DOC NO: E-EB-C-73-I204

REV: 01

Date: 06.05.2014

QSC-1 220kV/66kV SUBSTATION

METHOD STATEMENT FOR ABOVE & BELOW GROUND
COPPER PIPES INTERNAL & EXTERNAL INSTALLATION

PROJECT

: QSC-1 220kV/66kV SUBSTATION

CLIENT

: QATAR STEEL CO.

CONSULTANT

: MOTT MACDONALD

MAIN CONTRACTOR : SIEMENS

SUB CONTRACTOR : COMMODORE QATAR CONTRACTING CO.

METHOD STATEMENT FOR COPPER PIPES

INSTALLATION

Contract No. QS/01-26/2012 Doc. No. E-EB-C-73-I204 Rev.01

DOC NO: E-EB-C-73-I204

REV: 01

Date: 06.05.2014

QSC-1 220kV/66kV SUBSTATION

METHOD STATEMENT FOR ABOVE & BELOW GROUND
COPPER PIPES INTERNAL & EXTERNAL INSTALLATION

1. PURPOSE:
The purpose of this procedure is to ensure that all Copper Pipes Works and related activities are
executed in accordance with the contract requirements, hazards are analyzed, safety procedures
implemented, all quality assurance / control activities are conducted in a systematic manner,
works inspected and documented.
2. SCOPE:
The procedure is applicable to the Copper Pipes Works as associated with the project titled
QSC-1 220kV/66kV SUBSTATION.
3. REFERENCES:
3.1
3.2
3.3
3.4

Project Specifications
Project Approved drawings
Qatar Construction Specifications 2010
Approved Material Submittal

4. RESPONSIBILITIES:
4.1
4.2
4.4
4.5
4.6

Project Manager
Project Engineer
QA/QC Engineer
Foreman
Safety Officer

5. PLANT AND EQUIPMENT:

The equipments involved in Plumbing Works installation are listed below:
5.1
5.2
5.3

Portable Hand Tools

Plumbing Tools
Brazing Set

6. PROCEDURE:
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10

Check and verify to ensure that materials to be used are as per approved material
submittal.
Ensure that adequate quantity of the required pipe and fittings are available at site.
Ensure that proper tools and tackles are available at site.
Ensure that approved drawings are available at site.
Mark pipe layout as per approved drawing.
Fix the pipe supports as per approved standard specification.
Cut the pipe for required length.
Ensure pipe cut square before assembly with the fitting.
Remove all burred edges and clean the pipe with clean cloth.
Push the pipe into the fitting.

Contract No. QS/01-26/2012 Doc. No. E-EB-C-73-I204 Rev.01

DOC NO: E-EB-C-73-I204

REV: 01

Date: 06.05.2014

QSC-1 220kV/66kV SUBSTATION

METHOD STATEMENT FOR ABOVE & BELOW GROUND
COPPER PIPES INTERNAL & EXTERNAL INSTALLATION
6.11

Copper pipe work will be compression type except in the riser shaft. Inside the riser shaft
will be Integral solder ring (ISR) fittings in which no lead is used, the solders commonly
used being tin-silver or copper-tin. These are suitable for drinking (potable) water
supplies.
ISR and end-feed joints utilize a solder alloy of relatively low melting point (usually
copper-tin or silver-tin). The solder is drawn into a narrow gap between the tube and the
fitting. When solidified this produces a joint which is even stronger than the tube. In a
properly designed, installed and maintained installation, a suitably weld joint will, like the
tubing, last the life of the building. To ensure that the solder runs easily into the capillary
gap a flux must be used to remove any oxide films from the tube and fitting.
Compression Joints, use the tightening action of nuts on threads in the fittings to produce
a watertight joint on the tube, either by tightening up on an olive or by tightening up on a
pre-shaped end of the tube.

6.12

This method will follow for different size of pipe and fittings to finish the layout.

6.13

All exposed hot and cold water piping will be insulated with 25 mm thick fibre glass
insulation of 64 Kg/m density, wrapped with glass cloth and applied with two coats of
vapor barrier.

6.14

Penetrations for piping passing through shafts and walls will be sealed with noncombustible fire stopping materials for the full thickness and equal to the fire rating of
barrier to ensure full fire integrity of the shaft is maintained.

7. Testing:
7.1

Close all open end of the line with end cap or plug.

