SSP MGKT Ungw Ovpr MST 00512

MMC GAMUDA KVMRT (T) SDN BHD
PROJEK MASS RAPID TRANSIT LALUAN 2:

SG. BULOH - SERDANG - PUTRAJAYA
UNDERGROUND WORKS
METHOD STATEMENT FOR INSTALLATION OF

HOSE REEL SYSTEM C/W PUMPSETS
Reference No. : SSP-MGKT-UNGW-OVPR-MST-00512
Revision : 00
Date : 18 APRIL 2020

Action Name & Position Signature
Turnkey Contractor’s Supervision
Reviewed By:
Reviewed By DDC /
SIC
MMC GAMUDA KVMRT (T) SDN. BHD.

Goh Chee Young
Approved By
(Deputy Project Director)
James Whorlow
Reviewed By
(General Manager QA/QC, Risk & SA)
Chris Fenton
Reviewed by
(General Manager SHE)
Ian Donohue
Reviewed By
(General Manager M&E)
Joseph Lau Sie Won
Reviewed By
(M&E Manager)
Kassthurei Yogarajan
Prepared by
Engineer – M&E

SSP-MGKT-UNGW-OVPR-MST-00512, Rev 00
AMENDMENT HISTORY
REVISION NO. DETAILS OF AMENDMENT
00 First Issue

Contents
SCOPE OF WORK ............................................................................................................ 1
General Description..................................................................................................... 1
References .................................................................................................................. 2
Definitions ................................................................................................................... 4
Materials, Equipment and Manpower .......................................................................... 5
Plant and Equipment ............................................................................................. 5
Materials ............................................................................................................... 6
Manpower ............................................................................................................. 7
Procedures .................................................................................................................. 8
General procedures .............................................................................................. 8
Installation of Hose Reel Piping and Accessories ................................................ 11
Installation of Hose Reel ..................................................................................... 18
Installation of Hose Reel Tank and Accessories .................................................. 21
Installation of Hose Reel Pumps and Accessories............................................... 24
SAFETY AND HEALTH ................................................................................................... 28
Job Safety and Health ............................................................................................... 28
Information to Personnel ........................................................................................... 28
Emergency Arrangements ......................................................................................... 28
Permit Requirements................................................................................................. 29
ENVIRONMENTAL ASPECTS, IMPACTS AND CONTROL MEASURE ......................... 30
QUALITY ASSURANCE AND QUALITY CONTROL ...................................................... 31
Contractual Requirements ......................................................................................... 31
Inspection and Testing .............................................................................................. 31
Follow up & Evaluation .............................................................................................. 31
Appendices..................................................................................................................... 32
5.1 Appendix A Construction Workflow .......................................................................... 33
5.2 Appendix B Job Safety Analysis & Risk Assessment................................................ 34
5.3 Appendix C Environmental Operation Control Log ................................................... 35
5.4 Appendix D PICO Inspection Record Sheet ............................................................. 36
D.1 Hose Reel Piping System and Associated Equipment
D.2 Hose Reel Fire Equipment System
D.3 Hose Reel Tank and Accessories

SCOPE OF WORK
General Description
This document describes the methods to be taken by the personnel in charge of carrying
out the installation of Hose Reel System complete with Pumpsets. This document
applies to the installation at all underground stations line-wide and in the tunnels. The
methods employed shall be in accordance with the requirements stipulated in the
Materials and Workmanship Specifications (MWS), approved Material Submission
Approval (MSA), Quality Control, contractual requirements and approved shop drawings.
This document also considers the manufacturer’s recommendation.
MMC GAMUDA KVMRT (T) SDN. BHD. 1

References
Materials and Workmanship Specifications (MWS)
SSP-MRTC-GENE-OVPR-SPC-03501 (General)
SSP-MRTC-GENE-OVPR-SPC-03504 (Pumps)
SSP-MRTC-GENE-OVPR-SPC-03511 (Pipework)
SSP-MRTC-GENE-OVPR-SPC-03514 (Dry / Wet Riser and Hose Reel System)
SSP-MRTC-GENE-OVPR-SPC-03596 (Painting and Colour Codes)
SSP-MRTC-GENE-OVPR-SPC-03512 (Water Tanks)
Post Installation Checkout (PICO)

PICO Inspection Record Sheet for Hose Reel Piping and Accessories
PICO Inspection Record Sheet for Hose Reel Pump and Accessories
PICO Inspection Record Sheet for Hose Reel Tank and Accessories
Standard Detail Drawing

SSP-D-MGKT-UNGW-OVPR-FPS-STS-003001
Inspection & Test Plan (ITP)

SSP-MGKT-UNGW-OVPR-PLN-00537 Rev. 01
Method Statement (MST)

SSP-MGKT-UNGW-OVPR-MST-00546 (Cable Containment (Conduit, Flexible
Conduit, Junction Box, Trunking, Ladder & Tray)) for Mechanical & Electrical
Systems
SSP-MGKT-UNGW-OVPR-MST-00670 (Installation of Tunnel Electrical Fittings
Including Cable, Lighting, Socket Outlet and Earthing)
Material Submission Approval (MSA)

