Project Name: Compressor Air Piping work @ BM5,6,7&ANO Building,

Client: TATA Electronics Pvt Ltd..,

Consultant: TATA Consulting Engineers Ltd..,

WORK METHOD STATEMENT FOR COMPRESSOR AIR PIPING SYSTEM

Sl no. Content Remarks

1 Purpose
2 Scope
3 References
4 Definitions
5 Resources
6 Procedure
7 Quality assurance
8 Health and Safety
9 Environmental Issues
10 Attachments
11 List of Drawings

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1.0 PURPOSE
The purpose of this method statement is to describe the procedures and techniques along with
the health & safety measures to be implemented during installation / Erection of pipes, &
control valves site to ensure compliance with the contract requirements, quality control and
safety measures.

2.0 SCOPE
This scope of Method Statement covers the Compressor piping Installation, Testing &
Commissioning package at Project.

3.0 REFERENCES

Specifications
 Based on BOQ for Supply, Installation, Testing & Commissioning of Compressor Pipe line
work.
Drawings
 drawings (As Per Attached List)

4.0 DEFINITIONS

 HSE – Health, Safety & Environment

 ITP – Inspection and Test Plan
 IR - Inspection Request
 GFC - Good for Construction
 QCI– QA/QC Inspector
 PPE – Personnel Protective Equipment
 MS- Mild Steel
 GI – Galvanized Iron
 TBT –Tool Box Talk
 MOM – Minutes of Meeting
 T & C -Testing & Commissioning
 NCR – Non Conformance Report

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5.0 RESOURCES:

RESPONSIBILITIES:

Project Manager:

Shall manage, co-ordinate and control the entire project in the terms of cost, quality and
schedule. And shall be liaise with the Project Committee and external support / direct the
project team for successful and timely completion of the project. In terms of specific project
requirements, the Top Management / Project Manager are required to assume responsibility
and authority for all aspects of the construction of the project. And to direct the phasing in all
operations on the overall project and to ensure that suitably qualified personnel are in charge
of the various activities in the job. And Overall responsibility for ensuring that all technical
processes, tasks and functions are fully adhered and followed.

Project Engineer:
Shall coordinate with Construction Manager and Supervisor and ensure all the project activities are
performed according to the scheduled program, HSE procedures and Quality procedures. And shall
be responsible to ensure site Construction activities are being executed as per approved Method
Statement, Specifications, latest GFC drawing, relevant QC check list &formats are duly completed
as per Inspection & test plan. Materials used at site are as per Approved Material submittal. Shall
ensure the latest Drawings, Method Statements are available on site and is communicated down
to Supervisor.

HSE Engineer:
Shall advise the line staff & workers on HSE matters; organize / conduct HSE training, facilitate
implementation of HSE requirements, monitor compliance and report performance and non-
performance.

Site Supervisor:
Shall coordinate with the project Engineer and shall be responsible for individual activity. Ensure
that latest GFC drawings are being used at site. Organizing all necessary material, tools, equipment
to the work site and assigning workmen crew prior to commencement of work. Follow the
procedures and HSE control measures. Ensure that risk control measures are known to workers by
arranging daily toll box meetings.

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Storekeeper:
Shall takesuitable care during storage and handling of materials at the site and
Relevant handling, storing and preserving methods are mentioned in appropriate method
Statements.
Upon receipt of any material the storekeeper shall verify the same for physical damages, quantity
and general condition of the delivered material. Storekeeper shall in form the respective engineers
and QA/QC department for their inspection and route the document such as delivery memos, .
Indents, LPOs etc
As appropriate identification and traceability is maintained in the site. Materials are either
Stored in designated and marked places or identified with TAGS. Completed work is
Identified area wise and traceable to the drawing.

The storekeeper is responsible for maintaining all the records related to the material delivered.
The material indents, PO, Delivery Challans, Goods Receipt Note (GRN) shall be filed and
Maintained by the storekeeper and should be able to easily present the same for inspection and.
Verification, at any time.

Foremen:
Shall receive the work instruction from the supervisor and carry out the marking and cutting for
fabrication

Fitter:
Shall receive the work instruction from the foremen and carry out the activity in line with the
drawing within the scheduled time period.

