003 MS Pumpset

Project: WORLD TRADE CENTER DOHA QATAR Title of the Document Reference No.
QC-MS-FF-005 Method Statement for the Installation of Fire Pump set Revision No Date 00 25 JULY 2011
Page No. 2 of 13
Table of Contents
Sr. No. 01 02 03 04 05 06 07 08 09 10 11 12 13 14 Contents Scope of work References Definitions Responsibilities/ Supervision Description of Work Plant Requirement Manpower Requirement Temporary works to be designed and Installed Health and Safety Requirements Environment requirements Security arrangements Special Contractual Arrangements Records to be produced Attachments
Page 3 3 3 3 4-8 9 9
9 10 10 10 10 10
Project: WORLD TRADE CENTER DOHA QATAR Title of the Document Reference No. QC-MS-FF-005
1.0.
Method Statement for the Installation of Fire Pump set Revision No Date 00 25 JULY 2011
Page No. 3 of 13
Scope & Objective
This method statement covers the detailed procedure for installation of pressure reducing valve assembly. This procedure defines the method used to ensure that the installation of pressure reducing valve is carried as per the contract specification requirements and the approved drawings of Qatar World Trade Center
2.0.
References
Contract Documents:
Specification : 15310, 2.09 NFPA 13, 2007 Edition Standard for the Installation of Sprinkler System NFPA 14, 2007 Edition Standard for the Installation of Stand pipe and Hose systems NFPA 20, 2007 Edition Standard for the Installation of Fire Pumpset The Local Fire Authority, Qatar Civil Defence Directorate Shop Drawings: Marked ISSUED FOR CONSTRUCTION
3.0.
Definitions
Fire Protection System. Any fire alarm device or system or fire extinguishing device or system, or their combination, that is designed and installed for detecting, controlling, or extinguishing a fire or otherwise alerting occupants, or the fire department, or both, that a fire has occurred Electric Motors. Motors that are classified according to mechanical protection and methods of cooling. Fire Pump Controller. A group of devices that serve to govern, in some predetermined manner, the starting and stopping of the fire pump driver as well as monitoring and signaling the status and condition of the fire pump unit. Fire Pump Unit. An assembled unit consisting of a fire pump, driver, controller, and accessories. Flooded Suction. The condition where water flows from an atmospheric vented source to the pump without the average pressure at the pump inlet flange dropping below atmospheric pressure with the pump operating at 150 percent of its rated capacity.
Project: WORLD TRADE CENTER DOHA QATAR Title of the Document Reference No. QC-MS-FF-005 Method Statement for the Installation of Fire Pump set Revision No Date 00 25 JULY 2011
Page No. 4 of 13
Total Discharge Head (hd). The reading of a pressure gauge at the discharge of the pump, converted to feet (meters) of liquid, and referred to datum, plus the velocity head at the point of gauge attachment.
4.0.
Responsibilities/ Supervision
Project Manager shall have the overall responsibility of the project for execution, quality and
safety. He shall maintain the planning progress and co-ordination of works with main contractor. 4.2 Project/ Site Mechanical Engineer(s) shall be responsible for monitoring of the day to-day activities on site, for materials, drawings, allocation of resources to work areas on site and testing & commissioning. He shall report to the Project Manager. 4.3 Supervisor/ Charge Hand shall be directly responsible for the day-to-day job at site, for coordinating of work with Technicians or any other staff assigned his area. QA/QC Department will be overseeing the quality requirements and quality control measures for the project in coordination with Project/Site Engineer(s). Safety Officer shall be responsible for the health & safety aspects on site as per the ARABTEC/EFECO safety Manual.
4.1
4.4 4.5
5.0
Description of works
5.1
Pre Installation Check
5.1.1 Ensure that all safety requirements are in place in accordance with project
safety plan 5.1.2 Ensure that the latest revision of the approved working drawing is being used. 5.1.3 On receipt of material on site, QA/QC engineer/ Site Engineer shall inspect the material internally and inspection shall be offered to the engineer for approval in MIR ( Material inspection request form) 5.1.4 Ensure that the all materials used have passed receiving inspection in accordance with QA procedures and are not damaged or defective. Any nonconforming materials must be labeled by store keeper and returned to quarantine area in accordance with procedure. 5.1.5 Ensure that all the pipe fitters and helpers are aware of the correct materials handling and installation procedure to ensure that best quality of workmanship. Training shall be provided by site engineers / Supervisor as and when required. 5.1.6 Ensure space & access for installation is available at correct location as per the approved drawing and site conditions. 5.1.7 Check the tools required to install the Electric driven Pump, Diesel driven pump and Jockey pump with respective controllers and accessories. 5.1.8 Site Engineer shall ensure that correct tools are available and precautions are taken to install the Fire Pump set as per NFPA 20, recommendation of manufacturer, Local civil defense authority and project specification to achieve compliance with contract requirement.
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FIRE PUMPSET ASSEMBLY CONSISTS OF FIRE PUMPSET AT BASEMENT 4 1250 GPM @ 290 PSI Electric Driven Pump Diesel Driven Pump Jockey Pump Pump controllers ( 3nos) Diesel Tank Suction and Delivery valves GI ASTM SCH 4O Pipes. Flow Meter Air Release valve Pressure relief Valve FIRE PUMPSET AT BASEMENT 4 Electric Driven Pump Jockey Pump Pump controllers ( 3nos) Diesel Tank Suction and Delivery valves GI ASTM SCH 4O Pipes. Flow Meter Air Release valve Pressure relief Valve Note : Please refer the approved shop drawing for Exact pump capacity
Page No. 6 of 13
5.2
INSTALLATION OF FIRE PUMPSET