Hose Reel Pump (Duty & Standby) - SSP-MGKT-UNGW-OVPR-MSA-00936
Gate Valves - SSP-MGKT-UNGW-OVPR-MSA-00984, SSP-MGKT-UNGW-OVPR-
MSA-01009, SSP-MGKT-UNGW-OVPR-MSA-01442, SSP-MGKT-UNGW-OVPR-
MSA-01504, SSP-MGKT-UNGW-OVPR-MSA-01846
Check Valves - SSP-MGKT-UNGW-OVPR-MSA-01006, SSP-MGKT-UNGW-OVPR-
MSA-01503, SSP-MGKT-UNGW-OVPR-MSA-01441
Expansion Joint - SSP-MGKT-UNGW-OVPR-MSA-01443, SSP-MGKT-UNGW-
OVPR-MSA-01818
Pressure Gauge - SSP-MGKT-UNGW-OVPR-MSA-01089
Pressure Switch- SSP-MGKT-UNGW-OVPR-MSA-01855, SSP-MGKT-UNGW-
OVPR-MSA-01878
Galvanised steel pipes - SSP-MGKT-UNGW-OVPR-MSA-01206, SSP-MGKT-
UNGW-OVPR-MSA-01787
Y-Strainer - SSP-MGKT-UNGW-OVPR-MSA-01500, SSP-MGKT-UNGW-OVPR-

MSA-01444
Hose, hose reel drum, cradle, diffuser nozzle and coupling) / Hose reel cabinet -
SSP-MGKT-UNGW-OVPR-MSA-00932, SSP-MGKT-UNGW-OVPR-MSA-01076
SSP-MGKT-UNGW-OVPR-MSA-01499
Neoprene Strip - SSP-MGKT-UNGW-OVPR-MSA-01819
HDG HR Tank - SSP-MGKT-UNGW-OVPR-MSA-01877

Definitions
DDC Detailed Design Consultant
ERT Emergency Response Team
IEC International Electrotechnical Commission
ITP Inspection Test Plan
LDC Lead Design Consultant
MGKT MMC Gamuda KVMRT (T) Sdn Bhd
MWS Materials and Workmanship Specifications
MSA Material Submission Approval
MST Method Statement
MS Malaysian Standard
PTW Permit to Work
PAT Portable Appliance Testing
PICO Post Installation Checkout
QA Quality Assurance
QAQC Quality Assurance and Quality Control
RFI Request for Inspection
SHE Safety, Health and Environment
TCS Turnkey Contractor Supervision

Materials, Equipment and Manpower

Plant and Equipment
No. Plant and Equipment Description
1 Crane To lift/unload materials

2 Chain block To lift/unload materials
Webbing / Slings / Chains
3 To hold materials during lifting/unloading
Shackles
4 Forklift To lift and move materials
5 Pallet jack To lift and move pallets
6 Wrench tools To tighten/loosen object
7 Hammer To drive nails
8 Masonry drill To drill holes
9 Measuring tape For measurement
10 Safety Barriers To barricade working area
11 Circular Disc Cutting Machine To cut materials
12 Scaffolding For working at height
13 Scissors lift For working at height
14 Pipe threading machine To thread the pipes
15 Pipe grooving machine To groove the pipes
16 Centre Punch To mark the center of a point
To provide grip and mechanical advantage
17 Spanner
in applying torque to turn objects
18 Spirit Level To determine horizontal and vertical levels
19 Portable Vacuum Cleaner To suck up dirt/debris of leftover site works

Materials
No. Materials Description

Hose reel pump (duty &
1 To pressurise the system
standby)
2 Gate valve For isolation
3 Check valve / Globe Valve To prevent backflow

To reduce/expand to suit pump inlet/outlet
4 Eccentric & concentric reducers
diameter
5 Flexible joint To allow expansion/compression between pipes
To filter impurities in the water prior to the pump
6 Y-strainer
inlet
7 Pressure gauge To measure the system pressure
8 Pressure switches To set the cut in/out pressure of the pump

Galvanised steel pipes
9 To deliver water
(Medium Grade) Class ‘B’
10 Pipes fittings For pipes connections
11 C-channels For pipe bracket and support
12 Cables To deliver power supply to the pump/control panel
13 Conduits/Cable Tray/Trunking To run/protect the control cables of pumps
14 Galvanised threaded steel rod For pipe bracket and support installation
For pipe bracket and support installation
U-bolts and nuts / drop-in
15 For control panel installation
anchor / anchor bolts
For fixing the pump and tank
Hose, hose reel drum, cradle,
16 For the hose reel system
diffuser nozzle and coupling
17 Hose reel cabinet To house the hose reel
18 Pressure responsive gaskets To seal connection between flanges
19 Neoprene pad To absorb vibration
To store water solutions
HDG HR Tank
20 To provide clamp/preload joints for assembly of
HDG Steel Bolts
tank
Aluminium Ladder - external
21 To access the Tank for maintenance
Stainless steel Ladder - internal
To take static/dynamic loads of Tank/pumps and
22 HR Pump/Tank Plinth
limit vibrations
23 High/Low Level Electrode To monitor tank level
24 HR Pump Control Panel To power/controls and protect the pumps

