WORK METHOD STATEMENT – CHILLED WATER PIPING INSTALLATION

Job/ Activity/Task: CHILLED WATER PIPING INSTALLATION Ref: MS/SAEPL/HVAC/WMS/005

Codes/Standards applicable:
HVAC PROJECT NAME: MORGAN STANELY – PARIVARTAN
Project Location: Goregaon, Mumbai Area / Floor: 9th to 14th Floor
Risk assessment reference:
Prepared by: Mr. Himanshu Niveriya Reviewed by: Mr. Amod Mande
Designation: Project Manager Designation: Project Head
Date: 28/03/2023
Activity Carried by: - M/s Safe Air Engineers Pvt Ltd
Engineer available at site: -
 Mr. Tushar Gaikwad
 Mr. Nilesh Handure
 Mr. Nandukumar Mallshette
HSE Officers Available at Site : -
 Mr. Hannan Khan
 Mr. Mahesh Nikale
 Mr. Sharad Pawshe
SCOPE OF WORK:

 SITC of CHWP as per BOQ and Technical Specification 9.1 MS/AC/801/C

REFERENCE DOCUMENTS:

 Material Approval Submittal.

 Approved Shop Drawing.
 Technical Specification of Piping 9.1 to 9.12 TS Page No. 55 – 66

ORGANIZATION AND RESPONSIBILITES:

Sr. NO. Designation Job Responsibilities

1 Project Manager
2 Quality Engineer
3 Site Engineer & Site
Supervisor
4 Safety Engineer
1. It is the Project Manager duty to ensure that all necessary safety
and protective equipment are provided along with properly trained
and qualified personnel. Moreover, to ensure that all survey works
are carried out in accordance with this method statement.
1. It is the Quality Engineer’s responsibility to ensure that all surveying
equipment is being calibrated.
2. Ensure that all inspections and tests are carried out as per Project
requirements and that all are recorded.
3. Maintaining all quality records relevant to verification of records.
1. It is the Site Engineer / Site Supervisor’s duty to organize the work
force in a safe manner and to ensure that safety and protective
equipment are being properly utilized.
2. He must also ensure that the method statement procedure is
followed and notify the HAC Q.C / EHAF International for inspection.
1. The Safety Engineer is responsible for devising and implementing
programmers and plans to safeguard, health and safety of all
employees, and to prevent loss or damage to the existing assets and
projects.
 2. He is responsible for the implementing of the safety programs.
3. Provide support to site safety officers advising them on safe working
methods and assisting with training of personnel.
4. Carryout regular site safety audits and reports and correct unsafe
work practices and potential hazards.
5. Investigate and report all accidents near misses and recommend
prevention measures.
6. Ensure maintenances of good hygienic standards and availability of
safety equipment and first aid treatment.
7. Present monthly safety reports and required documents.

5 Safety Officer
1. The day-to-day activities of maintaining safety on project site, they
must: Understand and comply with requirements of the safety
manual.
2. Cooperate with the safety engineer to create and maintain safe
working conditions.
3. Assist the site engineers and foremen to organize the work area so
that the men can perform their duties with maximum efficiency and
minimize risk to themselves or to equipment.
4. Inspect equipment and tools before use to ensure correct storage
and properly utilization. Maintain record of all injuries and damages
on site, submit reports as required.

RISK ASSESSMENT:

Activity Sub Activities Identified Hazard and Assessment Controls

(Break the job down (What can cause a high degree of (What you are going to do to
into steps) harm?) make this step as safe as
possible, include equipment to
be used where appropriate)
1. Pipe 1.1 Pipe equipment
1.Pipe (MS & DI Pipe) may fall due to 1.Inspect lifting tackles before
Installation. Handling,Loading,Un
failure of cranes and lifting each use by competent person.
loading and
equipments.
Stacking. 2.Ensure crane capacity at the
2.Pinching of legs/hands of workmen lifting radius of load.
while handling the column.
3.Ensure nobody stands under
suspended load. Cordon the
area. Laydown area should be
free from obstacles.
4.Ensure that workmen keep
their hands / leg away from
pinching points.
5.Use proper tools like cross
bars etc.
6.Use PPE”s Like cut
Resistanace handgloves ,
helmet,Googles,Reflective
jacket, Safety Shoe Etc.