Welder:
Shall receive the work instruction from the fitter and started the welding at root and finishing in
line with the drawing within the scheduled time period.

Electrician / Technician:
Shall receive the work instruction from the supervisor and carry out the activity in line with the
drawing within the scheduled time period.

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 Helpers:
Shall receive the work instruction from the supervisor and carry out the activity by assisting with
Welder / Fitter to complete the activity within the scheduled time period.

5.1 Plant and equipment

The manpower to be used during the execution at site as includes but not limited to:

 Project Manager
 Project Engineer
 QA/QC Engineer
 HSE Supervisor
 Site Supervisor
 Store Keeper
 Foremen
 Welder
 Fitter
 Electrician
 Helpers

5.2 Plant and equipment

a) Installation Tools

 Measuring tape
 Drilling Machine with Drill bit set
 Drilling Machine (Metal) with Drill Bit and Hole saw cutter set
 Welding Machine
 Cutting set
 Cutting machine
 Cable Extension Wire Set
 Grinding Machine
 Appropriate spanners
 Hand Tools
 Pipe Cutter for AL Pipe
 Grooving Machine for AL Pipe

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 b) Safety Tools

 Mask
 Ear Plug
 Safety Goggles
 Full body safety harness
 Lifelines
 Hand gloves
 Safety Shoes
 Helmet
 Welding Dress

c) Testing Tools

 DP Kit
 Test Compressor
 Tools

6. PROCEDURE
NOTE THAT INSPECTIONS MUST BE CALLED WITH THE CLIENT / PMC AS LISTED IN THE ITP
ATTACHED WITH THE METHOD STATEMENT.
6.1 Materials

6.1.1 Material Receipt

 The materials received shall be checked for manufacturing details as per delivery note and
approved MAS to ensure delivered items are correct.
 Quantity, Delivery Notes, the Packing List, Country of Origin, Factory Test Certificates are
verified by store keepers per Purchase Order.
 Details of the material receipt shall be conveyed by storekeeper to Project Manager and
Quality Engineer.
 Quality checks shall be done by QA/QC Inspector and an Inspection request shall be raised
and records maintained.
 Check for physical damage.
 Check the quantities are correct as per the purchase order and delivery note.
 Check the materials are packed in the manufacturer’s original packing.
 Once the materials are received at the site, the QA/QC Engineer, as per ITP, shall intimate
and confirm with PMC for Inspection by raising MIR.

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6.1.2 Material Handling

 Hand gloves shall be wore during shifting / unloading / loading / handling etc
 Care shall be taken to avoid any physical damage when handling the piping installation items
& accessories
 All piping installation items & accessories shall be shifted with their packing in place
 Packing shall be maintained until time of installation
 For movement of the delivery vehicles HSE safety guidelines shall be followed.

6.1.3 Material Inspection:

 Submit material inspection request upon receipt of materials delivery to site .attach
delivery receipt, material submittal approval and other documents to show complete
compliance with contract specifications.
 Delivery and store materials in manufacturer’s original packaging labelled to show name,
brand, type, and grade, store materials in protected dry location off-ground in accordance
with manufacturer’s instructions.
 Materials to be shifted via hoist/manually, to the required floors/areas and arranged neatly.
 Only required material to be shifted to site and stored temporarily and ensure excess
materials are not dumped to site and congest the working area.
 Waste material management and storage.

6.1.4 Material Storage

Pipes:
 Galvanized steel / MS Pipes as per IS: 1239 / 3589 shall be stacked in stockyard, diameter-
wise.
 The pipes shall be supported at 4 meters intervals and shall be at least six inches above the
ground level.
 After receiving of pipe at site we apply one coat of primer except red colour strip at one end
for identification.
 As far as possible these pipes shall be stacked in a fairly level ground. Pipes can be held in
position by driving a rod into the ground at every 2mts interval.
 The stack should not exceed a maximum height of 1.80 Mts. All cut-pipe pieces shall be
segregated and stacked diameter-wise.
 Aluminium Pipes are stored in a separate rack.

