Project Offices -02 at DF1at Method Statement for

Dholera, Gujarat Fabrication, Installation and Testing

of Fire Sprinkler & Fire Protection
System

MST No .AEEPL-2526-LT-FPS-
MST-001
Work package: Fire Fighting

TATA Semiconductor Manufacturing

Private Limited

Organization Ascent Engineer L&T Package L&T EHS L&T QAQC

owner
Name: Mihir Paghdar
Designation Project Manager
Signature:
Date: 01.01.2026
 Document Change Record

Revision Date Submission Author

Table of Contents

1. Abbreviations & Definitions

2. Purpose
3. Scope of Work
4. Standards Specification & Referenced
5. Tools, Plant & Equipment
6. General Requirements
7. Site Location
8. Material Description, Transport, Delivery, Handling & Preservation
9. Storage on Site
10. Installation Methodology briefing
11. Organization & Responsibility
12. Workforce/Training
13. Quality requirement
14. Health, Safety & Environmental
15. Hira
1. Abbreviations
 IFC – Issued For Construction (final approved drawings issued for execution at site)
 TDS – Technical Data Sheet
 MIR – Material Inspection Report (document confirming material inspection and
approval)
 OEM – Original Equipment Manufacturer (supplier/manufacturer of equipment or
components)
 HSE – Health, Safety & Environment (site safety and environmental compliance
standards)
 BOQ – Bill of Quantities (itemized list of materials, equipment, and works with
quantities)
 WPS – Welding Procedure Specification (approved welding methodology and
parameters)
 UL – Underwriters Laboratories (international safety certification standard)
 NFPA – National Fire Protection Association (global fire safety standards body)
 IS – Indian Standards (Bureau of Indian Standards codes applicable in India)
 DFT – Dry Film Thickness (measurement of paint coating thickness after curing)
 GI – Galvanized Iron (steel pipe coated with zinc for corrosion resistance)
 IR – Inspection Request (formal request for inspection of completed activity)
 QC – Quality Control (inspection and verification of work quality)
 PPE – Personal Protective Equipment (helmets, gloves, goggles, safety shoes, etc.)

2. Definitions
 Method Statement (MS): A formal document detailing the step-by-step procedure,
workforce, safety, and quality measures for execution of specific works.
 Shop Drawings: Detailed drawings prepared by the contractor/vendor showing
fabrication, installation, and coordination details beyond GFC drawings.
 Sprinkler Drop: Flexible hose assembly connecting branch piping to sprinkler heads for
ceiling installation.
 Escutcheon Plate: Decorative cover plate used to conceal the gap between sprinkler
head and ceiling surface.
 Psychrometric Readings: Measurements of humidity and dew point taken to ensure
correct painting conditions.
 Riser Piping: Vertical fire water piping installed in shafts to distribute water across
multiple floors.
 Socket Weld Joint: Pipe joint where pipe is inserted into a recessed area of a fitting and
welded.
 Flanged Joint: Pipe joint using bolted flanges with gaskets for sealing.
 Pypkote/Pypstik: Cold-applied primer and wrapping material used for corrosion
protection of pipes.
3. Scope of Work

 This method statement provides a broad sequence for Installation of Sprinkler Piping and
its related accessories at locations in Project Office Building 2 at DF 1 at Dholera Gujarat
as specified in the approved drawings.

 This method statement is proposed for the Fabrication, Installation and Testing of Fire
Sprinkler & Fire Protection System. All work shall be carried out in accordance with Site
safety rules and regulations as guided by the Project specification are based on tender
documents

4. Purpose

 he objective of this method statement is to define construction sequence in relation to

the Fabrication, Installation and Testing of Fire Sprinkler & Fire Protection System as
applicable with Associated Support System at Project office building - 02
 The aim of the method statement is to set out the procedures, precautions to observe
during unloading, storage, lifting and shifting of Fire Protection System material to
desired location, and the installation sequence. This method statement shall be read in
conjunction with project specification, relevant codes for installation & testing.

