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METHOD STATEMENT FOR
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INSTALLATION
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TABLE OF CONTENTS

1.0 PURPOSE:........................................................................................................................................ 3
2.0 SCOPE:............................................................................................................................................. 3
3.0 LOCATION:....................................................................................................................................... 3
4.0 REFERENCES:................................................................................................................................. 3
5.0 DEFINITIONS/ABBREVIATIONS:.................................................................................................... 3
6.0 RESPONSIBILITY............................................................................................................................. 4
7.0 MATERIALS/EQUIPMENT:............................................................................................................... 5
8.0 WORK PERMITS............................................................................................................................... 5
9.0 SEQUENCE OF WORKS & METHODOLOGY.................................................................................5
10.0 HEALTH, SAFETY AND ENVIRONMENTAL ASSESSMENTS.......................................................6
11.0 QUALITY ASSURANCE AND CONTROL........................................................................................ 7
12.0 JOB HAZARD ANALYSIS................................................................................................................ 7

1.0 PURPOSE:
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METHOD STATEMENT FOR
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2.0 SCOPE:
.

3.0 LOCATION:

4.0 REFERENCES:

5.0 DEFINITIONS/ABBREVIATIONS:

6.0 RESPONSIBILITY
The primary responsibility of carrying out all the activities mentioned in this method statement
rests with the site in charge unless mentioned otherwise.

6.1 PROJECT MANAGER:

Has ultimate responsibility of compliance of work to, relevant methodologies, standards,
specifications listed, while assuring adequate organisation resources to conduct the work.

6.2 PROJECT ENGINEER:

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METHOD STATEMENT FOR
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Will directly supervises site team and has full control over site foremen and equipment and is
responsible to control the site quality during the work progress.

6.3 SAFETY OFFICER:

Will be responsible for the design, implementation, communication and coordination of all
environmental, health and safety programmes for the project. This position will develop and
provide technical and administrative direction on all HSE decisions.

6.4 QA/QC ENGINEER

Responsible for controlling and directing the activities complying with the quality requirements
given in the references. He reports to the project manager.

6.5 QA/QC INSPECTOR

Will be responsible for controlling the site quality during the work progress.

6.6 SURVEYOR
Will be responsible for survey of the whole project

6.7 SITE ENGINEER/SUPERVISOR

A Site Engineer/ Supervisor shall be full time at site when the work is in progress and
accountable for all the HVAC work progress including safety aspect. Under his responsibility to
ensure that all the surrounding involve in the job understand the work, their specific
responsibilities and the immediate action to be taken in case of Emergency.

7.0 MATERIALS/EQUIPMENT:
 Drill machine
 Hammer
 Measuring Tape
 Level Instrument
 Copper Pipe Cutter
 Flaring Tool kit & Manifold Gauges
 Vacuum Pump
 Screw Driver
 Crimping Tool
 Rivet Gun

8.0 WORK PERMITS

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 All necessary work permits will be obtained prior to the commencement of any activity at site and
will remain valid throughout the entire duration of the operation.

9.0 PROCEDURE

9.1 COPPER PIPE INSTALLATION

 Approved for Construction drawing shall be issued to the piping team. The routing shall be
rechecked as per present condition
 Copper pipe of required size and approved make shall be requisitioned from site store.
 Accessories like Bends, joints, Elbows, Reducers, Connection as per reference piping layout
from VRF manufacturer drawing shall be requisitioned from the store.
 On receipt of material, the same shall be rechecked for adherence to specific make & type
 The pipe routing shall be identified from the drawing and marked accordingly.
 Pipe support like GI angle, threaded rod, anchor fastener, clamps, etc. of approved make shall
be made ready.
 Support shall be marked taking into criteria the spacing requirement as dictated by project
specification, QCS & ASHRAE.
 Copper pipe may need to be cut to field dimensions. Make sure that all cuts are made in straight
section of the pipe.
 Mark the location of the cut on the pipe, Copper pipe cutting tool or a power saw can be used to
cut the pipe.
 All the copper pipe field joints should be completed in following manner:
 If the piping has been supplied with end protection, remove all end protection material.
 Properly align each field joints for brazing
 Brazing for each field joints should be done in accordance with the process as per
vendor recommendations.
 Perform pressure test (Nitrogen gas pressure test) of the copper pipe.
 RFI should be raised and relevant inspection shall be made by the QP QA/QC Engineer.
9.2 INSULATION
 Pipeline along with accessories shall be cleaned throughout before thermal insulation
carried out,
 Relevant materials shall be requisitioned from the store as per manufacturer’s
recommendation
 Material inspection shall be carried out by QP Engineers.
 Ensure surface of Copper Pipe are dry and free from duct or grease. Ensure that all pipes &
joints are tested before insulation installation.
 Cut insulation of required pipe size to required length so as to fit around the pipe.
 Apply pipe insulation over the surfaces of the pipe. Adhesive shall be applied on the end
joints and insulated. Rubber insulation shall be chosen 19mm as specified in Project
specification and as per approved materials.
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 Apply vapor barrier coating on thermal insulation surfaces as adhesive for canvas cloth. If
found any leak, apply second coat.
 The insulated copper pipe should then glass coated and identification marking for copper
piping shall be made.
 RFI should be raised and relevant inspection shall be made for QP QA/QC Engineer.

