Biện pháp thi công REE mechanical piping system installation work

Biện pháp thi công (Manner of Execution hoặc construction method statement) là trình tự và cách thi công 1 công trình cụ thể từ lúc bắt đầu thi công đến lúc kết thúc và bàn giao công trình, trong đó biện pháp thi công (BPTC) phải đề ra được: hiệu quả về thời gian, hiệu quả về phòng chống (như: tai nạn, phòng cháy…)

METHOD STATEMENT FOR MECHANICAL PIPING SYSTEM

INSTALLATION WORK

FOR CONSTRUCTION 26/08/2009

N.T.S

5 1

Công ty Cổ phần Dịch vụ & Kỹ thuật

CƠ ĐIỆN LẠNH R.E.E REE M&E CO.,JSC

364 Cong Hoa Street – Tan Binh District HCM City – VIET NAM Tel:38100017 * Fax: 84-8-38100337 Email: ree@reecorp.com.vn

C.T.PHUONG N.A.KIET L.Q.KHANH JRP

APPROVAL STATUS

Document Ref No.:

MC / REE / T+ / MS / G+ / GEN / 006 / B

NOTE: * – state N/A when external approval is not required – tick as appropriate

REE INTERNAL REVIEW:

PREPARED

Reviewed & Endorsed by:

INTERNAL APPROVAL:

External Review and Approval*

NAME N A Kiet P M Giang P K Tung C.T Phuong L Q Khanh

POSITION QA/QC

Engineer

Site Engineer

Safety

Project Manager

External Review and Approval*

NAME C.Abrogina P C Thuong T L Cong P V Hien OWa JDE

POSITION Project

Manager

M&E Engineer

QSE Manager

Safety Manager

M&E Manager

Project Manager

SIGNATURE

DATE

Review by I NDEPENDENT CHECKING ENGINEER on this Method Statement is

required not required.

DOCUMENT STATUS

Details of Revision:

Revision Rev Date Sections Amendment Source and/or Details

- 26-08-09 All First issue for endorsement

A 17-06-10 All

For Construction Follow comment sheet No.: SMC-BBI-ACT-COM-2237 issued by transmittal 009034 on date16-06-2010

B 01-11-10 All For Construction after add installation details of Cast Iron pipe under basement 5

Status of Page Revision:

Rev No Ö Page No.

C O N T E N T S

3.0 QSE Classification for Subcontractors / Suppliers 7

5.0 Organization chart & Responsibilities 43

7.0 Specific Safety Requirements & Precaution Measures 47

FOR CONSTRUCTION Follow comment sheet No.: SMC-BBI-ACT-COM-2237 issued

1.0 Scope of works:

The scope of this method statement is to provide a guideline for the implementation

of all piping system installation works for inside and outside of the SAIGON M&C

TOWER Project building

¾ Standards Required by Statutory Regulations:

1 Decree 06/ND-CP dated 20th January 1995 issued by Government to detail some clauses of Labour Code regarding to Occupational Health and Safety

2 Decree 209-2004_ND-CP dated 16th December 2004 related to Quality Management on Construction Works

3.0 Type of Materials / Suppliers:

The main suppliers used in this work or package is as following:

SUB-CONTRACTOR’s

Material Classification Type of Material (s) Supplier

M1 uPVC pipe & fittings De nhat / Snow / Nanya M1 Galvanized / Black steel pipe & fittings SeAH / Chunghung / Shijazhuang M1 Cast iron pipe & fittings Knack

M1 Ductile iron pipe & fittings PA M1 Copper pipe & fittings Haliang-China M2 The sub-materials using to install piping system VN

- M1 : Materials that must be submitted to the Client or its Representative for review and approval

- M2 : Temporary works materials that do not need to be submitted to the Client

or its Representative However, M2 shall be checked by BBI/JRP Engineer

In Charge when delivery on site

4.0 Materials / Sequence of work:

4.1 Material:

- uPVC pipe & fittings: Used for soil, waste, vent, storm water pipe and condensate water pipe

- Ductile iron pipe & fittings: Used for plumbing & drainage system

- Cast iron pipe & fittings: Used for drainage system

- Galvanized / black steel pipe & fittings: Used for fire protection system

- Galvanized steel pipe & fittings: Used for condensate water pipe system

- Black steel pipe & fittings: Used for chilled water pipe system

- Copper pipe & fittings: Used for refrigerant pipe system

- Braid, end cap, G.I cover, collar, rockwool, sealant, thread rod, clamp, rubber gasket, welding rod, soldering stick (silver, brass), oxyacetylen, N2 gas…

- Curved steel 30x5mm, steel plate 300x300x10mm, paint, adhesive, sealing tape (Teflon), bolt, nut, washer, accessories…etc

4.2 Preparation

- Task launch meeting will be held by Ree’s engineer in charge of the works with all the staff concerned by this activity to explain and remind for the Method Statement (MS), Inspection & Testing Plan (ITP), Safety