5. Standards Specification & Referenced

 NFPA13 Statement for installation of sprinkler system

 NFPA 14 installation of standpipe and hose
 NFPA 10 installation of Fire Extinguisher
 National Building Code of India: 2016
 Approved GFC Drawings/ Shop Drawings
 Material Approval Submission
 Approved Technical Data Sheets
 Materials TDS
 Approved Mockup Installation
6. Tools, Plant & Equipment

Ite Description
1 Measuring Tape
2 Toolbox
3 Drilling Machine
4 Grinder
5 Sprit Level
6 Welding Machine
7 Grooving Machine, and tape
8 Pipe Wrench
9 Chain Block
10 Testing Pump
11 Calibrated Pressure Gauge
12 Spanners
13 Vice Table
14 Laser light
15 Torque wrench, Rebar detector
16 Pipe lifter, forklift, mechanical elevators (scissor & boom
lift), scaffoldings (fixed & mobile type) as necessary
Materials
1 GI pipes & Fittings
2 Paint, Primer
3 Support material – anchors, hangers, threaded rod, nut
washers, bolts, ISA/ISMC, clamps, etc.
4 Valves
5 Flexible sprinkler drops
6 Sprinklers
7 Identification material
8 Gaskets
9 Electrode
7. General Requirements

 Engineers shall give proper Toolbox talk to Supervisors and labors on the job
specific requirements.
 Ensure that all workers engaged are properly gone through the induction process.
 Site Engineer/Safety Departments shall organize general awareness training for
Workers.
 Arranging tools required for to complete job, and ensuring all Safety procedure is
been followed