Before attempting to install the equipment it is important to familiarize yourself with the main items supplied and to ensure that the appropriate cables, pipes and fittings are available to mount and connect the equipment. Fire water pump sets and control systems should be Installed, and Accepted, in full accordance with NFPA 20. The pump should be installed as near to the water source as possible, with the shortes and most direct suction pipe practical. Allow sufficient access for inspection and maintenance with enough headroom for a sufficient capacity to lift the heaviest item of equipment. The location for a diesel engine driven pump may be dictated by the requirement of as the exhaust runs should be as short as possible. Small bore pipe and/or excessive length will cause backpressure on the engine, reducing engine performance and therefore pump output A foundation plinth should be constructed to support each pump set on a floor area free from expansion joints. These foundation plinths should be sufficiently substantial to absorb vibrations and rigid enough to avoid any twisting or misalignment. As a rough guide, they should be at least 12 inches wider than the pump set on all sides and weigh between 1 and 1.5 times the weight of the pump set. Plinths for fire pumps are recommended to have a minimum height of 300mm but height should be sufficient to achieve the necessary weight and to accommodate the pockets for fixing bolts. Ensure that the Chemical bolts are available as foundation bolts. It is important to install fire pump sets BEFORE installing the main suction and delivery pipe work. This is to ensure that the pipes are positioned to match the pump location and do not transmit load an induce strain in the pump casing. For long coupled pump sets, remove the coupling guard to provide access to the shaft and coupling.
INSTALLATION THE ELECTRIC AND DIESEL DRIVEN PUMPSET(S)

For chemical anchor fixing with channel section base frames it will be necessary to mount the pump set, mark the foundation bolt positions and lift off the pump set to give access for drilling. Hang the anchor bolts in their holes and lower the pump set in position having inserted the anchors into their fixing holes. After allowing sufficient time for the bond to cure, tighten the anchor bolts to the torque setting recommended in the manufacturer's instructions. Whilst tightening the fixing bolts check the shaft level and coupling alignment and if required, adjust the packers to maintain the shaft level and the coupling alignment within acceptable figures. The pumps and drivers were shipped from the factory with both machines mounted on a common base plate; they were accurately aligned before shipment. All base plates are flexible to some extent and, therefore, should not be relied upon to maintain the factory alignment. Realignment is necessary after the complete unit has been leveled on the foundation and the foundation bolts are tightened. After the pump and driver unit has been placed on the foundation, the coupling halves should be disconnected. The coupling should not be reconnected until the alignment operations have been completed.

