Method Statement For Installation of Chiller Pipe

RAKAN TRADING &
Royal Commission for

CONTRACTING
Jubail and Yanbu
COMPANY
INSTALLATION & TESTING

Document Type:
Method statement FOR CHILLED WATER PIPES
Method Statement
Company Name: Rakan Trading and Contracting Company
Contract Name: P&C of Labor Camp – Phase 1
Contract No: 021-C09
Document Number: 01-710-00
Method Statement for

INSTALLATION & TESTING FOR CHILLED WATER
PIPES
Method Statement No: 63

Rev.
Date Description Prepared Checked
No
METHOD OF STATEMENT
FOR
CHILLED WATER PIPING &
ACCESSORIES
1 19-11-2019 QC, MECH C.M
INSTALLATION & PRESSURE
TESTING
Page 1 of 16 CONTRACT NO. 021-C09

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

Document Type:
1. Description of Works
Supply, installation & Testing of the chilled water piping and its accessories for all
applications in line with project requirements.
2. Location and Work Limits (Area/Site Specific Layout)
Dining building, Pump Room, Chiller area
3. Access/Egress
SEE ATTACHED TMP
4. Protection and Isolation Arrangements (e.g 3rd Parties)

Area Protection/Isolation Measures
Dining Building, pump room, chiller Barricades with signage and proper PPE
area
5. Task Specific Emergency Arrangements

In –case of emergency foreman / site engineer shall informed immediately the site
male nurse for rescue operation / first aid.
1. Site male nurse accompanied by the ambulance driver with the first aid kit will
apply first aid to the injured person.
2. Follow the emergency call tree.
6. Work Methodology
Number Activity Description and sequencing
1. Material Storage & Handling

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

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On receipt of the material at site, necessary precautions shall be taken for

unloading, shifting, and storage as follows:
 All material shall be inspected, handled and stored properly upon receipt
at site.
 It shall be stored in a place free of water, dust and adequately covered to
avoid any kind of damages.
 All insulation materials shall be inspected for the thickness and densities.
 While unloading, shifting and storage, it should be ensured that there are
no transit damages.
 Any discrepancies, damage, and etc. found to the materials will be
notified and reported to QA/QC Engineer and Project Engineer for further
action.
 Materials found not suitable for site use should be removed from site
immediately.
2. Pipes preparation
 Before primer, all dirt, dust, grease, oil or other foreign matters shall
be removed by scrapers, wire brushes and solvents or grit blasting if
required.
 All finished surfaces shall be free from runs, drops, ridges, waves,
laps, brush marks and variations in color, texture and finish.
Coverage shall be complete, and each coat shall be so applied
as to produce a film of uniform thickness. Special attention shall
be given to ensure that all surfaces including edges, corners,
crevices, welds and rivets receive a film thickness equivalent to that
of adjacent painted surfaces.
 Adjacent areas and installations shall be protected by the use of
masking tape, drop cloths or other approved precautionary
measures. Metal surface adjacent to surfaces to receive water

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

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thinned paints shall be primer and/or touched-up prior to the

application of water thinned paints.
 The first coat on render or board finishing shall include such repeated
touching up of suction spots to produce a uniform color.
 Paint only in a well-ventilated area for avoided poisoning with thinner.
 Attention to all material and floor on the painting area for avoid paint
dripping and damages.
3. Pipe painting @ ground level and touch up above (RC specification shall be
followed)
a) Primer coat (Anticorrosive primer paint)
After pipe surface cleaned primer paint shall be applied immediately
i. red oxide paint as approved from RC engineer
2
ii. Spreading rate: 0.182kg/m /coat
iii. Paint brush or roller coating
b) Second coat (Finishing primer paint)
After pipe installation and prior insulation
i. red oxide paint as approved from RC engineer
2
ii. Spreading rate: 0.059kg/m /coat
iii. Paint brush or roller coating
4. Installation of Chilled Water piping
 The proposed chilled water pipes above grade is black steel SCH 40 in
accordance to ASTM A-53 Grade-B SCH-40 as per manufacturer
recommendation and approval.
 Fix the sleeves as per approved shop drawings and specification, during
the construction of structural elements.
 Pipe sizes 65mm and larger shall have welding joint. Pipe sizes 50mm and
smaller shall have threaded ends as per manufacturer recommendation.
Also refer to point #. 7.4.1 for threaded connection procedure and 7.4.2
for welding connection procedure.