1.2 Installation &
1.Fall of person while climbing.
alignment of pipe.
(Different sizes- 2.Fall of pipes, pipe spool or
25mm dia to 200 equipment due to failure of lifting
mm dia) gears and appliances Tripping
hazards.
3.Heavy wind pressure.
4.Fall of person due to hit by lifted
structure member, pipe, and
equipment or while erecting aligning
member due to sudden jerk.
7.While loading and unloading
of pipe material signal man
along with foreman to be
ensured.
8.Flagman to be deployed along
with green and red flag.
9. Water test certificate.
1.Ensure workmen use fall
arrester while climbing the
vertical ladder where height is
more than 6mtr.
2.Inspect ladder regularly.
3.Ensure Proper access while
removing slings.
4.Carry out inspection /
practical measurements of the
top of column and allign them
with the structural modules to
be erected.
5.Maximum modifications to be
done on ground itself for
smooth and fast erection at
top.
6.When going for modular
erection,ensure maximum
members are fixed to the
module at ground itself in order
to prevent working at height
jobs.
7.Inspect lifting tackles before
each use.
8.Provide proper sling
protection underneath the
structural members. Rubber
padding / scrap fire blanket or
similar such material is
suggested for sling protection.
9.Ensure Boom/Scissor lift
capacity at the lifting radius of
load. – Standard lifting plans as
per category of lift to be
available.
10.Ensure guy ropes do not
come under the line of
movementof equipment which

1.3 Grinding & Pipe 1.Electric Shock.
cutter machine 2.Struck by grinding/cutter wheel.
3.Unauthorised operation.
4.Defective machine.
5.Grinding & cutting sparks
may disturb it. Flag the guy
ropes. Guy ropes shall be of
wire rope only anchored with
bull dog clamps. PP rope shall
be allowed to be used as guy
rope.
11.Ensure nobody stands under
suspended load. Cordon the
area.
12.Use of additional PPE`s, cut
resistance hand gloves.
13.Secure all hand tools while
alignment of structural
members at height.
14.Ensure supervision at all
times during each lift.
15.All lifts to be carried out
with proper planning and same
to be well coordinated with the
co-workers. If required, they
should be removed from the
area at the time of lifting.
16.If wind flow is high then job
will be suspended and tie beam
connection to be provided as
soon as possible or tie-upwith
temporary structure or existing
structure by using guy rope.
1.Grinding & Cutter machine
power supply should be routed
through ELCB.
2.Double Insulated power
cables shall be used.
3.Ensure use of standard cable
glands near the machine. No
joints allowed in power cable of
grinding & cutter machine.
4.Machine wheel guards should
be ensured
5.The grinding & cutter wheel
should be checked for the RPM
and the expiry date.
6.Handling and storage of
grinding & cutter wheels shall
be as per standards.
7.Grinder & pipe cutter shall
use face shield with helmet in
addtion to safety goggles
underneath the shield.
8.Ring test, idle run of wheel,
physical inspection of wheel
may be performed by the
grinder ,pipe cutter before
installing the wheel to the
grinding & cutting machine.
9.Ensure availability of
standard spanners / keys to fix
or dismantle the grinding &
cutting wheel from the
machine..
10.Only trained and
experienced grinder,cutter to
be do the job. Trade validation
of the grinder is mandatory.
11.The grinding & cutting
machine should be inspected
from RASS & TCPL as per its
standary frequency and tagged
for fit.
12.Internalinspection at site to
be done on monthly basis and
recorded in the register.
13.Additional PPE’s coverall,
face sheild, apron, heat
resistant hand gloves, ear plug
shall be used by the grinder &
cutter.
14.Ensure no combustible
material or person works in the
vicinity of grinding & cutting
spark. Use barriers to prevent
the spark from flying in the
surrounding area of the
activity.
15.Ensrue availability of fire
extinguishers in the area where
grinding &cutting is being
performed.