Protection of the surface from environmental

25 Primer/Finish Red Paint
factors
Level utilizing mechanical device float to indicate
26 Mechanical Level Indicator
tank level
Balancing inflow and maintaining the level of tank
27 Modulating Valve c/w ball float
to the designated maximum level
To prevent vortices and air entrap within the HR
28 Vortex Inhibitor
suction pump
Manpower
No. Type of Manpower Job Function
Manage overall construction activities, resources

1 Construction Manager
and manpower involved.
Planning, coordinating and supervising materials
2 Site Engineer and people; liaise with client, representatives and
consultant
3 QA/QC inspector/Engineer To carry out QA/QC inspection at site
4 Site Supervisor Supervising construction activities
Qualified Mobile Crane
5 Operates crane
Operator
Organizes, monitors and assists mobile crane
6 Banks-man
operator
To supervise the compliance of safety and health at
7 Safety Supervisor
site
8 Scissors Lift Operator Operates the scissors lift
9 Skilled Workers Installation of materials
10 General Workers Carrying out general works at site
11 Scaffolding Erector Erect and dismantle scaffolding
12 Scaffolding Inspector Carry out inspection on scaffolding as required
Operating and managing industrial trucks to load
13 Forklift Operator
and unload materials

Procedures
General procedures
1.5.1.1 Materials Delivery, Inspection, Handling and Storage
1) Before leaving the suppliers/manufacturer’s depot, materials shall be secured to the
delivery vehicle to avoid movement and damage during transportation
2) Major equipment materials shall have their Material Submission Approval document(s)
approved by MGKT, QA, TCS and MRTC before delivered to site. Minor materials shall
have their Material Submission Approval document(s) approved by MGKT, QA and
TCS before delivered to site. All shop drawings shall be approved by MGKT and TCS
prior to installation. The MST and PICO must be approved by MGKT, QA and TCS
prior to installation. All materials shall be inspected and approved by MGKT and TCS
prior to delivery to the site.
3) All pipes and fittings shall be transported to the site via road truck.
4) Upon material arrival at site, materials will be inspected by MGKT & TCS using Material
Receiving Checklist prior to works proceeding.
5) A separate lifting plan shall be submitted and approved by main contractor safety
department before the lifting.
6) Upon delivery to the site, the pipes will have slings placed around the pipes and will be
unloaded using the crane. See Figure 1.
Figure 1: Example of crane lifting materials
7) Stored pipes shall be protected from damage and kept free from dirt and foreign
materials by closing the ends of the pipe. Other pipeline materials shall be protected by
appropriate packaging or wrapping. Gaskets shall be stored in a cool location out of
direct sunlight. Bolts, nuts, and washers shall be handled and stored in a dry location in
a manner that will ensure proper use with respect to types and sizes.

8) Pipes will be stored on timber cradle beams (see Figure 2) with safety barriers around
the storage area.
Figure 2: Example of storage of galvanised steel pipes
1.5.1.2 Delivery, Inspection, Handling and Storage of Pumps
1) Before leaving the manufacturer’s depot, the pumps shall be secured and arrange
accordingly to avoid and minimize movement and damage during transportation.
2) Upon arrival at site, all pumps will be checked for correct specification damage and
defects then unloaded by forklift and deliver to the designated crane to be hoisted
down to the designated level.
3) All pumps are equipped with rigging holes. As such, the units can be rigged by
ropes/chains. See Figure 3.
4) At the crane, the ropes/chains will be hanged onto the crane hook then transported
to the designated location.
Figure 3: Delivery of pump using ropes/chains

Arrival of Materials
Materials Inspection (RFI/Checklist) by MGKT & TCS
Submit lifting plan to MGKT for approval prior to arrival of

equipment/materials
Checking quantity and quality of materials
Transfer materials to installation location
Barriers shall be placed around stored materials to prevent

damage
Installation
Figure 4: Flowchart for material storage

Installation of Hose Reel Piping and Accessories

1.5.2.1 Installation of Brackets and Supports
1) Place safety barrier around the working area. Workers working at heights will use the
scissors lift/scaffolding to reach higher levels. Safety harness must be worn and
attached throughout the installation works.
2) Hangers, supports, anchor and fixing accessories shall be galvanised threaded steel
rod.
3) Mark the slab to establish the installation location of hangers according to the approved
shop drawings.
4) Using hammer/masonry drill, drill holes on the markings on the slab soffit. Clean the
drilled holes so that it will be free from dust or concrete debris prior to installation of
drop-in anchor.
5) Set the drop-in anchor using a hammer according to the following manufacturer’s
installation procedure. See Figure 5.
Figure 5: Installation of Drop-in Anchors
6) Cut the galvanised threaded steel rod to the desired length using cutting machine then
fix it onto the anchor bolt. Tighten the nut and washer using a wrench. The cut portion
shall be painted with zinc rich/anti corrosion paint. Applicable for all cut portion of
hangers and supports. See Figure 6.