8. Site Location

 Project Offices – 02

9. Material Description, Transport, Delivery, Handling & Preservation

9.1 Material Description

Sr. No Description
Fire shaft door (double leaf) made of 18 gauge M.S sheet with glass front door (4mm thick)) -
complete with hinges, handle, locking arrangement, recessed key provision and painting.
1 The size shall be 900mm x 2100mm x 100mm with all neccesary accessories including
fitting , suitable for fire shaft enclosing.
RRL Hose pipe shall be rubber lined woven jacketed 63mm in diameter and 15m long - Non
2 Percolating type conforming to IS 636 with stainless steel coupling - instantaneous spring
lock type and also as per the requirement of local fire service department.
First aid hose reel equipment with hose reel guiding bracket, hose tubing globe valve, stop
cock and nozzle conforming to IS [Link] tube shall conform to IS 12585 type 2 made of
3 thermoplastic 20mm dia and 36 m long thermoplastic hose and 25mm dia globe valve for
isolation and also as per the requirement of local fire service department.
 Butterfly valve
4 C.I Butterfly Valve , Hand Lever operated wafer ends of PN 10 Conforming to BS 5155:
1984./IS 13095
5 Non-Return Valve Cast Iron - Double Flanged - Dual plat type - PN 10 for terrace pump
6 Fire water terrace tank HDPE O/H Water Tank with ball brass valve
G.I Heavy Grade piping as per IS : 1239 - 2004 / IS :3589 - 2001. Above ground piping with
7 supports necessary flanges ,fittings(butt weld) such as elbows, tees and painting etc.
complete
8 Gun metal air release valve - 25 mm with isolation valve
9 Gun metal Ball Valve PN 10.
10 Fire Brigade inlet - 2 way with inbuilt NRV- For Feeding downcomer
11 Pressure gauge 150 mm (0-15 bar) with isolation valve
12 Fixed type pressure switch with isolation valve
Terrace pump - Booster pumps for 440 V, 3 Phase, 50 Hz Confirming to IS- 12469 :1988 With
CI Casing bronze impeller and stainless steel shaft mounted on heavy duty bearings
13 suitable for 440 volts, 3 phase, 50 Hz 35m head, (kirloskar model KDS or equivalent) - Cat
iron body /bronze impeller/stainless steel shaft/Mechanical or gland pack sealing and IP 55
enclosure protection
CO2 extinguisher - wall mounted type with holding brackets, fixing arrangements , BIS
14 approved & marked
Water type fire extinguisher 9 lts. Capacity, initial filling in brand new cylinder of powder
15 coated finish, fitted with Gun metal union, high pressure CO2 gas cartridge & wall mounting
bracket and other fixing accessories etc. complete confirming to IS:15683
Dry Chemical - ABC type extinguisher - wall mounted type with holding brackets, fixing
16 arrangements , BIS approved and marked
Mechanical Foam type extinguisher - trolley mounted type with holding trolley made of
17 black painted steel, fixing holding & moving arrangements 50 litres (for DG yard)).
G.I Heavy grade piping as per IS : 1239 (Part 1) - 2004 / IS:3589 - [Link] pipes complete
18 with necessary specials fittings such as tees, bends, flanges, reducers, etc.
Above ground piping with necessary flanges & Buttweld joint (above 50 mm) , socket
weld/threaded connection (up to 50 mm)& fittings such as elbows, tees and Painting one
19 coat primer with two coats synthetic enamel, supports necessary complete as per the
requirement of fire service department.
G.I Heavy grade piping as per IS : 1239 (Part 1) - 2004 / IS:3589 - [Link] pipes complete
20 with necessary specials fittings such as tees, bends, flanges,reducers, etc.
Underground piping with necessary flanges ,butt weld joint & fittings such as elbows, tees
and providing and fixing anchor blocks in PCC 1:2:4 at all bends, tees, along with pipe
21 coating and wrapping of underground pipes with 4mm thick conforming to IS : 10221 - 1982/
AWWA C 203.
Quatrazoid bulb type Standard Coverage Sprinkler of 15mm nominal size to operate at
22 specified temperature,UL/FM approved.
Sprinkler installation control valve (Alarm valve) of 150 mm dia, PN 16 comprising of a
23 mains gate valve, in and out pressure gauge, water motor gong,test connection of adequate
size with valve and other accessories complete , UL/FM approved.
 M.S. cabinet (size 600x450x150mm) fabricated from 16 gauge M.S. sheet with full front
glass door and locking arrangement with suitable shelves for keeping 24 [Link]
24
sprinklers and 1 No. spanner properly fixed. Cabinet painted with enamel paint of approved
shade.
Inspection Test and Drain valve with integral sight glass and 1/2'' dia orifice, Threaded
25 ends,suitable for Horizontal and Vertical installation of size 25 mm dia .
Precast underground chamber 1200 x 1200 x 2000 mm depth size with RCC wall of 200mm
26 thick and cover slab of 150mm thick & FRP heavy duty lid (600 mm X 600 mm ) manhole and
proof plaster inside / outside of pit to avoid water leakage..
Flow switches for sprinkler system piping. Flow switch shall have a paddle made of flexible
material of the width to fit within the pipe bore. The terminal box shall be mounted over the
paddle/ pipe through a connecting socket. The switch shall be potential free in either NO or
27 NC position as required. The switch shall be able to trip and make / break contact on the
operation of a single sprinkler head. The terminal box shall have connections for wiring to
the Fire alarm panel. The seat shall be of stainless steel. The flow switch shall have IP : 55
protection.

9.2 Material Transport, Delivery

 Material to be delivered after obtaining dispatch clearance from main contractor and client.

 The materials received at stores / site shall be checked for manufacture details, as per delivery
note and as per approved material submittal to ensure delivery is correct.

 Verification of quantity as per delivery notes/Identification label, country of origin, test

certificates, shall be done as per approved TDS

 Unload pipe bundles using FARANA and nylon belt sling and D-shackles. Lift pipe bundle or pipe
with Farana and keep on wooden block/stack 300mm above ground level in designated area.
Ensure enough manpower available at site.

 Ensure HSE permit shall be taken before starting pipe lifting.

 The contractor shall be responsible for the arrangement of unloading the fire water pipe at the
store.

 Details of the material receipt, test certificate shall be conveyed to Main Contractor & Client
Through MIR. Documents shall be made available at site during inspection.

 Forged fittings markings to be verified as per standard markings required thro standards and as
per approved sample during Incoming material inspection.
 It shall be ensured that MIR is raised within 3 days of receipt.

9.3 Material Handling (Material and Equipment preservation)

  If mechanical lifting equipment is used, ensure no metallic slings, hooks and chain shall be used
in direct contact with the items. A rope or nylon belt sling shall be preferred which shall not be
damaged.

