENTS
8.2. Inspection & Test Plan
8.3. Installation Check Sheet
8.4. Testing Check Sheet for Fire Fighting Piping System
8.5. Testing & Commissioning Check Sheet
8.6. Risk Assessment
Ref: NFPA, OHS & Internet.
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