16. Ensure electrical supply

isolated before starting job.
Strictly follow LOTO system

17. All people should take LOTO

affected training.
1.4 Bolting, 1.Fall of tools / fastners due to 1. Ensure full tie-up of tools
clamping & improper tie-up & mishandling. with rope to body.
Tightening of 2.Fall of person while bolt fixing & 2. Ensure while doing bolting
pipe & torquing. proper carrier (Canvas bags)
allignment to be used.
3.Noise Pollution 3. Ensure proper platform with
hand rails for bolting &
torquing.
4. While torquing of bolts
with wrench machine, large
noise will generate. So, use
proper ear protection while
torquing jobs.
1.5 Bracing Erection 1.Fall of person due to hit by pipe 1. Once the pipe is clamped
in Pipe while erecting aligning due to sudden from one side, the crane
jerk. shall not be used for
2.Fall of loose/ unsecured pipe. matching the hole of other
side.
2. If at all, any wedges are
used to get sufficient gaps
between the angles of
piping, it should be secured
using lanyard so that it does
not fall down freely once,
pipe is fixed.

1.6 Pressure Testing 1.Water leakage during the testing.
Of Pipe
2.Coagulation of water on the ground
level.
1. Ensure the testing area
barricaded by caution tape
and displayed the signage
board
2. Ensure that electrical cables
are not cross the testing
area.      
3. The pipe must be welded /
clamped immediately after
erection
4. Twisted wire must be
installed during pressurized

1.7 Hot works at 1. Slip & Trip 1. Inspect all electrical

the time of 2. Electrocution equipments DB’s and
Monsoon Season extension boards. 
2. Proper earthing should be
provided. 
3. Protect the machines and
cables from water
ingress.    
4. Ensure that electrical
cables are not in damaged
and proper joints are
provided in all cables.      
5. Ensure that work area and
 personnel protective
equipment are not
wet.      
6. Electricians to check all
machines switch boards
and cables before starting
the work and ensure that
all in well condition then
start the work.     
1.8 Working in Hot Adverse weather condition. 1. Provision of potable
environment 1. Heat Disorders: drinking water to be
2. Sun burns ensured at site at all
3. Heat cramps times.
4. Heat stroke 2. Provde access to rest shed
5. Heat exhaustion near working area.
3. Take breaks in cool rest
areas.
4. Rotate physically
demanding tasks.
5. In case of any sysmptoms
of heat stroke,
immediately take help of
nearest first aid centre.

1.9 Rigging Works 1. Inadequate Supervision and 1. Ensure adequate

Rigging. supervision and effective
2. Accident due to signaling and Rigging.
miscommunication Ensure provision of trained
and validated rigging
foreman.

2. All riggers shall be

validated.

3. Ensure Communication
with proper hand signals,
whistles, intermediate
signal man, etc. during
erections
1.10 General, 1. Adopting short cut 1. Daily TBT should be given
Activity method,negligence,wrongpercepti to all workers.
on, absent mind, using cell phone. 2. Everyone should know
2. Proper Illumination emergency procedure &
Contact Number.
3. Training for motivation is
reqd.
4. Ensure effective
supervision.

5. Same person should not be

allowed to continue in
 night shift.
6. Proper lighting is to be
provided in all area where
work is going on.
7. All Workmen & Staff must
have taken LOT Affected
training.

2. Manually 1. Shifting the 1. Fall of Material from height. 1. Allow only authorize
MS pipe fixing required 2. Slippage of materials. Failure of /Trained person to work.
materials at lifting material. 2. Ensure work specific tool
work location. 3. Fall from height. box/training to all the
2. Make a proper 4. Due uneven surface ladder can be workmen conducted by the
scaffold toppling. site Engineer.
arrangement for 5. Injury due to rough edges. Check the access for
access at height. 6. Injury due to sudden arc flash. fabrication /welding work &
3. Fixing the MS 7. Eye burn/ Irritation due to workers movement before
pipe vertical up welding. start the job.
to as per 8. Serious injury. 3. Horizontal lifeline to be
standard. 9. Fire. fixed and worker who will
4. Fixing of fix the 'U' Clamp, threaded
Horizontal pipe rod & anchor his full body
and support, harness.
clamp to be 4. Ensure the availability of
done. Fire extinguisher near
5. Verticality to be fabrication /welding
checked with machine.
plumb after 5. Ensure the double body
fixing. earthing of all electrical
equipment/ machinery and
all power cable should be
overhead & double
insulated.
6. Ensure the all-power supply
should be through 30 M.
AMPS ELCB.
7. Job specific PPE to be used.