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Pipe fittings and specials:
 Up to 50mm diameter, all pipe specials (As per approved GFC Drawing) shall be neatly
arranged and labeled in wooden compartments, diameter-wise.
 Beyond 50mm diameter, all pipe specials shall be kept in bags and segregated according to
sizes. Pipe specials above 100mm size shall be kept in open, arranged neatly and labeled.
 Aluminium Pipe fittings separately handle in a container.

Cables:
 Cables shall be kept open inside the storage area coiled properly with proper labeling
mentioning size and make of cables.
 The necessary length of cables shall be cut and used.
 The cut pieces shall be kept properly in one corner of the storage area segregated according
to sizes.
 No cable pieces shall be left on the construction area
 The available cable lengths shall be returned to site store properly to achieve proper stock
at Site office.

Pipe Erection:
 Before the fabrication start , Pipe shall be coated one coated yellow Primer & One Coat of
Blue color paint
 After complete the fabrication, Pipes shall be shifted fabrication yard to plant by using man
power/crane.
 Horizontal pipes are erect using hydra or man power
 The horizontal pipes shall be hanged on the ceiling by means of Hi-tech supports and spaced
as per drawing accordingly.
 The other way horizontal pipes shall be placed in the pipe rack and U Clamp supports are
provided for pipe and spaced as per drawing accordingly.
 Pipes shall be carried through the duct / stairs properly using required manpower.
 Vertical rise of the pipes shall be erected using boom lift.
 These pipes shall be fixed rigidly to the Angle support by using bright rod ‘U’ clamps and
additional pipes shall be butt-welded to raise the riser as per standards.
 Random welding joints are testing with DP Kit.
 Air to be filled via testing compressor through the GI pipes and the pressure hold for the 2
hours, without drop in pressure and shall be notified to the concerned authorities before
start and finish of the hydrostatic testing.

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  During commissioning stag, flush entire piping network with pressurized air by means
ensure no foreign particle is left inside.
 The pipes shall be cleaned properly and painted with one coat of blue enamel paint final
coat

Welding and Cutting Operations

 Welding is the common process that is extensively used in the fabrication of items from
metal plates / rolled steel sections (pipes), etc. that are to be joined together.

Arc Welding Machine

For arc welding, Inverter type welding machine is used. The transformer receives the A.C supply
between 200 and 440 volts and transforms it to the required low voltage in the range of 50V to 80
volts. A high current of 95A to 125A will be suitable for general arc welding work. Adequate spares
shall be kept in stock at site during the execution of the work for routine maintenance. While
execution welding machine, electric cables, distribution boards and connections shall be carefully
checked regular interval.

Arc Welding Electrodes

Consumable-coated electrodes shall be used to fill the joints, with the coating providing….
i) The protection from oxygen and nitrogen of the air by providing a gas shield around the arc, and
the molten pool of metal.
ii) Helping to establish and maintain the arc throughout welding.
iii) The formation of slag over the joint thus protects from rapid cooling
iv) The addition of alloying element.
AWFS E-6013 welding electrodes shall be performed using Shielded metal arc welding (SMAW)
operation; the electrodes shall be stored indoors free from moisture.
Welder should be qualified and skilled to perform the welding joints and follow all safety
procedures during the performance of welding sequence.

Gas Cutting Equipment

Gas cutting is fusion method of cutting, in which a strong gas flame is used to raise the temperature
of work pieces so as to melt them. The following gases can be used for heating and cutting
a) Oxygen and Acetylene mixture.
After cutting all the ends shall be properly grind to the required size/length and proper finish.
The oxy-acetylene gas equipment consists of two large steel cylinders; one containing oxygen at
high pressure, and the other dissolved acetylene also at high pressure, rubber tubes, pressure

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 regulators and blowtorch. The oxygen and the acetylene are supplied to the blowtorch separately,
where both of them get mixed and come out through the nozzle of the blowtorch.