 Loading and unloading to be performed manually or with forklift with adequate protection to
avoid mechanical damage.

 No material and equipment should be dropped on to hard surfaces nor dragged along the
ground.
 Use hand gloves for shifting / unloading / loading / handling etc.

 For movement of the material and delivery vehicles, approved safety guidelines shall be
followed.

10. Storage on Site

 Material to be protected from direct sunlight, rain, dust, and other foreign objects by covering
them with tarpaulin with ends closed.

 The pipes shall be stacked in the site store/yard, wooden sleepers shall be used to avoid direct
contact on ground, and overall stack height not exceeding 1.5 meters.
 Suitable site arrangement towards side locking to be done to avoid slippage of pipes.

 FIFO (first in first out) shall be ensured for all materials.

 Its shall be ensured that Pipe Ends are protected.

 Sprinklers and flexibles shall be stored in closed, ventilated containers with original packing,
segregated, identified type wise.
 Fittings shall be separately packed and stored as per the sizes required for the project.

 Usage of Paints, consumables as per shelf life to be ensured. To be stored in dry place under
normal temperature conditions as per OEM recommendations.

 Storekeepers shall inspect for any damage in shipping, handling and storage and shall be
responsible for proper storage as per the requirements.
 Materials, equipment, and components to be stored as recommended by the manufacturer &
proper storage/shelter to be provided.

11. Installation Methodology briefing

 Check for the availability of latest IFC/Shop drawings. Hard copies of the same shall be readily
available at the site for reference.
 Ensure the materials, equipment and components are as per approved material sheet/submittal
and as per project specification.
 Ensure WPS and PQR is approved Before work start.

 Welder Qualification test will be conducted as per approved WPS and PQR (Procedure
Qualification Record) shall be recorded
 Ensure that the materials are inspected, and MIR is approved before start of installation.

 All relevant documents and material applicable to section of work shall be checked by site
Quality, site engineer/ Site Supervisor prior to commencement of work.

 Inspection invitation will be sent to L&T Quality Team 24 Hours in advance.

 Check whether the area is clear and civil & HSE clearance available for installation, keeping 3 days
stock.

 Ensure easy access and enough clearance is provided for future operations and other services.
 Verify for the wall cutout, sleeves are provided and available as per the approved IFC/Shop
drawing.

 Make sure annular space of cut out shall be in accordance with the requirement of UL /equivalent
applicable standard.

 Clean the sleeve and pedestals surfaces and the surface is dry.

 Site Engineer shall ensure that calibrated pressure gauges, testing manifold, pumps are available
and are in good condition for testing.

 All pipe work shall be free from burrs, rust and scale and shall be cleaned before installation.
 Check for any physical damage to the pipes, fittings, valves & accessories.

 Red band of GI pipe shall be removed prior to application of primer.

 Ensure that all workers are aware of the correct materials and safety procedures to ensure the
best quality of workmanship.

 It is to be ensured that all anchor fastener applicators are trained through OEM, and OEM
methodology followed during installation of it. Pull out test to be conducted as per OEM
methodology as per the agreed intervals.

 Any activity / method not mentioned in MS but required to be followed for the successful
completion of work, must be done on site.
Note: Illustrative Pics of activities to be further added upon approval of TDS
8.1 Installation of aboveground Fire water piping Installation

 Foremen shall carry out a site survey and mark the route of fire piping as per approved IFC/ shop
drawings of respective services.
 Co-ordination with other services shall be carried out while marking the route of piping.

 Any clashes identified during the survey shall be resolved prior to the start of installation or if the
cutouts shown in the approved drawings do not meet with the requirements it shall be marked
in the drawing and brought to the notice for further approval and incorporation in the structural
drawings.
 Approved IFC drawing shall be followed for Pipe routing, sizing, and elevations.

 An anchor fastener of approved make and design to be used for RCC slabs and walls / floors.

 Mark the location of the pipe supports (trapeze, wall bracket, Riser supports) with the help of
measuring tape, as per the approved shop drawing.

 Chalk marking is to be executed at slab level with reference to the grid line prior to proceeding
the works.