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

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 Welding of the pipes must be as per specifications and approved

procedure.
 Mark the location of piping as per specification and approved shop

drawing.
 Install approved supports, brackets for piping as per specification,

approved shop drawings and site requirements for each individual case
(ie. Slab, Wall etc.).
 Supports shall be installed as per pipe manufacturer’s recommendations.
 Readymade hardwood / rubber support insert shall be used for

supporting the vertical chilled water piping, which is placed on galvanized
L angle or U channels and fastened with GI threaded rods.
 Flexible Pipe connectors shall be installed at all air handling units, pumps,
and chillers.
 All the open ends of the pipes shall be protected properly at the end of
each day’s work.
 Drains shall be installed at low points in mains and branch lines (Vertical /
Horizontal) consisting of gate valve and short threaded nipple and cap so
that the system shall be drained completely.
 Valves, Piping specialties and accessories shall be installed as per

manufacturer recommendation and approved shop drawings.
 Unions shall be provided adjacent to each screwed type valve and shall be
on the outlet side of the valve.
 All valves shall be installed suitably to permit easy access for future
maintenance.
 Eccentric reducers shall be installed in Horizontal chilled water system &

concentric reducers shall be installed in vertical chilled water system.

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

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 Automatic Air vents shall be installed at high points and where ever
required in order to trap air from the chilled water system.
 Air separator to be installed within the networks.
 Condensate drain piping shall be connected to the equipment drain pan

connections as per approved shop drawings.
 Condensate drain piping will be extended to the nearest floor drain and
connected to the drain system.
 Plug all open ends of pipes at the end of each day’s work using end caps.
 Raise Request for Inspection of Installation of Chilled Water Piping and

fittings including supports / brackets, valves, piping specialties and
accessories as per the approved shop drawing, by Consultant.
 After approval of installation of pipes and fittings, flushing shall be done

for chilled water Pipes with clean water to remove dust and debris that
might have been present during construction work.
 Plug all connections / branches / drains and fill with clean water for hydro
testing.
1.) Threaded connection procedure.
 Use the appropriate sealing material.
 The internal parallel threads of the fitting have to

be joined to the taper external threads.
 The surfaces of the treads have to be cleaned

before being threaded.
 The sealing material has to be applied

homogenously and thoroughly on the external
thread, using only sealing material suitable for
the application.

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

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 A film of lubricant should be applied on the

surface to be threaded in order to prevent the
sealing material from getting stuck and thus
avoid irregularities in the sealing effect.
 Check if all axes of the different threaded joint

components are aligned according to the
tolerance.
 Scissor lift will be used in most areas but if not

accessible we will use scaffolding
(2.5Mx2.5Mx3M).
Welding connection procedure @ above

In order to ensure that all welding takes place in safe manner, the following will
be defined:
I. Welders
II. The welding Equipment
III. Working requirements
A. Welder:
I. The welders to be trained and certified
II. The welder must be healthy
III. The welder must be trained for safe work i.e.
toolbox talk etc.
B Equipment:
On site, arc welding is usually carried out with direct current (DC), supplied from
diesel driven generator or Power source. Welding leads and welding return cables
are frequently dragged over rough surface, their insulation should therefore be
suitable for resisting fear and wear.
I. The cables and couplings should be examined

frequently for defects.
II. The part of the cable which connected to the
electrode holder should be as flexible as possible.
III. The welding return should be firmly connected to
the metal by constructed clamp.

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

Document Type:
IV. Electrode holder should be fully insulated.