Quality Control for Welding

1) Cracking: - It occurs due to incorrect electrodes or wrong working procedures. Cracked welds
must be cut and re-welded.
2) Incorrect edge preparation:- Too narrow and angle of the edges of the work pieces result in
poor fusion, slag inclusion and weak weld. Too wide an angle between the inclined edges results
in heavy welding, resulting in overheating and locked up stresses.
3) Craters:- These are concave depressions in the external surface of the welded joints which
reduces the volume of the weld and thus the strength of the joint.
4) Under-cutting:- It is excess melting of the parent metal which reduces its strength.
5) Unequal legs:- In fillet welding, the unequal length of the legs of the weld reduces the strength
of the joint.

PRE INSTALLATION PROCEDURES:

 Prior to commencement of work all equipments, materials and documents relaxant to

particular section of works will be checked, ensuring that the materials are as per approved
shop drawing and material submittals.
 QA/QC inspector to check physical verification of materials will be carried out for any damage
prior to taking stores.
 Ensure that all pipes installation is coordinated with other services in order to avoid
obstructions and smooth finishing of the work.
 All the required materials, fittings and other equipments necessary for the erection of the
piping shall be collected from stores and shifted to the respective location.
 Prior to commencement of work, area and access will be inspected to confirm that site is ready
to commence the work
 All relevant documentation and materials applicable to particular section of work will be
checked by site supervisor prior to commencement of work.
 The site engineer /site supervisor will give necessary instruction to tradesmen and provide
necessary approved shop drawings along with coordinated layouts(if required)
 The site supervisor/ foremen will also check that proper equipments/tools/ work front are
available to carry out the work and are in compliance with contract specification.

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  Site supervisor will ensure that all grid lines and datum lines are marked by main contractor’s
surveyor and all the route and markings are based on that datum line provided by the
surveyor.
 Ensure that the location of pipe installation should have civil clearance prior to commence the
work.
 The site supervisor also explains the tradesmen regarding safety precaution to be observed.
 Ensure worked area should be clean and excess & waste material shall be removed.

6.2 Installation Works:

A. Fabrication Procedure for Piping.

 Prior to commencement of work required permits such as daily permit / holiday permit, night
work permit etc., shall be obtained in accordance with the project HSE plan / guidelines along
with details like schedule of man power , timing and work activity location etc.
 For all layouts, direction, Orientation, GFC drawing shall be followed.
 Specific Task briefing for the site installation method shall be provided by site supervisor /
Project Engineer prior to start the work
 Compressor air piping installation items & accessories are received at site shall be checked in
accordance with MAS and GFC drawing
 All relevant document : GFC drawing , check list, work procedure, approved material schedule
etc., shall be available with site execution team and are understood by them.
 As per the work front the required quantity of pipe, valves, fittings & supports and necessary
accessories for installation shall be shifted from the stores to site based on scheduled period.
 Settable Lifts / tools shall be arranged for the installation.
 Project engineer / site supervisor shall give necessary shall give necessary instruction to
technicians to regard to installation items
 Site supervisor shall check and ensure required hand tools and equipment are available to carry
out the work activities
 Site supervisor ensure availability of skilled, semi – skilled and unskilled workmen to perform
the job.

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B. INSTALLATION OF HORIZONTAL RUNS:
 Ensure that all civil / Structural works are completed where the pipe is running
 Mark the routing of the Compressor air piping on the Rafter line
 Install the supports as pr approved shop drawing and spacing between support/hangr will be
maintained in accordance with latest approved shop shop drawing /manufacturers
recommendation and as per construction specification.
 Install the pipes in the position on supports and make sure that all pipes are aligned.
 Wherever pipes are passing through wall and floor sleeve to provide as per construction
specification .gap between sleeves and pipe shall be filled with insulation materials and sealed
with sealant at both ends .Fire rated sealant shall be used in case if the pipes are penetrating
fire rated walls.
 Wherever pipes are crossing building expansion joints, proper expansion fitting to be used as
per construction specification.
 Assemble the pipe and fittings as per approved shop drawings.
 Joining of M.S/G.I pipes carried out as per manufacturer recommendations.
 Ensure that all open ends of pipes, fittings are covered with polyethylene sheet before leaving
work place.