3. Shifting and 1. Make proper 1. Contact with rough edge. 1. Ensure Work Permit from
fixing of arrangement of 2. Fall of material. client, if required and
Accessories scaffold and 3. Failure of lifting equipment. further issue work permit to
fixing (Like - working platform 4. Slippage of material contractor by Civil Engineer
butterfly for working at only after physical
valve, landing height. verification of work
valve, hose location.
reel drum, pr. 2. Workers will lift 2. Allow only authorize
Gauge, Deluge Valves manually /Trained person to work.
Valve, flow to the location 3. Ensure work specific tool
switch, by rope. box/training to all the
Sprinklers 3. After alignment, workmen conducted by the
etc.) bolt will be done site engineer and safe route
in the flanges to be discussed with workers
 4. Bolt tightness & operator
will be done & 4. Ensure the lifting area
washers fitted to barricaded by caution tape
ensure and displayed the signage
board.
5. Not less than 8mm wire rope
should be ensure for
anchoring the bull body
harness, Safety Helmet,
safety Shoes, reflective
jacket, Goggles)
6. PPE (Cut Resistance hand
gloves, Leather hand gloves
Helmet with attached face
shield, Welding apron, hand
sleeve leg guard, Safety
Helmet, safety Shoes,
reflective jacket, Goggle)

RESOURCES:

 Equipment & Machinery:

- Mechanical Hand Tool

- Fork Lifter
- Material Handling trolley
- Chain Pully
- Welding Machine
- Grinder Machine
- Cutter Machine

 Tools Required:

- Standard Mechanical Toolbox kit.

- Standard electrical toolbox kit
- Pipefitter toolbox with complete hand tools
- Measuring tape
- Marking Pen
- Cleaning Brush
- PPE (Hand gloves, face masks, safety goggles)
- Safety harness (for high-level work)
- Trouble Light
- Mobile Scaffolding & Ladders

MOBILIZATION:
 Preparation and Planning

1. Precautions, manpower, and equipment are available before the commencement of work.
2. The Site Team shall make sure that access roads are always clear from any obstruction and the site
 is always accessible.
 Site clearance

1. Before commencing the work, the area shall be cleared of all debris, materials, or other
obstructions.
2. The Site Team with the assistance of the Safety Officers shall coordinate logistics and materials
movement through the site following the direction on site.
3. The Work Permits and Operator Certificates shall be compiled and files for reference by authorized
personnel.
 Pre-construction Safety Meetings

1. The meeting shall be scheduled prior to the beginning of the work and before any Subcontractor
starts on the project.
2. Safety awareness meetings will be conducted every working day morning/every other day to brief
the workforce on safety prevention measures. The equipment check for safety shall be recorded/
documented during the daily Safety Awareness Meeting.
3. Traffic safety will be discussed to emphasize these meetings.
4. Each worker will be instructed to follow specific safety requirements related to his trade. They will
be required to follow installed safety signs, observe barricades and use PPEs.
5. The Safety personnel will perform hazard risk analysis by identifying all steps, hazards identified in
those steps, with a focus on the relationship between the work task, the tools, and the work
environment. After identifying uncontrolled hazards; the Contractor will take steps to eliminate or
reduce them to an acceptable risk level.
6. General Contractual Safety, Health, and Environmental requirements.
7. Roles of the contractor, subcontractors, authorized representatives, and all project workers.
8. Accident reporting requirements.
9. Specific details of the work to be performed along with the use of personal protective equipment.
10. Emergency procedure.

 Operating Procedures

A site investigation has to be carried out to develop safety precautions and measures prior to the
commencement of the work. After such investigation, relevant signboards will be displayed and
barricades will be installed where and as necessary, such as but not limited to the following:

1. Relevant information, advanced signs, warning, and mandatory signs will be placed as required.
2. After completion of the work, safety cones and barricades have to be removed accordingly.