Figure 6: Installation of Bracket onto slab
7) For floor bracket support, see Figure 7.
Figure 7: Installation of bracket onto floor

8) For brackets mounted vertically, C-channel will be fixed to the wall using anchor bolts,
U-bolts will be used to secure pipes to the C-channel, as shown in Figure 8.
Figure 8: Installation of bracket onto vertical wall
9) The U-bolt sizes are listed as below, see Figure 9.

Figure 9: List of U Bolt Size according to Diameter of Pipe
10) See Figure 10 for bracket spacing for pipes
Maximum intervals Maximum intervals Rod sizes

Diameter of
for Vertical Run for Horizontal Run
Pipe (mm)
(m) (m)
15 2.5 1.2 6
20 – 25 3.0 1.5 10
32-50 3.0 1.8 10
65 – 80 3.0 3.0 16
100-150 3.0 3.0 20
150 above 3.0 3.0 22
Figure 10: List of Bracket Spacing according to diameter of pipe

1.5.2.2 Threading of Pipes

1) All pipes that have a diameter of 50mm and below will be threaded.
2) Safety barriers will be placed around the pipe fabrication area.
3) Ensure all pipes are in good condition and have not been damaged.
4) A drain pan will be placed under the threading machine to collect oil spills and dripping
from the machine. See Figure 11.
Figure 11: Threading and grooving of pipes setup
5) Obtain the exact length of the pipe which is described in the approved shop drawing
by using the circular disc cutting machine. Ensure that safety goggles and gloves are
worn and a fire extinguisher is ready nearby. A Hot Works Permit will be required for
this work.
6) After cutting the pipes, the pipe end is then threaded using a threading machine. See
Figure 12.
Figure 12: Example of a threading machine

7) After the pipes have been threaded, clean the pipes from burrs and debris.
8) Apply Teflon tape onto the pipe threads.
9) Repeat the above steps for other pipes.
1.5.2.3 Grooving of Pipes

1) Unless otherwise stated, all pipes that have a diameter of 65mm and above will be
grooved.
2) Ensure all pipes are in good condition and have not been damaged
3) A drain pan will be placed under the grooving machine to collect oil spills and dripping
from the machine. See Figure 11.
4) Insert the pipe into the grooving machine and begin turning. See Figure 13.
Figure 13: Grooving process of a pipe
Figure 14: Examples of Grooved Pipes

Figure 15: Joining of two grooved pipes

1.5.2.4 Installation of Pipe
1) Read the shop drawing and define the areas where the pipes will be installed.
2) Place barriers around the installation area and station one worker as a look-out. The
barriers which will be placed in a safe zone shall be a distance of 1.5m greater than
the length of the pipe which is being raised.
3) A scissors lift/scaffolding with materials and tools will be raised to the desired working
height with two workers on board. Harnesses must be worn and attached to the
scissors lift throughout installation work.
4) The workers shall lift the pipe to the designated location and join it with other pipes
depending on the type of joints.
5) Where pipes pass through walls and floors, pipe sleeves shall be provided to allow
free axial movement of the pipe.
6) Coupling with pressure responsive gaskets and shoulders to fit the grooves are used
to join grooved pipes or grooved components
7) Make sure the gasket and housing in the correct position to avoid any leaking
8) Tighten the bolts and nuts uniformly until the upper housing is in complete surface
contact in the gasket pocket area and the assembly is rigid. See Figure 14 and 15.
9) Repeat the above steps for another pipes
10) The pipe will then be aligned and fixed onto the pre-installed brackets by the workers.
Ensure that a neoprene pad is inserted in between the pipes and the brackets.
11) Tighten the brackets securely.
12) Labelling and painting for pipe works shall be based on M&WS Section 596.6.
13) Pipes shall be earth bonded as indicated on the approved shop drawings.
14) Housekeeping will be done upon completion of all works.

1.5.2.5 Installation of Valves

1.5.2.5.1 Installation of Valves to Threaded Pipes
1) Place the pipe in a pipe vice then position the valve in between the pipes
2) Make sure the threads are free from dust.
3) Guide one of the pipe ends onto the valve’s thread, slowly turn the pipe in the clock-
wise direction.
4) Hold the valve firmly with a wrench and spanner on the nearest flat joint then rotate the
pipe until the end of the spindle. See Figure 16.
Figure 16: Tightening of valve using wrench
Installation of Hose Reel