 Check the measurement from Wall / Slab / grid etc. as per approved drawing.

 Drill the holes in slab / beams for fixing anchor bolts.

 While drilling for the anchors, ensure that there is no damage to any adjacent services present.

 Fix the anchors with the use of proper setting tool to obtain max operating load caring capacity
as per the pull-out test.

Note: anchors type to be as per the approved TDS and as shown in the approved support detail
drawing.
 The threaded rod or structural member of suitable size as per approved support drawing to be
fixed to the mechanical anchor fastener / clamps using proper lock nut.
 Supports to be installed according to the required support spacing as shown on the approved
shop drawings.
 Cut the threaded rods to appropriate size and length and fix using nut bots and washers.

 The approved type of hanger/supports to be attached to the threaded rod by nut washers and
bolts.
 Supports, angle pieces of required lengths to be cut by oxy acetylene gas and cleaned by electric
grinder.

 Clean, finish any cut edges of angles, channels, or threaded rods, and touch up with zinc rich paint
/ zinc spray.

 Install the pipes in position on the hanger supports. Wherever possible pre-assembly of pipes and
fittings at ground level shall be carried out.

 Perform the pipe fit up and welding as per the sequence detailed in 6.5.4.a. Erect the fire pipes
to the position and join the two pipes.
 Follow approved WPS for root pass and full welding.

 A 6G qualified welder to be utilized to perform the tacking, root, and full welding.
 All Welded Joint undergo visual Inspection, with details captured in the welding visual traceability
records including welder ID, heat number welding process, welding date, etc. as per the provided
forms
 Fabrication of Spools shall be carried in designated areas, marked for threading, welding, and
grooving.

 Sprinkler pipe to be temporarily identified, along the execution stage till final marking is
performed towards easy identification and to avoid any connection issues.

Supporting

 Single Pipe up to 100 mm Dia shall be supported with galvanized Clevis Hanger.

 Pipe of Dia 150 mm and above shall be supported with structural support with U bolt type clamp.
 Additional support to be installed at thrust generating points such as change of direction of pipes.

 Pipes and fittings shall be fixed truly vertical, horizontal or in slopes as required with neat
workmanship.

 It shall be ensured that the Pipe accessories such as gauges, meters, control devices, etc. shall
have the same working pressure rating as the associated pipe work. Material taken for
installation is approved through MIR.
  It shall be ensured that the Fabricated support to be painted with one coat of Zinc Etch primer
and Galvanized paint only where welding is carried out, Final finish shall be neat and clean.

 In addition to the above details, the following areas GI fabricated structural supports shall be
provided irrespective of their sizes as per the approved typical support detail drawing.
1. Fire pipes running together (more than one) as shown in Typical details drawing.
2. Inside pump room (support from floor / ceiling /wall)
3. Horizontal pipes Inside Utility tunnel
4. Vertical pipes Inside shafts

8.2 Riser Piping

 On completion of the slab on the highest floor of each zone, the shaft to be inspected prior to
taking handover from the Civil department.

 Thereby avoiding any material fall off during workmen working inside the shafts.

 The shafts to be inspected for completeness and measurements to be taken for support.
 The pipe size to be identified based on the approved shop drawings and shifted to the respective
floors.
 Start the work with marking and fixing of pipe supports. Span and details to be as per approved
support typical detail drawing.

 Riser support to be provided at the lowest level, at each alternate level above, above and below
offsets, and at the top of the riser. As per the approved support arrangements drawing.

 Where risers are supported from the ground, the ground support constitutes the first level of riser
support. Where risers are offset or do not rise from the ground, the first ceiling level above the
offset constitutes the first level of riser support.

 Additional anchoring support and flexible coupling (as applicable) through approved shop
drawings to be provided to accommodate expansion / contraction.

 Upon securing the supports, the lengths of pipe to be lowered into the shaft.

 The subsequent lengths of piping to be installed in the same manner, one length at a time.
  Temporary caps to be provided to all the open ends of the piping, upon completion of work or
commencement of further works.
 Air vents and drain points to be provided in locations as shown in approved shop drawings at high
and low points respectively.