C. INSTALLATION OF VERTICAL RUNS:

 Ensure that the required provision for maintenance of shaft piping is provided in the block work
as per approved shop drawing and sketches
 The inside faces of the shaft to be finished before fixing of the vertical riser pipes.
 Make sure that proper working platforms certified by authorized safety personnel are made for
safe working inside the shaft.
 Fix the pipe fittings on the outlets pipes protruding from the slab opening and align to the
plumb of vertical riser.
 For joining of GI/MS pipes and fittings manufacturers recommendation will be followed.
 Fix the clamps to vertical riser pipes at specified intervals of as per approved drawings or
manufacturer’s recommendation which are already fixed to structural members.
 Make sure that the vertical or riser pipes are isolate as per approved shop drawings and
contract specification.
 After approval of piping layout, flush the piping system with clean water to remove all
dirt/debris that might have been during construction work.

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D. JOINTING METHODS OF GI/MS PIPES ;
 Assemble the pipes and fittings as per approved shop drawing
 For joining of GI/MS pipes and fittings manufacturers recommendation will be followed.
 Prior to threading the pipes and fittings should be degreased, dried and thoroughly cleaned.
 Using pipe cutter/hack saws to cut and prepare the length of pipe to be joined, and ensure the
pipe edges are square.
 Prepare the pipe ends according to the type of jointing i.e. threaded joints.
 The end preparation shall be done at site.
 For making threading use threading machine/threading tools.
 Use lubricant while making the threading.
 After the end preparation clean the pipe ends and ensure no material and dust is left inside.
 Joints for threaded pipes shall be made with an approved Teflon tape or graphite compound
applied to the male threads only.
 Make sure that tapered threads with the ends being reamed before installation.
 Threads, exposed after joints are made up, shall be mopped with compound.
 Tighten the pipe/fitting joint with wrench with adequate torque.
 Depending on the site condition, assemble the piping into manageable lengths on the floor
using threaded jointing as applicable.

F. FLANGED PIPE JOINT:

 Flanged joints shall be installed at all valve size above 2” and other places where necessary.
 Ensure that jointing flanges shall be truly parallel to each other so that bolts are used only to
tighten joints.
 Make sure that flanges shall be as per approved material to suit the maximum working pressure
of the system.
 The bolts , nuts and washers shall be as per approved materials or as per recommendation of
flanges manufacturer.

G. WELDING JOINT:
 Welding is a metallurgical process in which the junction of the two parts to be joined are heated
and fused together with or without the application of pressure to produce a continuity of the
homogenous material of the same composition and the characteristics of the parts, which are
being joined. Fusion or non-pressure welding.
 Prior to welding the pipes should be degreased, dried and thoroughly cleaned.
 The fitter shall use a normal welding transformer to join pipes by tack-welding the component
pipe-pieces & fittings. Joint-gap of minimum 2 mm shall be maintained for ‘butt-weld’ items.

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  Good quality electrode shall be used, to fill the gap (with molten weld-metal) with proper bed,
for fill and cap runs.
 The skilled welder shall start a root weld run, and wire brush the root bead so that the flux on
the joint is completely removed.
 After letting the joint to solidify for a few minutes, the final weld run shall be performed and the
flux removed once again.

H. INSTALLATION OF VALVES AND ACCESSORIES:

 Install control valves & accessories etc. according to the approved drawing and specification.
 Ensure that union/flanges are provided for the valves.
 Make sure that proper clearance to be provided for maintenance.
 Ensure that the system equipment, valve and accessories are securely and rigidly mounted by
anchor bolts on the civil base constructed for this purpose.

I. PRESSURE TEST (PRESSURE PIPES):

 Arrange for witness of all tests by the consultant/client. provide everything necessary for
carrying out testing and cleaning including water, pipe connections , stop ends and all other
temporary works.
 Ensure that joining of pipe work is completed before starting the pressure testing and having
approval of consultant/client.
 The entire area of pipe network subjected to pressure test should be barricaded with safety
warning tapes and warning sign “PRSSURE TEST IN PROGRESS KEEP AWAY”.
 All open ends to be plugged.
 Calibrated gauges to be installed at injection point and farthest point of network.
 Fill the air slowly into the pipe network by using hydraulic testing pump via the injection point
at 0-bar pressure.
 Pipe system should be tested for leakage at 2 times the operating pressure or 1.5 time shut-off
pressure.
 If any leaks observed during the pressure stages, notify immediately to stop and the pressure to
be dropped to 0-bar.
 Follow the repair work at leak position and repeat the process again.
 The pressure testing to be hold for 2 hours.
 Once successful test pressure is hold up to 2 hours, reading to be completed and signed off
witness to be done.
 Once the works are completed as built drawing will be submitted for the final handing over of
the works