1.5.3.1 Installation of Hose Reel with Cabinet
1) From the finished floor level, measure 1200mm and mark it as a reference point to the
topmost part of the hose reel cabinet. See Figure 17.
2) The hose reel cabinet must be swing-out type and able to open to 180° and coated
with the designated colour.
3) Use a centre punch to remove the knockouts from the pre-drilled holes at the back of
the hose reel cabinet.
4) Mark the mounting wall/pre-cut channel using the holes at the back of the hose reel
cabinet as guides.
5) Use masonry drill to drill the required amount of holes on the markings, clean the drilled
holes and drive in the drop-in anchors with hammer.
6) For mounting of cabinet against ‘D’ wall, install first the pre-cut C-channel and check
level behind cabinet for proper installation.
7) Two workers will lift the cabinet while another tightens the cabinet to anchor after fixing
the cabinet firmly to C-channel using M12 hexagon nuts and washers.
8) Using the reel bracket as a guide, mark the holes for the position of the reel bracket to
the wall. Make sure the bracket is installed in a vertical position and that the centre of
the hose reel drum is 750mm from the finished floor level. Use masonry drill to the
required amount of holes on the markings, clean the drilled holes and drive in the drop-
in anchors.
9) Preinstall the lower bolt, lock washer and washer on the bracket but make sure there
is enough space so the base of the hose reel can be slid behind the washer

10) Slide the slider base in the pre-installed bracket and immediately insert the top bolts,
lock washers and washers.
11) Tighten the bolts, nuts and washers using a wrench.
12) Connect the hose reel to the pipelines then cover the hose reel with tarpaulin to protect
from scratches, damage and defects.
Figure 17: Height of the hose reel and cabinet to the FFL
1.5.3.2 Installation of Hose Reel without Cabinet

1) Ensure that the reel spooler is in a vertical position to ensure proper retraction
2) Use appropriate fasteners according to the size of the reel.
3) Make sure supply lines are off.
4) Use centre punch to mark the drill spots.

5) Using the reel bracket as a guide, mark the holes for the position of the reel bracket to
the wall. Make sure the bracket is installed in vertical position and that the centre of
the hose reel drum is 750mm from the finished floor level. Using hammer/masonry
drills, drill the required amount of holes on the markings. Clean the drilled holes and
drive in the drop-in anchors.
6) Preinstall the lower bolt, lock washer and washer on the bracket but make sure there
is enough space so the base of the hose reel can be slid behind the washer.
7) Slide the slider base in the pre-installed bracket and immediately insert the top bolts,
lock washers and washers. Refer to Figure 17.
8) Tighten the bolts, nuts and washers using a wrench.
9) Connect the hose reel to the pipelines then cover the hose reel with tarpaulin to protect
from scratches and damages.

Installation of Hose Reel Tank and Accessories

1.5.4.1 Installation of Hose Reel Tank
1) The material of hose reel tank shall be hot dipped galvanised (HDG) pressed steel
panels.
2) Safety barriers will be placed around the installation area before proceeding with the
construction of hose reel tank.
3) As each panel is unpacked, check for defects and/or damage.
4) Ensure the tank pipe connections will be installed towards the direction of the pre-
installed pipe work.
5) The civil contractor shall prepare the reinforced concrete bases that will support the
water tank. The height and length of the reinforced concrete bases shall take into
consideration the static/dynamic loads of Tank/pumps and to limit vibrations. Therefore,
the reinforced concrete bases will be based on the recommendation of the tank supplier
and approved shop drawing. Refer to Figure 18.
Figure 18: Example of concrete base for hose reel tank
6) To ensure that the completed reinforced concrete bases are levelled, use a spirit level
to check.
7) Assemble HDG pressed steel panels according to manufacturer’s installation
instruction. Installation must be guided or serviced by the manufacturer if necessary.
8) Hand tight the bottom panels with bolts. Never fully tighten any bolts before the whole
tank assembly is complete.
9) Once the bottom panels are installed, hardboard will be laid on top of the bottom panels
to protect the panels from workers stepping on it while working.
10) Assemble the side to base panels. Use a spanner to align panels, insert stainless steel
bolts from inside of the tank. Use galvanised steel bolts for external assembly.
11) Start the assembly from one corner and proceed simultaneously in two directions to the
diagonally opposite corner.
12) Ensure that all flange faces are thoroughly wiped clean and that the sealant strip does
not come in contact with the floor area.
13) Press sealant in position and ensure sealant is returned beyond corners. Bolts may be
pushed through the sealant strip when bolting panels together. Prevent dust from falling
into the joints.

14) Install the inside supports and fix it using supplied stainless steel bolts, nuts and
washers.
15) Mount and install the outer lacing board.
16) Install aluminium external ladder and stainless-steel internal ladder as per Item 1.5.4.2.3
17) Install the mechanical level indicator and inlet and outlet piping as per Item 1.5.4.2.2.
18) Install the top cover of the HDG pressed steel tank.
19) Ensure that everything is correctly installed and all bolts tightened after the whole tank
assembly is completed according to the manufacturer’s installation instructions. See
Figure 19.
20) Hardboard shall be placed whenever stepping into the bottom panels and also prior to
inspection of the internal tank.
21) Ensure the hardboard is removed from the tank after completion.
Figure 19: Example of installation of hose reel tank
1.5.4.2 Installation of Hose Reel Tank Accessories

1.5.4.2.1 Tank Outlet Flanges and Pipe Connections
1) Check the sizes and the fit-out height of the puddle flanges relative to the HDG tank’s
top water level.
2) Install the valves and accessories at the tank outlets according to the shop drawings.
3) Fit out the gate valves onto respective outlet and connect the pipes according to the
shop drawing.
4) Fit out a balancing pipe connection with gate valve in between the 2 tank
compartments.