8.3 PIPING JOINTS

Following methods of piping joints shall be adopted for fire protection system:

 Pipe to Pipe joint: (For Aboveground)

 Below 65 mm – Socket weld joint

 65 mm & above – butt-weld Joint

 Pipe to Valve joint: (For Aboveground)

 Below 65 mm – Threaded Connection

 65 mm & above – Flange Joint

 Pipe to Fitting joint: (For Aboveground)

 Below 65 mm – Socket Weld Joint

 65mm & above – butt-weld Joint

8.4 a. Welding

 Erected Fire Pipe of 50mm and below shall be joined by socket welding.
 Welding shall be as per the approved WPS and by the Qualified welders.

 All pipes shall be accurately cut to the required sizes as per shop drawing and make bevel,
grinding smooth all the sharp edges before fit up & tack welding the pipe to pipe or fittings.

 Gap of 1.5mm minimum shall be maintained all fit-up joints shall be checked for alignment HI-
Lo, root gap as, bevel angle, and cleanliness as per approved WPS
 All equal & unequal fittings, including but not limited to bends, elbows, tees, reducers, sockets,
etc. shall be forged and sockets welded, as per ASME B 16.11.
 Approved filler electrodes shall be used. Welding shall be done by the electrodes as qualified and
approved through WPS.
  Fit-up and Weld visual inspection to be performed by the Site execution and quality inspector,
Inspection report to be prepared and submitted along with the IR raised for Pipe Installation.

8.5 Drain Piping

 A drain riser shall be installed along with the sprinkler riser.

 This arrangement of test and drain assembly shall be connected to the main sprinkler line of the
sprinkler system at each floor.
 The components of the drain line to be as per the approved typical drain assembly arrangement
drawing.
 Slope of drain piping to be maintained.

 The tapping for the drain line to be taken from the grooved coupling in the main line.

 The drain riser shall be routed to the nearest sump at lowest floor in coordination with the
plumbing department and approved GFC drawing.
 Illustrative Pic

Valves Installation

 Gate Valve / Ball Valve shall be used for isolation of flow in pipelines for sizes up to 50 mm Dia at
location shown in drawings.
 Sluice Valve and Check Valves shall be used in the pipelines for sizes Dia 65mm and above at
location shown in drawings.

 The Butterfly Valve should be located as per the approved GFC and layout drawings, also to make
sure that it is located where it shall be readily accessible for operation, inspection, and
maintenance.

Installation

 Take care to avoid any kind of damage to the pipes, valves, and fittings during fabrication.
 All prefabricated pipe spools should be painted in the work shop prior to installation, except for
field weld joint areas.
 After Field Welding, protect these joints until visual inspection acceptance.

 Examine the valve interior for cleanliness, freedom from foreign matter and corrosion and any
kind of damage.
 Remove special packing materials, such as blocks, used to prevent disc movement during
shipping and handling.
 Operate valves in positions from fully open to fully close. Examine guides and seats made
accessible by such operations. Examine threads on valve and mating pipe from cleanliness.
  Verify that connecting equipment and lines to be properly aligned prior to valve installation.

 Inspect the distance between the two flanges to accommodate the valve.
 check mating flange faces for conditions that might cause leakage. Check bolting for proper size,
length, and material.
 Verify that gasket is of proper size and material that it is free from defects and damage.

 Place the valve with the Orientation as per the approved shop drawing.
 Check valve to be as per the flow arrows.

 When installing the valve and gaskets, the pipe to be spread apart just enough to allow the valve
and gaskets without actually coming in contact with the flanges.
 Care should be taken to not damage the surfaces of the flanges or valve.

 Proceed with Bolt tightening sequence as per the standard and OEM recommended torquing.
 It shall be ensured that the inlet and outlet piping adjacent to the valve should be properly
supported to prevent excessive stress on the valve body.

 The in-built tamper switch for zone control valve shall be installed, and connections secured as
per the manufacturer recommendations.

 Air release valve shall be installed at top of each riser and all other locations as shown in the IFC
Drawings.

Note: OEM Catalogues and recommendations to be referred towards installation of valves of each
type.