METHODOLOGY:

The installation of CHWP will be according to as follows:

 OFFLOADING:

1. Special care must be taken to ensure that units are offloaded from the containers.

2. Rough handling can result in damage to pipes and fittings.

3. It is possible to lift the pipes by slings. Slings, preferable nylon, must be placed around the pipes.

4. In the case in which the lifting tube is utilized, it must be inserted into the specific hole, then
the sling, which is equipped with a particular loop, must be connected to the tube. After that,
the section can be lifted.

5. Note: It is strongly recommended that offloading and installation operations will be carried out by
specialists with the necessary equipment and proper tools.

6. Special care must be taken to ensure that pipes are offloaded from the containers.

7. Rough handling can result in damage to pipes.

8. In the case in which the lifting tube is utilized, it must be inserted into the specific hole, then
the sling, which is equipped with a particular loop, must be connected to the tube. After that,
the pipes can be lifted.

9. Note: It is strongly recommended that offloading and installation operations will be carried out by
specialists with the necessary equipment and proper tools.

 STORAGE:

1. All material while unloading shall not be dropped, but slowly lowered to the ground.

2. For pipes, wooden supports shall be placed beneath at equal distance.

3. Pipes shall be stacked on a flat surface with adequate supports.

4. End caps of pipes shall be in place until removed for installation.

5. While stacking, it shall be ensured that pipes of bigger sizes are placed below and smaller
sizes on top.

6. All pipes shall be covered and shall not be exposed to direct sunlight.

7. All other items such as valves, fittings, gauges, etc. shall be kept on racks within site
stores and shall be segregated as per size, model, type etc. for easy retrieval.

8. Elastomeric insulation shall be stored in manufacturer’s packing and

shall not be exposed direct sun light.

9. Insulation material shall be segregated as per size, thickness for easy retrieval.

10. All supporting materials shall be stored in a covered storage area, segregated according to size,
type, model, etc. for easy retrieval.

11. Manufacturer’s instructions for storage shall be followed for applicable items.
12. Any items found damaged or not suitable as per project requirements shall be removed from site.
If required to store temporarily, they shall be clearly marked and stored separately to prevent any
advertent use.
 PREPARATION:

1. Check and ensure all drawings used for installation are latest and
approved for construction.

2. Mark the pipe routing and support locations in the trench as per approved drawings.

3. Check the co-ordination of piping layout with other services and decide pipe route with
minimum bends/offsets.

4. Check and ensure sufficient clearance around the pipe for applying insulation / cladding as
applicable.

5. Check the access and clear space around valves, vent points, drain points locations for
maintenance and servicing.

6. Fabricate t h e s t r u c t u r a l s u p p o r t s form MS angles/channels as p e r support schedule as

required.

7. Clean and apply primer / red oxide on all ERW black pipes.

 INSTALLATION:

1. Drill the holes in trench wall for fixing supports.

2. Fix the anchors and threaded rods with clevis hangers/ structural supports as applicable.
Threaded rod length shall be sufficient to allow for levelling of piping. Supports details as per
attached sketches.

3. Cut the pipes accurately to measurements determined at site.

4. Prepare the pipe ends according to the type of joints ie. threaded joints, welded joints /
grooved coupling joints.

5. The end preparation shall be done at site work shop.

6. For grooved joints pipe end should be square and cut with machine.

7. Flow process of grooving the pipe will incorporate a 1 Mtr long sprit level at least two nos. of
pipe stand for 6 Mtr long pipe and a completion check for squareness.

8. End preparations for welded joints shall be done as per approved welding procedure.

9. After the end preparation clean the pipe ends and ensure no material and dust is left inside.

10. Depending on site conditions, assemble the piping into manageable lengths on the floor.
Using threaded, welded/groove coupled jointing as applicable.

11. Qualified and approved welder with current certificates shall be engaged for welding
 works.

12. Install the pipe sections at heights as per approved drawing in a neat and tidy manner.

13. Insert the approved hard insulating material of suitable thickness between the pipe and
support.

14. Align and level the piping as per approved drawings.

15. Sleeves of suitable sizes shall be provided at wall crossings.

16. Hole saw cutter shall be used to cut the holes in the pipe work for fixing branch
connections for Victaulic fittings.