V. Electrode holder is essentially a pair of spring-
loaded jaws.
VI. The electrode holder must be made from good
quality material.
C welding procedure specification:

I. Raise the pipe up to the required location. position
and tighten pipe support to secure the pipe the
pipe shall be checked for correct level, alignment
and position if necessary, adjust the pipe support
or re-level the pipe
II. The pipe shall be chamfered to 45 degree using the
angel grinding machine and groove size and groove
will be as standard.
III. Electrode (molted metal) shall fill the groove and
stele properly. E6010 Class welding electrodes shall
be used for first root run and E7018 class for
second and final run root.
IV. The skilled welder will start a root welded, and wire
brush the root joint so that the flux on the joint is
completely removed, if necessary, grinding will be
performed to remove the flux.
V. After allowing the joint to solidify for few minutes
the second and final weld shall be performed and
flux shall be remover after each weld as mentioned
in point 3.
VI. Dye penetrant test shall be conducted on all
welded joints and initiated by third party.
D Working requirements:
I. Arrange good ventilation in case of welding

enclosed resets.
II. Insulated materials will be used in case of wet
floor.
III. Working instructions.
IV. Fire extinguisher required with welding all the
time.
RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

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V. Screens to be used when necessary, available all

the time.
VI. Avoid welding near flammable materials.
VII. Checking area before leaving is strongly required.
VIII. Monitoring of the area for gasses will be done.
5. Testing of chilled water pipes and fittings
 Care shall be taken to all the equipment’s, apparatus, devices to a

pressure exceeding its prescribed test pressure as obtained from its name
plate data or product catalogues.
 Care shall be taken to Equipment’s, apparatus and devices that might be

damaged by the test pressure shall be removed or blanked off.
 Ensure All Valves are in open condition before starting pressure test, NO
pressure shall be applied against closed valves.
 Ensure Temporary blank flanges are anchored firmly in a way to

accommodate all developed end trust.
 The Piping system shall be tested closed by plugging all openings in the
system in a proper way and filled slowly with water.
 Ensure all system is free from air lock, if so all the vent all entrapped air
from the system.
 Ensure water is reached to the entire system by releasing plugs

temporarily.
 Pressure shall be applied to the system by means of hand pump drawing

from a water container. The pump discharge shall be connected to the
system through a globe valve, check valve and calibrated pressure gauge
of suitable range to have the test pressure range in the middle of the
range.
 Subject the Cold-Water piping to hydro test, Test pressure shall be at

least 1.5 times the working pressure for 4 hours.
 Ensure Test pressure is same at highest point of the system.

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

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 Repair the leaks and defects if any until satisfactory results are obtained
 Raise Request for Inspection of hydro testing to witness the same, by

Consultant.
 After approval of inspection of hydro testing, release the water gradually

and protect the piping installation, and end cap the pipe.
 DPT shall be conducted on all welded joints.

6. Insulation of chilled water piping
 Check all required approved chilled water pipe insulations materials are
readily available on site.
 Aluminum jacket shall be used for all external piping it should be as per
RC approval.
 Pipes shall be generally insulated as per scope of work with rigid sections
of aluminum foil faced glass fiber/rock wool fiber insulation with density
of not less than 64 Kg/m3 having a thermal conductivity factor of 0.029
w/m.k at 10 deg. C.
 Internal chilled water pipes (inside buildings) shall be insulated as per

scope of work by not less than 40mm thick rigid insulation for pipes up to
40mm dia and 50mm for pipe sizes 50mm dia and above.
 External chilled water pipes (on roofs and in chiller yard) shall be
insulated as per scope of by not less than 50mm thick rigid insulation for
pipe sizes up to 40 mm dia and 75 mm for for 50mm dia and above.
 For both internal and external pipes, the insulation shall be finished as
per scope of work or finished with a water proof 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.
 Where insulated pipework is run on roof, in plant room, chillers yard and
tunnels it shall be clad using an outer covering of plain aluminum sheet of
0.7mm or thicker.