9.5 BASIC STEPS IN JOINTING PROCESS- BRAZING

 Measuring: Measuring the length of the tube must be accurate. If the tube is too short it will
not reach all the way into the socket of the fitting and a proper joint cannot be made
 Cutting: Cutting of tube can be accomplish in a no of different ways to produce a
satisfactory, square-end cut. The tube can be cut either with a disc type cutter, a hacksaw,
abrasive wheel or stationary or portable band saw. Care must be taken that the tube is not
deformed while being cut. Regardless of cutting method used, the cut must be square with
the run of the tube so that it will seat properly in the fitting socket.
 Reaming: Most method of cutting leaves a small burr on the end of the tube. Unless these
rough edges are removed, erosion-corrosion may occur due to local turbulence and
increased velocities in the tube. Tool used to ream tube end includes the reaming blade on
the tube cutter half-round or round files, a pocket knife, or a suitable deburring tool. With
annealed tube, care must be taken not to get the tube end out-off round by applying too
much pressure. Both the inside and outside of the tube may required removal of burr. A
properly reamed piece of tube will provide a smooth surface for better flow.
 Cleaning: cleaning is quickly and easily done. The removal of oxide and surface soil is
crucial if filler metal is to flow properly. Oxides, surface soil and oil can interface with the
strength of the joints and this may result I the joint’s failure. Mechanical cleaning is a simple
operation. The end of the tube should be cleaned using sand cloth or nylon abrasive pad for
a distance only slightly more than the depth of the fitting socket. The socket of the fitting
should also be cleaned using sand cloth, abrasive pad or properly sized fitting brushes. The
same precautions, as where reaming the tube should be observed. Copper is a soft metal; if
too much material is removed, a loose fit will result and interfere with satisfactory capillary
action is making the joints. The capillary space between tube and fittings is approximately
0.004 inch. Solder or brazing filler metal to flow into the gap and form a strong joint.
Chemical cleaning may be utilized, providing the tube & fitting are throughout rinsed,
according to manufacturer’s recommended, further with cleaner. This will help neutralize any
acidic conditions that may exist. The surfaces, once cleaned, should not be touched with
bare hands or oily gloves. Skin oils, lubricating oils and grease impair solder flow and
wetting.
9.3 BRAZING
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 Applying Flux: The flux used for brazing copper joints are different in composition from
soldering fluxes. They cannot and should not be used interchangeably.
 Brazing Flux: Brazing flux are water based. Similar to soldering fluxes, brazing fluxes
dissolves and remove residual oxides from the metal surfaces, they protect the metal
surfaces from deoxidation during heating and they promote the wetting of the surfaces to be
joined by the brazing filler metal. Fluxes also provides the craftsman with an indication of
temperature. If the outside of the fitting and the heat affected area of the tube are covered
with flux, it prevents oxidation and greatly improve the appearance of the joints
 Brazing Filler Metals: There are two general types of brazing filler metal used for joining
copper tube; BcuP (Brazing-copper-Phosphorus) and Bag (Brazing-Silver). These brazing
filler metals are classified according to their components.
 BaCuP Filler Metals: BaCuP Filler metals are preferred for joining copper tubes and
fittings. The phosphorus in these filler metals act as a fluxing agent and the lower
percentage of silver makes them relatively low-cost filler metal. When using copper tub,
wrought copper fittings and BCUP brazing filler metals, fluxing is an option due to the self-
fluxing action of the phosphorus present in all component of the brazed joints
 Heating: Oxy/fuel torches are generally used brazing because of the higher temperature
required. Due to recent innovation in air/fuel torch tip design, they can now be used on a
wider variety of size for soldering and brazing. When working with high temperature, safety
precaution must be followed and care must be taken to protect both the technician and the
material being used. For the heating operation, first preheat the tube and then the tube and
fitting. When the brazing filler metal starts to melt, apply these of the fitting socket to help
draw the brazing filler metal in by capillary action
 Applying Brazing Filler Metal: One thing remembers to allow the heat of the joint to melt
the filler metal, Do not melt the filler metal with the torch. The melted filler metal will be
drawn into the joint by capillary action. It is very important that the flame be in continuous
motion and should not be allowed to remain on any one point long enough to burn through
the tube or fitting. When the joints are complete, a continuous filler should be visible
completely around the joint. If the filler metal fails to flow, or has the tendency to ball-up, it
indicates oxidation on the melted surfaces or insufficient heat on the part to be joined. If the
Filler metal refuse to enter the joint and tend to flow over the outside of either part of joint, it
indicated that this part is overheated or that part is under-heated.
 Cooling and Cleaning: When the joint is complete, allow to be cool naturally. Flux residues
can be removed by washing with hot water and brushing with a stainless-steel wire brush.