17. Install the valves in locations as per approved drawings.

18. Install the piping connections with valves and accessories wherever equipment’s are
installed as per approved drawings.

19. Fix the blind plugs / temporary valves on all drain, air vent, pressure gauge, thermometer
and test points tapping’s approved drawings.

20. Check and ensure proper supporting is provided as per approved drawings.

21. Make temporary tapping provisions at multiple points for easy and quick filling and draining
of pressure testing water.

22. Ensure all joints are properly tightened in line with manufacturer recommendation.

23. While installation is going on of the pipe work, the insulation will be fitted to the pipe work
prior to pressure testing. But all fittings and joints will be left exposed until the pressure testing
and inspection is completed.

24. Raise t h e “ WIR” f o r piping installation by NMX QA/QC and consultant. Obtain signoff for
hydraulic pressure testing.

 PRESSURE TESTING:

1. The chilled water piping shall be tested according to the system working pressure and PN
ratings of the pipes, pipe fitting and valves used in the piping.

2. The piping may be tested in sections or in total depending on site requirements.

3. Estimate the piping volume and make arrangement for required quality of clean water.

4. Arrange for temporary piping / hose pipe connections for filling and draining the water.

5. Fix the temporary valves at air vent / drain points and pressure gauges.

6. Fill the piping system with clean water.

7. During initial filling, employ sufficient man power to monitor the entire length of the piping
system for possible leakages.

8. If leakages are observed, arrest the leakage immediately. If leakages are major, isolate the
leaking portion with nearest isolating valve and / or stop the water filling.

9. Rectify the leakages and again fill with water.

10. Ensure no leakages throughout the entire piping system.

11. Observe for the leakages and pressurize the system using hydraulic test pump.

12. During pressurization observe the joints and entire piping system for leakages.

13. Pressurize the system till pressure on the pressure gauge at lowest part of the system indicates
pressure.

14. Observe the pressure gauges readings for 8 hours and ensure there is no drop in gauge pressure.

15. Raise the “WIR” for witnessing the hydraulic pressure testing by QA/QC and consultant.

16. Obtain signoff with clearance for insulation only after satisfactory pressure testing.

 PIPE INSULATION:

1. The pipe surface shall be thoroughly cleaned to remove dust, traces of oil, grease etc. All welded
joints are painted with red oxide primer.

2. For smaller pipe sizes, pre-for me insulation pipe section of suitable thickness, as per approved
drawings/submittals to be used. For larger pipe sizes insulation sheet shall be used in thickness
described in the materials submittal.

3. Smaller pipe which are not exposed to direct sunlight and insulation is not susceptible for damage,
insulation may be done by inserting the pipes in to insulation sections during pipe installation.

4. When insulation is done after pressure testing following procedure shall be followed.

5. Slit the pipe insulation section, longitudinally and apply adhesive on inner surface and longitudinal
slit as recommended by manufacturer.

6. Apply the adhesive on the surface of the pipe to be insulated, as recommended by manufacturer.

7. Fix firmly the insulation on the pipe surface and hand press the insulation to remove any air locks.
The longitudinal seam shall be joined properly by hand pressing.
 8. Fix the elastomeric self-adhesive tape over the longitudinal seam.

9. Continue the same procedure for successive lengths. Adhesive shall be applied on circumferential
joint properly. Seal the circumferential joint by fixing self-adhesive tape.

10. For larger pipe sizes, cut the insulation sheet of suitable width to suit pipe size. The length shall
be as manageable as per site conditions.

11. Complete the insulation as explained earlier in point No.

12. Under no circumstances insulated pipes shall be exposed to direct sunlight.

13. Vapor seal must be achieved 100%.

14. Raise the “WIR” for QA/QC and consultants and obtain the signoff.

 INSPECTION:

1. WIR” by QA/QC and Consultant shall be raised for piping installation, pressure testing, joint
insulation and signed by Consultant.

2. Inspection shall be carried out as per installation checklist during installation, testing and
insulation stages.

3. The entire installation work shall be supervised by the supervisors/engineers.

Note :
If required for a specific work, detailed method of control for any additional hazards will be provided
separately.

Accepted by: ____________________