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

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 Where exposed, insulated pipework runs through occupied or public

areas it shall be clad using an outer covering of plain aluminum sheet of
0.7 mm or thicker as per manufacturer recommendation in the material
submittal.
 Make-up for pipe insulation shall be provided for consultant review and
approval.
 Apply the approved insulation materials and accessories according to

specification and manufacturer instructions.
 Ensure all insulation materials are in dry condition during the application.
 Pipe surface shall be cleaned properly and painted as per specification.
 Apply insulation with longitudinal seams at top and horizontal pipe runs
 Pipe insulation shall be applied with least number of joints.
 Approved adhesive shall be applied in longitudinal seam and end faces of

the insulation and entire pipe surfaces as per Approved material.
 For flanges, elbows, fittings and valves mitered section of pipe insulation
of same material shall be used.
 Permissible access shall be maintained to the valves to operate without

disturbing the insulation.
 In case of rising steam valves used in chilled water system, insulation shall
be extended and insulation joints and valve seams shall be sealed
properly in order to prevent passage of air to pipe surface.
 Aluminum tape shall be applied on the joints of insulation segments

properly as per manufacturer recommendation.
 Cover the approved THERMOFOIL sheet properly on the entire

circumference of the Insulated duct and pull sheet tight and smooth.
 Use Thermo foil recommended Tape to seal the joints in a way no air can
penetrate through the joints

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

Document Type:
 Raise request for inspection of Insulation of Chilled Water Piping, by

Consultant.
 Identification for Chilled Water Supply and return line and valves and
specialties shall be done as per specification with approved identification
materials. RC specification for identification requirements must be
followed.
 Raise request for inspection of Identification of Chilled Water Piping and

Accessories, by Consultant.
7. Resources
a. Site Key Personnel and Workforce

No.
Title Task Specific Training Required (if applicable)
Required
Site Engineer 01 Safety Induction, MEPI training, Working at height training,
Rules for driving & operating heavy equipment.
Foreman 02 Safety induction, MEPI training, working at height training.
Welder 03 Safety induction, MEPI training, working at height training.
QC Mechanical 01 Safety induction, MEPI training, working at height training.
Engineer
Scaffolder 03 Safety induction, MEPI training, working at height training,
scaffolder TPC.
Scaffold 01 Safety induction, MEPI training, working at height training,
Competent scaffolder TPC.
Person
Safety Officer 01 Safety induction, MEPI training, working at height training.
Forklift Operator 01 Safety induction, MEPI training, working at height training.
TPC, Rules for driving & operating heavy equipment.
Scissor lift 01 Safety induction, MEPI training, working at height training.
Operator TPC, Rules for driving & operating heavy equipment.
Competent 01 Safety induction, MEPI training, working at height training.
mechanic Valid Saudi license, Rules for driving & operating heavy
equipment.

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

Document Type:
Electrical 01 Safety induction, MEPI training, working at height training,

competent Electrical training (cable management, maintenance) LOTO
person training.
b. Plant and Equipment

Item Specific Requirements
Welding Machine Quarterly color code, Daily inspection
Cutting Machine Quarterly color code, Daily inspection
Water pump Quarterly color code, Daily inspection
Safety Relief Valve TPC, Quarterly color code, Daily inspection
Pressure Gauge TPC, Quarterly color code, Daily inspection
Manifold TPC, Quarterly color code, Daily inspection
Threading Machine Quarterly color code, Daily inspection
Chain Block TPC, Quarterly color code, Daily inspection
Forklift TPC, Daily checklist, operated by certified operator with TPC
Scissor lift TPC, Daily checklist, operated by certified operator with TPC
Full body harness Quarterly color code, daily inspection prior to inspection, quarterly
checklist, unique number
Retractable lanyard Quarterly color code, daily inspection prior to inspection, quarterly
checklist, unique number
Scaffolding Daily inspection, tagging system, erected by competent scaffolder
(2.5Mx2.5Mx3M)
Stationary portable Quarterly color code, Daily inspection
Electrode ovens
c.
Materials and Tools
Item Reason for use
Drill machine / Portable drill For Drilling
Measuring tape For measuring
Steel Hammer For hammering
Spirit Level For leveling
Hole saw Cutter For cutting hole
Marking Pen / Chalk Line For marking