7.2

Fill water in the system with pump.

7.3

Raise the pressure up to 7.5 Bars using Hand Pump or electrical Test Pump.

7.4

Remove all air from the system or purge the system.

7.5

Keep the system for 4 hours in pressure 7.5 Bars.

7.6

If there is any leakage find out, rectify and test again.

7.7

After getting approval from the consultant, release the pressure.

7.8

Cleaning & Sterilization: The entire piping system is filled with chlorine solution of
200 mg/litre for a period of 30 minutes and flushed and cleaned. The entire system will
be flushed until it is clean and free from dirt, solids, chemicals or other foreign matters
which may affect the quality of water. After cleaning potable water is fed into the system
and sterilization chemical solution containing 50 mg/ litre of free chlorine (ie, 50 ppm of
free chlorine) is fed in to the system and kept for 24 hours. While the system is being
sterilized, all outlets kept closed and no water shall be allowed to flow through outlets.
After sterilization the water will be drained from the system and fresh water will be
admitted to the system. Water samples shall be taken from the system for bacteriological
and chemical analysis. If the test reports are unsatisfactory, sterilization shall have to be
carried out again.

Contract No. QS/01-26/2012 Doc. No. E-EB-C-73-I204 Rev.01

DOC NO: E-EB-C-73-I204

REV: 01

Date: 06.05.2014

QSC-1 220kV/66kV SUBSTATION

METHOD STATEMENT FOR ABOVE & BELOW GROUND
COPPER PIPES INTERNAL & EXTERNAL INSTALLATION

8. SAFETY:

Toolbox meeting must be conducted and all hazards have to be identified before starting
work.
Personnel Protective Equipments (PPE) to be used by the Task force during site work.
Obstacles should be cleared from surrounding area to avoid accidents.
Manufacturer recommendations must be followed on health and safety aspects while making
grooves and threads.
All hand and portable power tools to be used shall be of good order and be used for the
purpose intended.

9. QA/QC DOCUMENTATION:
9.1 Internal check list.
9.2 Inspection Request (RFI)
10. Attachments

Job Hazard Analysis

Inspection Test Plan
**************

Contract No. QS/01-26/2012 Doc. No. E-EB-C-73-I204 Rev.01

DOC NO: E-EB-C-73-I204

REV: 01

Date: 06.05.2014

QSC-1 220kV/66kV SUBSTATION

METHOD STATEMENT FOR ABOVE & BELOW GROUND
COPPER PIPES INTERNAL & EXTERNAL INSTALLATION
JOB HAZARD ANALYSIS

Contract No. QS/01-26/2012 Doc. No. E-EB-C-73-I204 Rev.01

DOC NO: E-EB-C-73-I204

REV: 01

Date: 06.05.2014

QSC-1 220kV/66kV SUBSTATION

METHOD STATEMENT FOR ABOVE & BELOW GROUND
COPPER PIPES INTERNAL & EXTERNAL INSTALLATION
Job Title

INSTALLATION OF COPPER PIPES

Job Location

Mesaieed Industrial City

Analyst

HSE Inspector

Hazard Type

Medium, (or high) due to electric shock or falling.

1

Risk of getting injuries to working personnel/ damage of materials by

mishandling of materials.

Description of
Risk

Risk of getting injury while working in the night with poor lighting effect.

Risk of getting electric shock causing human injury.

4
5

Risk of getting injury due to falling.

Risk of getting injury due to brazing.

Consequences Injuries, electric shock, death

1 Adequate personal protective equipment will be worn such as
hand gloves, safety shoes, safety helmet, goggles, etc.
2 Safety Toolbox Talks to be provided to all personnel, to promote
awareness of job hazards and risks and required precautions.
3 Trained and competent personnel will be employed for the work.
Risk Control

4 Safe and reasonable access shall be provided for the working areas.
5 Specified/ recommended industrial sockets/ plugs shall be used
for extension wires.
6 Power supply will be switched off when the power tool is kept idle
for longer period.
7 Sufficient lighting to be provided while night work is to be carried out.
8 Tools should be used for the intended purpose
9 Tools should remain in good condition

Comments

Strict supervision to be carried out by the site supervisors.

Contract No. QS/01-26/2012 Doc. No. E-EB-C-73-I204 Rev.01