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J. PAINTING OF PIPE:
 After successfully completion of pressure testing the pipe are painted with special prime one
coat, Yellow Primer one coat, Blue color two coated as per specification in the left out areas

K. Operation & Maintenance Manuals

The O & M manuals should contain following minimum information:
 A brief description about the project and the installations carried out.
 Schedule of mechanical / electrical equipment installed.
 Schedule of as-fitted drawings.
 Manufacturer’s operation & maintenance manuals and any warrantees issued by
manufacturers.
 List of recommended spare parts.
 Notes / recommendations on preventive and remedial maintenance works.
 List of manufacturers with their local contact details.
 Technical catalogues of important products used on the installations.

7. QUALITY ASSURANCE

The Quality Assurances encompass of following.

 ITP shall be followed and coordinated accordingly with the PMCs site activities.
 Execution of work shall be done as per latest “Issued for Construction” drawings and
Specifications.
 Ensure materials used are as per method statement.
 Inspection Request forms (IR) shall be raised and approval from the PMC shall be taken
before proceeding with next activity as per ITP clause.
 Marked up drawings, shall be prepared as per site conditions.
 Final as built drawing shall be prepared and approval shall be taken from the Design
Consultant.

8. HEALTH & SAFETY

 All employees involved in the activity shall undergo site HSE induction course prior to
deployment to the work site.
 Site activities shall be carried out in a safe manner according to the approved “Project
Health, safety and environment plan and Task Risk Assessment.

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8.1 Training (workers & supervisors)

The following HSE training shall be delivered to the crew but not limited to:

 Working at height.
 Hot work
 Manual Handling
 Safe Material Handling
 Use of hand tools/ power tools.
 Safe Lifting operation (Rigger and lifting supervisor)

8.2 `Risk Assessment and Control - through HSE Plan

 HSE Hazards involved in the activity has been assessed through approved HSE Plan.
 The contents in HSE Plan shall be disseminated within the crew by the supervisors via Toolbox
Talk.
 Any new hazards identified other than in the HSE Plan with reference to site conditions shall be
assessed and control measures shall be taken by the Site Engineer/Supervisor prior to
commencement of any activity.
 General risks and controls shall be implemented vide HSE Guidelines for supervisory staff and
copy of the same must be available with site supervisory staff whilst on duty.
 General control measure:
 Correct usage & maintenance of tools and equipment.
 Deployment of competent personnel for the task.
 Conduct tool box talk prior to work commencement.
 Provision of adequate warning signs, barricading.
 Provision of first aid and fire fighting equipment.
 Good housekeeping.
 Adequate and effective supervision.
 Use of necessary PPE.
 Provision of welfare facility.

8.3 Additional Personal protective equipment (PPEs)

 Dust Mask, Ear Plug, Safety Goggles, Full body safety harness, Lifelines and suitable hand
gloves and helmet for the operatives.

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 8.4 First aid / Medical facility / Emergency Response

 Availability of First Aiders with ready access to first aid boxes kept at site shall be ensured at
worksite.
 Follow project wide Client/PMC emergency response arrangements.
9. ENVIRONMENTAL
9.1. Environmental Issues

 Waste generation.
 Dust.
 Noise.
9.2. Mitigation Measures

 Collection, segregation and disposal of waste materials at designated areas.

 Water spraying and dust masks to control dust impact.
 Ensure ear plugs are made available and worn.

10. ATTACHMENTS
10.1. Inspection Checklists
10.2. Inspection & Test Plan (ITP)
10.3. Inspection report for Pipe welding joints
 Pressure test report for GI pipes.
11. List of Drawings

Sl
Drawing Description Revision
no.
1
2

TAPCO Pneumatics TCE

Name
Signature
Date

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