1.5.4.2.2 High/Low Level Electrode Sensors and Mechanical Level Indicator

1) Install the ball float c/w modulating valve at the incoming pipe into the tank.
2) Fit the electrode sensor c/w with its base casing internally in the tank. Electrode rods
shall be installed and measured with different length for High/Low level signal
indication. Conduit in wiring shall be run from the SLC loop to the junction box nearby
the tank for its water level monitoring.
3) Ensure the Mechanical level indicator are installed in a visible location of the tank.
4) Place the ball float of the mechanical indicator into the tank internally.
5) Insert the cables, through the pipe for Level Indicators and fit-out the level indicator
assembly. Check for ease of movement of the pointer.
1.5.4.2.3 Access Hatch and Ladder

1) Fit out a minimum 300mm wide stainless steel ladder with suitable height inside the
hose reel tank.
2) For ladder outside the hose reel tank, the ladder shall be made of aluminium and not
less than 375mm wide.
3) Fit-out the hinged metal access hatch with opening of not less than 600mm in diameter.
The hinges shall be made of stainless steel.
4) Install a wire mesh as insect and vermin protection to the vent pipes.
5) See Figure 20, for the schematic of hose reel tank.
AS PER MANUFACTURER’S
RECOMMENDATION
Figure 20: Schematic of a hose reel tank

Installation of Hose Reel Pumps and Accessories

1.5.5.1 Plinth
1) The duty and standby pump for hose reel are to be installed onto the plinth.
2) Ensure that each of the size of the pump plinth provided is in accordance to the
approved shop drawing.
3) Check for defects. If satisfactory, proceed to the pump installation.
4) Measure and mark the points where each of the pump assembly anchor bolts are to
be fitted into the plinth.
5) Drill the appropriate size for the anchor bolts into the plinth. Remove any debris.
1.5.5.2 Installation of Hose Reel Duty and Standby Pump

1) Insert the appropriate size of anchor bolts into the holes.
2) Set the bolt and ensure the anchor bolts are vertical, adjust if necessary.
3) Measure and cut the neoprene pad to match the size of the pump base. Cut out the
required holes for the anchor bolts.
4) Set the neoprene pad flat on the plinth with the holes as guides.
5) Set the duty and standby pump onto the anchor bolts and hand tight the nuts on the
anchor bolts.
6) Using a spirit level, check for levelling of the suction and discharge flanges.
7) If satisfactory, tighten the nuts and ensure the pump is securely fastened before
proceeding to piping works. See Figure 21.
8) Pipes shall be earth bonded as indicated on the approved shop drawings.
Figure 21: Detail of hose reel pump connected with accessories

1.5.5.3 Installation of Pump Accessories

1.5.5.3.1 Installation of Suction Pipe Accessories
1) The suction valve shall be connected to the hose reel tank outlet. See Figure 21.
2) Ensure that the linear length of the suction pipe is at least 3 times the required
diameter.
3) The installation order shall start from the pump to the tank outlet pipe.
4) With matching flange of size, install from the pump suction flange in the following
sequence :
a) Eccentric reducer.
b) Flexible joint.
c) Y strainer
d) OS&Y Gate valve
5) Ensure that the top surface of the eccentric reducer is flat and horizontal to avoid
formation of air pocket.
6) Use pipe brackets (with neoprene pad) at appropriate intervals as independent pipe
supports to avoid disturbances to pump shaft and bearing alignment and to keep its
weight off the pump casing.
7) Check pipe alignment and levelling. Adjust if necessary.
1.5.5.3.2 Installation of Discharge Pipe Accessories

1) The discharge valve shall be directed vertically. See Figure 21.
2) The installation order shall start from the pump to the delivery pipe.
3) With matching flange of size, install from the pump discharge flange in the following
sequence :
a) Concentric reducer.
b) Flexible joint.
c) Check valve
d) Gate valve
4) Use pipe brackets (with neoprene pad) at appropriate intervals as independent pipe
supports to avoid disturbances to pump shaft and bearing alignment and to keep its
weight off the pump casing.
5) Check pipe alignment and levelling. Adjust if necessary.