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A check for angular alignment is made by inserting the taper gauge or feelers at four points between the coupling faces and comparing the distance between the faces at four points spaced at 90-degree intervals around the coupling. The unit will be in angular alignment when the measurements show that the coupling faces are the same distance apart at all points. A check for parallel alignment is made by placing a straight edge across both coupling rims at the top, bottom, and at both sides. The unit will be in parallel alignment when the straight edge rests evenly on the coupling rim at all positions. Allowance may be necessary for temperature changes and for coupling halves that are not of the same outside diameter. Care should be taken to have the straight edge parallel to the axes of the shafts.
Angular and parallel misalignment are corrected by means of shims under the motor mounting feet. After each change, it is necessary to recheck the alignment of the coupling halves. Adjustment in one direction can disturb adjustments already made in another direction. It should not be necessary to adjust the shims under the pump. When the alignment is correct, the foundation bolts should be tightened evenly but not too firmly. The unit should be checked for parallel and angular alignment, and, if necessary, corrective measures taken. Ensure that all alignment checks are made with the coupling halves disconnected and again after they are reconnected. Install the diesel engine driven pump in the same procedure as above. Now the electric and diesel driven pump is ready for suction and delivery pipe works with valves.
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ELECTRIC DRIVEN PUMP ( GENERAL ARRANGMENT)
DIESEL ENGINER DRIVEN PUMP ( GENERAL ARRANGEMENT) Note : Please check the material submittal and shop drawing for specifications and arrangement for this project.
INSTALLATION OF JOCKEY PUMP

Ensure that the pump was not damaged in shipment before accepting delivery and Installation. If damage is evident, please report to the project engineer immediately. Ensure that the pump labels against the requirement to make sure you are installing the proper pump specified for the job. For chemical anchor fixing with channel section base frames it will be necessary to mount the pump set, mark the foundation bolt positions and lift off the pump set to give access for drilling. Hang the anchor bolts in their holes and lower the pump set in position having inserted the anchors into their fixing holes. After allowing sufficient time for the bond to cure, tighten the anchor bolts to the torque setting recommended in the manufacturer's instructions. Make sure that the pump suction, marked by a sticker, is connected to the liquid source and that the discharge, similarly marked, is connected to the discharge side. Make sure that the pump base is firmly secured to a solid flat surface and that the suction and discharge lines are aligned and properly supported to prevent pipe strain on the pump. Ensure that the suction and discharge gaskets are properly installed to prevent leaks and that they do not restrict the flow to or from the pump. Ensure that the Standard ANSI mating flanges should be used to connect the pump to the piping. Suction and discharge piping should be no smaller than the respective pump port sizes.
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Ensure that the adequate space and ventilation around the pump are available for service and motor cooling. Now the pump suction and delivery lines shall be connected.
INSTALLATION OF SUCTION AND DELIVERY LINES