9.4 Nitrogen Gas Pressure Test:

 Gas pressure testing for copper pipes shall be carried out section by section as and when
required
 Ensure that the nitrogen cylinder is either secured or located in a position so that it cannot
fall over.
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 Ensure the regulator valve is wound fully (counter clockwise/Anti-clockwise)

 Fit the regulator to the cylinder
 Fi gauge to the system and ensures there is no isolated sections within the part of the
system to be pressure tested.
 Fit the common manifold to hose to the nitrogen cylinder.
 Open the system valve and open the high side manifold valve (to avoid damaging the low
side manifold gauge do not pressurized the low side of the manifold with the test pressure)
 Open the nitrogen cylinder valve and slowly wind the nitrogen regulator in (Clockwise) to
Pressurize the system.
 Ensure only pressurize the relevant sections of the system to their maximum allowable
pressure.
 Listen for audible pressure loss at every pressure increment increase.
 If the leak is identified, the nitrogen should be vented, the leak repaired and the leak
procedure repeated.
 When the maximum system allowable pressure has been reached, close the nitrogen
cylinder valve and the highest-pressure manifold valve.
 Note the pressure shown on the high-pressure gauge.
 Wind the nitrogen regulator fully out (Counter-clockwise/Anti-clockwise).
 Carefully remove the common hose from the regulator, slowly venting the nitrogen pressure.
 Maintain the system at the maximum allowable pressure for the duration of the test.
 Test each joint with leak detection spray or soapy water to identify the leak point. If leaks are
found, they must not be repaired with the system pressurized. Slowly vent the remaining
cylinder.
 Repair any leak found and the repeat the test procedure using OFN. When it is established
that the system is safe and leak tight the OFN can be evacuated. Now the system can be
recharge with refrigerant.


10.0 HEALTH, SAFETY AND ENVIRONMENTAL ASSESSMENTS

 Before commencing any work, it shall be ensured that all permits are valid until the completion of
activity.
 Scaffolding access shall be provided to the excavation area.
 All staff and workmen shall wear Personal Protective Equipment.
 Tool box meetings shall be conducted on every day before the start of the work.
 Both Safety Officer and Worksite Supervisor to be present at site, full time.
 Experienced personnel shall be deployed for the work.
 In a situation where the work involves night shift, Contractor will ensure that there are no
obstructions to the work & appropriate site clearance and lighting is available to carry out the
scheduled works.
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 Muster point shall be free from all form of obstruction and shall have enough lighting during the
period of work. All work access must be free from obstruction. Alarm system shall be in good
condition. Emergency plan and evacuation shall be included in daily Tool box talk. First aid
facilities shall always be available. Periodic test or practice of emergency evacuation shall be
conducted.
 Emergency contact details for key personnel who have specific roles or responsibilities under the
emergency plan, for example fire wardens, floor wardens and first aid officers.
 Contact details for local emergency services, for example police, fire brigade and poison
information Centre shall be displayed at all notice boards
 Emergency signage shall be provided and shall be self-explanatory.
 Sufficient lighting shall be provided for all operations, no exceptions are to be made. Any personnel
working outside the illuminated area shall be directed to return to a lighted area or the operation
shall be stopped.
 All work vehicles, including heavy equipment like wheel loader, compactor, backhoe loader, etc. are
required to have working headlights and taillights respectively. Vehicles without appropriate
lighting should be kept out from working.
 Due to limited visibility at night, a signaller should be mandatory for all reversing operations.
 Any stockpiles or equipment parked in the construction area should be delineated with safety
cones.
 No worker shall be required or knowingly permitted to work in unsafe place, unless for the purpose
of making it safe and then only after proper precautions have been taken to protect the employee
while doing such work.
 Construction areas, rest areas and storage areas etc. shall be illuminated.
 Proper sign boards, lighting, barricades shall be made available at site for smooth workflow.
 All personnel shall be cautioned while working near the pipes/cables.
 Temporary sheds shall be provided to workers while working at site.
 All equipment shall be provided with reverse horns.
 Health and safety risk assessments shall be as per attached JHA.
 Personal Protective Equipment (PPE) Requirement
 Hard hat
 Safety Shoes
 Safety Eye glasses
 Hand gloves
 High visibility vest.
 Red, green flags
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 Coverall

11.0 QUALITY ASSURANCE AND CONTROL

11.1 QUALITY ASSURANCE

 The inspection associated with this method statement will be carried-out in accordance with
inspection and test plan and in compliance with project scope and specifications.
 All equipment and tools that will be used must be in good condition and having valid
calibration certificates