RAKAN TRADING &
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d. Chemicals Required
Item MSDS Number Specific Requirements
01 95370 Wear protective gloves/protective
clothing/eye protection/face protection. Eye
wash station.
02 29208 Wear protective gloves/protective
clothing/eye protection/face protection. Eye
wash station.
03 OK 63.30 (Electrode) Use respirator or air supplied respirator. Wear
hand, head, eyes, ear and body protection like
welders gloves, helmet or face shield with
filter lens, safety boots, apron, arm and
shoulder protection. Eye wash station.
04 ZL-60D Wear protective gloves/eye protection. Eye
wash station.
05 NPD-4 Wear protective gloves/eye protection. Eye
wash station.
e. Task Specific PPE Required (Refer control measures from Risk

Assessment)
Item Reason for use
Welding Helmets with filter plates Help protect users from arc rays and from weld sparks and
spatters that strike directly against the helmet.
Flame Resistant gloves, Arm protection.
Flame-resistant aprons To provide protection to the front of the body.
Air-purifying or air-fed respirator Use during hazardous work painting activity.
Full body harness During working at height a full body harness is required for
the involved person.
Retractable lanyard Use for fall arresters.
Note that all works require mandatory PPE as follows Hardhat, gloves, safety glasses, safety
boots, hi-vis vest.
8. Interfaces – Other sites, work activities, general public etc.

Interfacing party or activity Description of Interface
N/A N/A

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

Document Type:
9. Permits
Permit Type Issued By Additional Information (Reference No. etc)
Hot work permit Foreman Inspected by the safety officer
10. References Drawings / Specifications / Other

Document Number Title
021-040-22RG-ME-6115-1 CHILLED WATER PLANT LAYOUT
11. Risk Assessment (See attachment)

12. Other Documents (See attachment)
o Safe Sequence of Work
o Organizational Chart
o Emergency Procedure
o Call Tree Notification
o Third Party Certificate Details
o TMP
o Pipe Details and Chain Block
o Pipe pressure testing schematic diagram
o Procedure Qualification Record
o Welding Procedure Specification
o Welder’s Certificate Details

RAKAN TRADING &
CONTRACTING
Jubail and Yanbu
COMPANY

Document Type:
WEIGHT OF CHILLED WATER PIPES

S/N SIZE OF PIPE (MM) WEIGHT OF PIPE (KG)
1 20 10.14
2 32 20.4
3 50 32.64
4 100 96.42
5 150 169.56
6 200 255.3
7 250 361.74
8 300 478.2
Product description
Chain Block Safe Working Load - 1 Ton (1000KG) Lift - 6 Meters Minimum Distance Between Hooks -
340MM Chain Falls - 1 Load Chain Diameter - 6MM Hand Chain Length - 5.8 Meters Factor Of Safety
- 4:1 Conforms To: BS EN 13157: 2004+A1: 2009 These Are Manufactured With A Chain Guide To
Provide Smooth Chain Operation And Lightweight Steel Construction For Ease Of Use And Transport.
The Safety Hooks Are Drop Forged And Heat Treated To Ensure Safety And Durability.

P&C OF LABOR CAMP PHASE-1
Contract # 021-C09
THIRD PARTY DETAILS

EQUIPMENT
S/N NAME TPC EXPIRY DATE REMARKS
1 Scissor Lift 31 December 2019 Active
2 Fork Lift 11 November 2019 Active
OPERATOR
S/N NAME TPC EXPIRY DATE REMARKS
1 Geronimo Jr. Ostaga (Scissor lift operator) 19 August 2020 Active
2 Muhammad Arif (Forklift operator) 19 August 2020 Active

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Method Statement For Installation of Chiller Pipe

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RAKAN TRADING &

Royal Commission for

INSTALLATION & TESTING