Ensure that pipe, valves and fittings having pressure rating equal to or greater than the maximum system pressure. Ensure that the pipes and fitting are available as per project specification and approved by consultant. Install all the suction pipes and Delivery pipes as shown in the drawing by following the procedure of Installation of Fire Protection pipes & fittings. Both suction and discharge piping should be supported independently and close to the pump so that no strain is transmitted to the pump when the flange bolts are tightened. Use rigid supports at intervals to provide adequate support. Ensure that the expansion joints installed beyond the piping supports closest to the pump. Ensure that suction and delivery lines are connected with proper reducer as shown in the approved drawing and as per the drawing shown below. Ensure that the check valve are installed properly and with the rated pressure as the large fire protection systems experience severe water hammer caused by backflow when the automatic control shuts down the fire pump. Where conditions can be expected to cause objectionable water hammer. Automatically controlled pumps in tall buildings could give trouble from water hammer as the pump is shutting down.
Ensure that the Gate valves, Butterfly valve are installed as per the method statement respectively. All the valves shall be installed as shown in approved shop drawings and ensure that the valves are rated for the system working pressure.
Page No. 10 of 13
After installation, pipes and fittings with valve connections must be tested in accordance with the recognized installation standards. If a leak occurs on the groove joints, normally the unit must be removed and the joints should be done again or the coupling has to be replaced with the gasket. This is due to the fact that the groove of the pipe might more or the groove fittings gasket might be damaged or the coupling is not installed properly. The inspection should include a visual check for leakage at the valve pipe connection and body to operator connection Final touch up of painting is to be done if required. The valve shall be kept in close condition until the fire protection system is energized. Conduit and electrical connections to the electrical controllers must be in accordance with National Electrical Code (NFPA 20, 70 & 72) and requirements of the local authority having jurisdiction. Final touch up of painting is to be done if required.
INSTALLATION OF CONTROLLERS
Ensure that the location of the electric motor starter panel is in a convenient position for use. Ensure that wiring drawings are available inside the controllers. The electric panel is supplied with a base frame which shall be used to installing the panel in the foundation base or on the floor. Mount the electric controller by using the provision provided below the electrical starter pane and wire up to mains supply, to the electric motor and to the trunk main pressure switch. Ensure that the Earth bonding connections are provided on all base frames and must be connected to a suitable earth point. For Diesel engine control panels, mount the panel in a convenient position for use and wire up to the diesel driven pump set following instructions on the wiring diagrams supplied in the manual. Connect the control panel to the mains electrical supply as shown in the wiring diagram. For Jockey pump panels are mounted with a suitable support from the floor to ensure that the panel switches are in operating level. Mount the jockey pump panel in a convenient position for use and wire up to the electric pump set following instructions on the wiring diagrams supplied in the manual.
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Connect the control panel to the mains electrical supply as shown in the wiring diagram. Ensure the cables are connected with proper compression glands and after testing the cables. Ensure the visual check is arranged for the installation of the cables to the motor, main supply and to the batteries. Ensure that the batteries cables are not connected until the system is energized. Ensure that the power is switched off until the system is energized.
INSTALLATION OF DIESEL TANK

The fuel tank is supplied separately, it is intended to be positioned it in a safe location with convenient filling access and giving short and direct fuel line runs. When a fuel tank stand is supplied it is normally designed to be fixed to a floor having the same level as the pump house. If a stand is not supplied or when special conditions apply, reference should be made to the diesel engine manufacturer's instructions for guidance on the correct level to mount the fuel tank. It is important to comply with the requirement for gravity fuel feed to fire pump engines and to provide access for refilling and topping up the fuel. Mount the diesel tank in the position as shown in the approved drawing and ensure that the fuel is having gravity to feed to fire pump engine. The fuel gauge is normally supplied loose and must be fitted to the fuel tank as shown in the diesel tank drawing. Install the fuel connection tube and accessories as shown in the diesel tank arrangement drawing. Fill the tank with sufficient fuel for one hour during commissioning.
INSTALLATION OF COOLING SYSTEM FOR ENGINE

Ensure that diesel engine arrangement drawing is available before installing the cooling system The Diesel engine is supplied with Heat exchanger closed circuits are cooled by a supply of coolant from the pump discharge.