1.5.5.3.3 Installation of Pressure Switches

1) The pressure sensing line for pumps shall be fitted with pressure switches bracketed
onto the wall.
2) The setting for the duty and standby pump pressure switches are as follows:
a) Starting and stopping the duty pumpset set at 80% and 110% of the system
pressure respectively
b) Starting and stopping the standby pumpset set at 60% and 110% of the system
pressure respectively.
3) Measure the wire length required from each pressure switch to the designated control
panel.
4) Run and securely fasten a conduit, from the pressure switches to the control panel.
5) Pull the cables into the conduit and terminate at the pump control panel.
6) Repeat for each set of pressure switches wiring. See Figure 22.
Figure 22: Schematic of installation of pressure switches and pressure gauge

1.5.5.4 Installation of Hose Reel Pump Control Panel

1) Ensure optimum space for maintenance and ease of operation of each panel.
2) Panel shall not be installed under any pipe and in proximity to wet services and also to
refer to approved shop drawing for location and other details.
3) Measure and mark the drop-in anchor openings of the control panel onto the
designated wall.
4) Drill to its required diameter and depth. Insert the appropriate sized flush anchors into
the holes.
5) Mount the panel onto the flush anchors bolts and tightens accordingly. Check for
evenness of installation. Adjust accordingly.
6) Labelling for panel shall be based on M&WS Section 596.6.
7) Panels shall be earth bonded as indicated on the approved shop drawings.
1.5.5.5 Pump Cabling Works for Duty and Standby Pumps

1) Measure the distance between each of the pump motor to its designated control panel.
2) Select appropriate cables according to the approved shop drawing. Measure and cut
to the required length, the cables for the pump motor.
3) Pull the cables into the tray/trunking, each end terminating at the motor and control
panel respectively.
4) Insert cable and terminate the cable onto the pump motor terminal box according to
the manual.

SAFETY AND HEALTH

Job Safety and Health
Hazard analysis with risk assessment shall be carried on the project site. The hazards
in a particular activity and the control measures implemented shall be briefed to the
workers during Safety Induction, Tool Box Meeting and MS Briefing. The specific
hazards, risks and associated control measures of the work described in this document
are detailed in the Job Safety & Health Analysis.
Information to Personnel
Prior to the commencement of works described in this document, a Job Safety Analysis
and risk assessment briefing will be conducted. Attendance to a safety induction course
held at site is mandatory for all site personnel. Tool Box meeting will be conducted on a
daily basis by Safety, Health and Environment (SHE) Supervisor, where attendance and
minutes will be taken for archiving purposes. Possession of a valid CIDB Green Card
and CSCS Card is mandatory for all site personnel.
Emergency Arrangements
Emergency Response Team (ERT) shall be formed at site. A list of emergency contact
person with phone numbers will be provided and displayed on the notice board on site.
First aid kits are in place for workers surrounding the vicinity to be prepared and regularly
checked by operation team. During emergency, the site management staff must
evaluate the situation and take the following necessary actions:
1) Raise the alarm.

2) Stop all works.
3) Remain composed.
4) Make sure all workers are assembled at designated assembly point.
5) Headcount shall be carried out.
6) First aiders shall attend to the injured workers.
7) Prepare assessment reports for the losses.

Permit Requirements
A Permit-To-Work (PTW) system is a formal written system used to control certain types
of work which are identified as potentially hazardous.
The objectives and functions of such a system can be summarized as follows:
1) Ensuring the proper authorisation of designated work. This may be work of certain
types, or work of any type within certain designated areas, other than normal
operations.
2) Making clear to people carrying out the work the exact identity, nature and extent
of the job and the hazards involved, and any limitations on the extent of the work
and the time during which the job may be carried out.
3) Specifying the precautions to be taken including safe isolation from potential risks
such as hazardous substances and energy sources.
4) Providing not only a system of continuous control but also a record showing that
the nature of the work and the precautions needed have been checked by an
appropriate person or people.
For this scope of work, these are the possible PTW that might need to be applied:
a) Lifting Permit: Safe work loads and calculations of the crane.
b) Night Work Permit (Applicable for night work activity only)
c) Hot Works Permit

ENVIRONMENTAL ASPECTS, IMPACTS AND CONTROL

MEASURE
Installation area will be cleaned before installation work commences. After completed
installation work, the working area will be cleared of any waste and disposed of at the
correct site disposal location.
All equipment should be maintained in good working condition to reduce emission of
smoke and noise. The following measures should be implemented if smoke and noise
levels increase:
a) Increase maintenance frequency;

b) Replace with an equipment in better condition if necessary;
c) Switch off the equipment when not in use;
d) Fully utilize the equipment’s silencer system;
e) Possible local enclosure of equipment

QUALITY ASSURANCE AND QUALITY CONTROL

Contractual Requirements
It is the contractual obligation of contractor to meet all the requirements outlined in Project
Plan & Procedures:
a) SSP-MGKT-UNGW-OVPR-PLN-0013 Rev 02 Project Quality Plan

b) MGKT-QSHE-PRO-0001 Rev00 Management System Document Control
c) MGKT-QSHE-PRO-0002 Rev00 Control of Records
d) MGKT-QSHE-PRO-0004 Rev00 Risk Management & Improvement
e) MGKT-QSHE-PRO-0005 Rev01 SHE Internal Audit
f) MGKT-QSHE-PRO-0010 Rev00 Hazard Identification, Risk Assessment and
Determining Controls
g) MGKT-QSHE-PRO-0013 Rev02 Centralized Document Control
h) MGKT-QSHE-PRO-0017 Rev00 Control of Subcontractors
i) MGKT-QSHE-PRO-0018 Rev00 Control of Variation and Claims by Subcontractors
j) MGKT-QSHE-PRO-0019 Rev01 Inspection, Testing & Laboratory Arrangement
k) MGKT-QSHE-PRO-0020 Rev00 Control of Inspection, Measuring and Test Equipment
l) MGKT-QSHE-PRO-0021 Rev01 Control of Non-Conformance
m) MGKT-QSHE-PRO-0026 Rev00 Receiving, Handling, Storage & Protection, Issuing
and Disposal.
Inspection and Testing