- uPVC, PPR, cast iron, ductile iron, galvanized/black steel pipe, fittings and accessories… are brought to the site and inspected by authorized person (BBI/JRP Engineer)

- All pipes smaller than Ø65mm will have screwed connections

- All pipes and joints with Ø65mm and above shall be welded or mechanical coupling except at valves where flanged connections shall be used

- Pipe shall be cut by power hacksaw, circular cutting machine with abrasive wheel, hand hacksaw Metallic wheel cutters shall not be permitted

- Welded joint shall be used for branch connections from Ø25mm diameter to smaller than Ø65mm diameter with main pipes

- During period work is not in progress, pipe, fitting shall be temporarily capped

to prevent entry of foreign materials

- All equipments and valve connections shall be fitted with union joints if pipe diameter smaller than Ø65mm and flange joints if pipe diameter over Ø65mm

- Each piping system shall be thoroughly flushed until proven clean before connecting to plant or equipment For carbon steel pipe, water must be filled

in pipe after finishing pipe leakage test or flushing in order to avoid the corrosion

- Pipe work will follow the arrangement shown on the approved shop drawings

b.) Pipe joint :

- If welded joints are impractical to be performed, flange joints or mechanical coupling shall be used for Ø65mm pipe and above where necessary

- If screwed joints are impractical to be performed for pipe size smaller than Ø65mm, approved steel socket steam union may be used

i Screwed joint

- Do not damage fittings surface, remove burrs and ream smoothly Apply teflon tape to the male thread All excess jointing material must be cleaned thoroughness

ii Flanges joint

- Use matched flange faces and 3-4mm thick compressed gaskets

iii Soldered joint

- Remove burrs and ream smooth Clean outside of pipe and inside of the fittings with sand cloth Apply flux and move flame evenly to joint position Clean joint of excess flux leaving a fillet around of the fittings & pipes

iv Brazed joint

- Prepare & clean joint surface Apply flux evenly to tube end and fitting socket when wrought copper fittings are used Ensure that heat joints must

be required about uniform temperature and apply filler metal Clean joint of excess brazing flux with wet brush or swab

v Welded joint

- Butt welded joints shall be open type by electric arc

- When welding is carried out in the proximity of inflammable material, special precautions shall be taken

- Upon completion of pipe joint, all welded joints shall be thoroughly cleaned off with stiff wire brush and painted with a coat of anti-corrosion paint

vi PP-R pipe joint

- PP-R pipe joint shall be show on item installation of PP-R pipe and fittings

4.3.2 General step by step for realization

a.) Preparation of Work for Site Fabrication

- Preparation work shall be carried out by workers

- Cut pipe to the required length

- All joints as mechanical coupling, welded joints, screwed or flanged connection shall be used for piping system

- Define the piping, fittings, accessories location and marking on concrete slab, floor or wall if necessary

- Before execution of pipe works, all pipes and fittings must be cleaned, unobstructed and free of any damage

- Upon completion of piping system, all pipe works shall be flushed with clean water prior to carrying out pressure testing

b.) Pipe Work Process Flow Chart

PIPING WORK INSTALLATION

TESTING COMMISSIONING

MAT'L INSPECTION

NO

YES

PIPE WELDING

b.) General scope of pipe installation work for realization

- Pipe sleeves are provided and installed as per approved method (refer to method statement for M&E penetration installation work MC-REE-T+-MS-G+-GEN-002)

- Mark the locations of pipes on the concrete/wall, trench or riser

- Measure and cut pipe into required length

- Install pipe supports as per approved method (refer to method statement for M&E support system installation work) The supports will be fastened to floor slab/wall structure

- The pipes will be adjusted to required position and clamped with proper supports

- Connect prefabricated pipe with another pipe or fittings by approved joints

- The gap between the pipe and sleeve will be packed with rock wool and cover up by using G.I sheet 0.8mm thickness (refer to method statement for fire stopping installation work MC-REE-T+-MS-G+-GEN-004)

- Clean all pipes with clean water

- Check of pipeline leakage by pressure test or water filling test upon hydrostatic test

4.3.3 Installation of PPR pipes & fittings

I.) Adhesive bonding joint for PP-R Pipes and fitting

a Cutting of the pipe

- Mark pipe according to the necessary length

- Cutting the pipe follow the marking Cut the pipe at right angles to the pipe axis

Cutting of the pipe

b Heating of pipe and fitting

- Push the end of the pipe up to the welding depth into the welding tool

- After the stipulated heating times quickly remove pipe and fitting from the welding tool (See table 1)

- Join them immediately until the marked welding depth is covered by the PP-R bead from the fitting

Heating-up of the pipe and fitting

Joining and fixing

Pipe and fitting are aligning

Table1: The fusion data

Pipe external - d

(mm)

Welding depth (mm)

Heating time (sec)

Welding time (sec)

Cooling time (min)

- Weld in saddles are available for pipe outer diameter of 40, 50, 63, 75, 90,

110, 125, 160, 200 and 250 mm The maximum sensor well diameter is specified in the following table 2

- Weld in saddles are used for:

• Branch connections in existing installations

• The substitution of a tee

• Branch connections in risers

• Sensor wells, etc

Weld-in saddle detail

- Drill through the pipe wall at the intended outlet point by using the drill

- Insert the heating tool on the concave side into the hole drilled in the pipe wall until the tool is completely in contact with the outer wall of the pipe

- The pipe outer surface and the pipe inner wall of weld-in saddle shall be fused and connected with highest stability

Drilling through the pipe wall

…

Drilling through the pipe wall

The welding tool is inserted into the pipe wall … …heating-up of the elements

Table2: The saddles data

d Butt welding

Pipes and fittings are fused, as explained below by butt welding ( pipe dimension 160, 200, and 250mm)

- Cut pipe into required length

- Plastic pipes are aligned and fixed by means of the clamping elements

- Push the pipes onto the heating place with a defined adjusting pressure

- When heating time has expired, divide the machine slide, remove heating element quickly and join the pipes (by putting both parts of the slide together)

- The welded connection can be unclamped when the welding process is finished

The parts to be welded are fixed and aligned respectively

Positioning of heating element

Divide the machine slide, remove heating element

Join the pipe, cool down under pressure

II.) Pipe installation :

a Installation for exposed pipes:

Hanger rod

Anchor boltConcrete slab

SleeveWall

(For exposed pipe on ceiling only)

PP-R PipePipe clamp

Pipe clampG.I sheet cover 0.8mm thk

(For exposed pipe on ceiling only)

G.I sheet cover 0.8mm thk(For exposed pipe on ceiling only)

Concrete slabFirestop material

Firestop material

Typical installation of exposed vertical PP-R pipe Typical installation of exposed horizontal PP-R pipe

b Installation for concealed pipes

- Mark location of pipes and outlet on walls according to approved shop

drawings

- After layout has been established, marking the pipes route on the brick wall

with two marked lines according to installed pipes size (Follow table 3)

Table 3: Wall Opening Size for PP-R Pipes

Item Pipe size (d) mm Opening (b) mm Depth(t) mm

InletPP-R Pipe

PP-R PipeCutting line

Typical installation of concealed PP-R pipe

4.3.4 Installation of uPVC pipes & fittings

I.) Adhesive bonding joint for uPVC pipes and fitting

- Mark the measured length on the pipe by permanent marker pen Cut the pipe using a power handsaw or a PVC cutter Be sure to cut the pipe squarely

- Clean away dust, dirt and oils with a clean rug before applying adhesive

- Before jointing, insert the pipe into the joint socket and confirm that the length from zero point to the end of pipe is 1/3 to 2/3 of actual socket length

- Mark the pipe surface by permanent marker pen Marking position shall be actual socket length from the end of pipe

- Apply adhesive uniformly and thinly with the brush for outside of pipe and inside of socket and insert Do not twist after inserting, but insert strongly, and press it down as it is Standard control times is 30 seconds for diameters of 50mm or less, take 60 seconds for diameter of more than 50

uPVC fitting

Typical installation of adhesive bonding joint for uPVC pipe & fitting

II.) Pipe installation

a Installation for exposed pipes

uPVC PipeHanger rodAnchor boltConcrete slab

SleeveWall

Pipe clampuPVC Pipe

b Installation for concealed pipes:

Table 4: Wall opening following pipe size

Item Pipe size (d) Opening (b) mm Depth (t) mm

Cutting line

Backfill

uPVC Pipe

End cap(cover)

uPVC PipeCutting lineConcrete slab

Wall

& Fitting

Concrete slab

Wall

c Installation for pipes through concrete

Installation work for all uPVC pipes (less than 50mm, 50mm up to 160mm, and over 160mm) through concrete slab shall be refer to method statement for fire stopping installation work (MC-REE-T+-MS-G+-004)

4.3.5 Installation of Cast iron pipes & fittings

I.) Cutting of pipe

- All cutting must be done in warehouse or in designated areas at each floor All cutting must not be done at work area

- Cutting angle must be right angle

- Pipe shall be cut by power hacksaw, circular cutting machine with abrasive wheel, hand hacksaw or square end for sawing vice only

- Inside edges shall be reamed smooth by reamer or sand paper

Typical installation of concealed uPVC pipes

II.) Coupling joint

a Pipe joint with pipe

1 Push the supplied complete connector on to the pipe end right up to the middle spacing ring of the seal

2 Turn over the open half of the sealing collar

Example for Cutting pipes

3 Install the next pipe or formed part flush with the spacing ring and fold back the turned over half of the collar

4 Place the clamping sleeve around the collar

5 Alternatively tighten the two clamping screw uniformly and hard tight The guiding and threaded plates of the clamp must come together parallet to avoid any deformations

b Pipe joint with fittings

1 Push the supplied complete connector on to the pipe end right up to the middle spacing ring of the seal

2 Push the pipe end from the other end into the connector

3 Firmly tighten the hexagon socket screw with a socket spanner, hard ratchet or impact screwdriver to the point where the two clamping jaws come together