Page No. 12 of 13
Please check the inlet connection and outlet connection flange of the heat exchanger in the diesel engine arrangement drawing. Connect the Inlet pipe to pump discharge with a mechanical tee on the discharge line. Install the flow control system to prevent continuous flow of water to waste under standstill conditions. This supply is passed through the heat exchanger and is then piped to waste. Final touch up of painting is to be done if required.
6.0
PLANT
REQUIREMENT
Wrench Box Spanners Round Ended Spanners General tools Hole saw machine Dial Gauge Feeler Tape Drilling Machine Lifting tools Pump aligning tools
Engaged personnel on site will wear or use the following safety equipment as appropriate: Hard hats, safety boots, overalls / work wear, high visibility clothing, safety goggles, gloves and Masks.
Protective clothing / equipment 7.0
MANPOWER REQUIREMENT
Manpower requirement like Site Engineer, Supervisor/ Foreman, and pipe fitters depends upon the planning organization chart and site progress of works.
8.0.
TEMPORARY WORKS TO BE DESIGNED & INSTALLTED

All the Safe Working Scaffolding Platforms will be installed in compliance to safety standard requirements.
9.0.
HEALTH AND SAFET REQUIREMENTS
Page No. 13 of 13
Implementation of Health & Safety mechanisms and checks shall be done as per contract agreement and the approved EFECO safety manual. The safety officer shall carryout the necessary routine inspections. Safety Lighting : Safety lights will be used in case of power failure ensuring good illumination for the personnel. Green color safety jacket shall be worn on site for all personnel who are in site. Task Lighting : Adequate lighting will be provided ensuring the good illumination of the working area. Task Lighting will be connected to the nearest site distribution board which is RCD protected. Emergency Arrangements : Site general safety procedure will be followed. In of emergency, the safety officer will stop the work. He will put in to action the emergency arrangements as described in EFECO safety Manual. Risk Control : Risk Assessment and their controls are carried out for the activity / hazard and enclosed with this method statement.
case
following

is not process.
Using Hand Tools Disposal of Waste Material Temporary Site Electrical Supply
The safety officer has the right to stop all the fire fighting works activity, if he satisfied with the safety arrangement on site during installation and testing
10.0
ENVIRONMENTAL REQUIREMENTS
All remedial measures to control all the operations within the environmental legal limits for Information and record.
11.0
SECURITY ARRANGEMENTS
No additional security arrangements over and above those already in place at the site, restricted access to the job site and the maintaining of the boundary fence security guards will be posted on all entrance points being used by vehicles during the camping out of this item of work to control and coordinate traffic movements.
12.0
SPECIFIC CONTRACTUAL OBLIGATIONS

We are executing all the works by following the Project Specifications Section No. 15310 and the related issued For Construction drawings.
13.
RECORDS TO BE PRODUCED
Page No. 14 of 13
The following Form(s) / Checklist(s) shall be prepared and raised to verify the above activity to ensure that the activity is carried out as per the contract requirements.
Inspection Request (IRs) Revision 0 shall be raised along with QC checklist for Fire Pumpset installations QC Checklist for Installation of Fire Pumpset. 14.
ATTACHMENTS
The following documents are enclosed with this method statement:
Form ITPF-03-Inspection and Test plan for Installation of Fire Pump set. QC Checklist for Installation of Fire Pump set. Risk Assessment Form Using Hand Tools ( QC-RAF-01 ) Risk assessment Form Disposal of Waste Materials ( QC-RAF-02 ) Risk assessment Form Temporary Site Electrical Supply ( QC-RAF-03 )
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Project: WORLD TRADE CENTER DOHA QATAR Title of the Document Reference No.

Scope & Objective

Pre Installation Check

INSTALLATION OF FIRE PUMPSET

INSTALLATION THE ELECTRIC AND DIESEL DRIVEN PUMPSET(S)

ELECTRIC DRIVEN PUMP ( GENERAL ARRANGMENT)

INSTALLATION OF JOCKEY PUMP

INSTALLATION OF SUCTION AND DELIVERY LINES

INSTALLATION OF DIESEL TANK

INSTALLATION OF COOLING SYSTEM FOR ENGINE

Protective clothing / equipment 7.0

TEMPORARY WORKS TO BE DESIGNED & INSTALLTED

HEALTH AND SAFET REQUIREMENTS

SPECIFIC CONTRACTUAL OBLIGATIONS

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