To carry out the necessary Testing of Materials, Workmanship of Installed Works,
Plants and sets of Equipment to conform to the contractual requirements and to fulfil
the expectations of client.
ITP Reference Number: SSP-MGKT-UNGW-OVPR-PLN-00537 Rev. 01
Follow up & Evaluation

• Completion of relevance tests as per Project Specification
• Completion of all test, RFI and closing the comments if any such that all records are
completed.

Appendices
5.1 Appendix A Construction Workflow
5.2 Appendix B Job Safety Analysis & Risk Assessment
5.3 Appendix C Environmental Operation Control Log
5.4 Appendix D PICO Inspection Record Sheet

5.1 Appendix A
Construction Workflow

5.2 Appendix B
Job Safety Analysis & Risk
Assessment

5.3 Appendix C
Environmental Operation Control
Log

5.4 Appendix D
PICO Inspection Record Sheet
Appendix D.1 - PICO Inspection Record Sheet for Hose

Reel Piping and Accessories
Reel Pump and Accessories
Reel Tank and Accessories


SSP MGKT Ungw Ovpr MST 00512

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MMC GAMUDA KVMRT (T) SDN BHD

PROJEK MASS RAPID TRANSIT LALUAN 2:

METHOD STATEMENT FOR INSTALLATION OF

Reference No. : SSP-MGKT-UNGW-OVPR-MST-00512

Date : 18 APRIL 2020

MMC GAMUDA KVMRT (T) SDN. BHD.

MMC GAMUDA KVMRT (T) SDN. BHD.

MMC GAMUDA KVMRT (T) SDN. BHD.

MMC GAMUDA KVMRT (T) SDN. BHD.

MMC GAMUDA KVMRT (T) SDN. BHD. 1

Post Installation Checkout (PICO)

Standard Detail Drawing

Inspection & Test Plan (ITP)

Method Statement (MST)

Material Submission Approval (MSA)

Y-Strainer - SSP-MGKT-UNGW-OVPR-MSA-01500, SSP-MGKT-UNGW-OVPR-

HDG HR Tank - SSP-MGKT-UNGW-OVPR-MSA-01877

MMC GAMUDA KVMRT (T) SDN. BHD. 3

MMC GAMUDA KVMRT (T) SDN. BHD. 4

Materials, Equipment and Manpower

1 Crane To lift/unload materials

MMC GAMUDA KVMRT (T) SDN. BHD. 5

No. Materials Description

3 Check valve / Globe Valve To prevent backflow

8 Pressure switches To set the cut in/out pressure of the pump

11 C-channels For pipe bracket and support

12 Cables To deliver power supply to the pump/control panel

13 Conduits/Cable Tray/Trunking To run/protect the control cables of pumps

MMC GAMUDA KVMRT (T) SDN. BHD. 6

Protection of the surface from environmental

No. Type of Manpower Job Function

Manage overall construction activities, resources

MMC GAMUDA KVMRT (T) SDN. BHD. 7

Figure 1: Example of crane lifting materials

MMC GAMUDA KVMRT (T) SDN. BHD. 8

Figure 2: Example of storage of galvanised steel pipes

1.5.1.2 Delivery, Inspection, Handling and Storage of Pumps

Figure 3: Delivery of pump using ropes/chains

MMC GAMUDA KVMRT (T) SDN. BHD. 9

Materials Inspection (RFI/Checklist) by MGKT & TCS

Submit lifting plan to MGKT for approval prior to arrival of

Checking quantity and quality of materials

Transfer materials to installation location

Barriers shall be placed around stored materials to prevent

Figure 4: Flowchart for material storage

MMC GAMUDA KVMRT (T) SDN. BHD. 10

Installation of Hose Reel Piping and Accessories

Figure 5: Installation of Drop-in Anchors

MMC GAMUDA KVMRT (T) SDN. BHD. 11

Figure 6: Installation of Bracket onto slab

7) For floor bracket support, see Figure 7.

Figure 7: Installation of bracket onto floor

MMC GAMUDA KVMRT (T) SDN. BHD. 12

Figure 8: Installation of bracket onto vertical wall

9) The U-bolt sizes are listed as below, see Figure 9.

MMC GAMUDA KVMRT (T) SDN. BHD. 13

Figure 9: List of U Bolt Size according to Diameter of Pipe

10) See Figure 10 for bracket spacing for pipes

Maximum intervals Maximum intervals Rod sizes

Figure 10: List of Bracket Spacing according to diameter of pipe

MMC GAMUDA KVMRT (T) SDN. BHD. 14

1.5.2.2 Threading of Pipes

Figure 11: Threading and grooving of pipes setup