8.6 Orifice Plate Installation

 Make sure that the pipeline is not under pressure and has been properly drained or purged as
required.

 Loosen all studs. Remove the studs in one half of the flange union.
 Spread flange union by turning jackscrews clockwise. Note bevel placement.

 Install new plate or remove existing plate for replacement or inspection. (Be sure that beveled
side is toward the downstream.)
  Install new gaskets when installing plates. Always install new gaskets each time the flange union
is separated.
 Release the flange union by turning jackscrews counterclockwise.

 Replace studs. Tighten studs evenly, starting with two studs that are opposite of each other.
 Re-pressurize the system and check for leaks.

Note: OEM Catalogues and recommendations to be referred towards installation of valves of each
type.

8.7 Painting of Pipes

 Clean shop-fabricated and factory-built fittings and pipes, and apparatus which are not
galvanized and not protected by plating or a baked enamel finish and apply one shop coat of
primer paint.

 Red Band on C class pipe to be removed prior application of primer coat.

 Recoat portions of shop coat damaged in delivery, during construction, or prior to finishing
painting.

 All above ground sprinkler pipes to be finished with Fire Red shade colour paint.
 Ensure all tests are performed on the piping system before starting painting work.

 Painting shall not be applied on nameplates, labels, placards, tags, stainless steel or plated items
as valve stems, motor shafts, levers, handles, trim strips, etc.

 Paint manufacturer recommendations and methodology shall be followed towards the painting
process.

Application:

 All GI Pipe shall first be cleaned thoroughly before application of primer coat.
 The surface to be cleaned to remove oils, grease, dirt, and any other foreign materials.
  Coating application shall not be carried during fog, mist, or rain.

 Ensure proper room temperature and humidity levels.

 Coating application should not be permitted when the relative humidity is 85 percent or above,
when the steel surface temperature and/or ambient temperature is below 10°C (50°F), when the
steel surface temperature and/or ambient temperature is above 50°C (120°F) and when the steel
surface temperature is less than 3°C (5°F) above the dew point.

 Humidity and dew point readings to be taken by contractor with a sling Psychrometric meter and
calculated using psychrometric tables.

 Readings to be taken prior to coating operations commencing and at least every four hours while
coating application is ongoing.
 Mix the contents thoroughly before and during use.

 Apply 2 coats of approved primer as per OEM recommended methodology with DFT as per the
approved paint system.

 Apply paint coats after previous coats have dried up, as per instruction manual of paint
manufacturer.
 Dry film thickness shall be taken on each coat after drying and curing of the coat.

 Dry film thickness (DFT) readings are to be taken using a non-destructive dry film thickness
instrument capable of storing the readings.

 Sufficient readings to be taken covering each coat prior to application of the following coat to
ensure the correct required DFT.
 Two coats of synthetic enamel paint of approved Fire red shade shall be applied above the
primer.
Note: an approved painting scheme/system shall be followed for the selection of Primer and Paint
materials.

 Stripe coats to be applied on welded areas and on edges as per OEM recommended
methodology.

 Pinholes, slag, runs observed during the inspection shall be suitable rectified as per the
methodology recommended by the OEM.

8.8 Flexible Sprinkler Drops

 Sprinkler drops shall be installed as per the Manufacturer’s recommendations and approved shop
drawing.

 Secure the end brackets to the ceiling frame with butterfly nut.
  The lever of end brackets shall be pressed to latch firmly with both levers.

 To adjust the level of reducer with ceiling tile, move the reducer vertically and push the latch
down firmly to secure into position.

8.9 Sprinkler heads

 Exact locations as per drawings shall be coordinated for the level of the sprinkler heads with the
space finished ceiling elevations before installing the sprinkler drops to ensure that sprinkler
heads are properly installed.
 Sprinkler Heads to be installed according to approved IFC drawing and OEM recommendations.

 It is to be ensured that sprinkler head cover plates are taken up for installation only after the
ceilings have been finished painted.

 Proper wrenches/spanner sizes as mentioned in the data sheet shall be selected for tightening of
sprinkler.

 In the event of a thread leak, remove the unit, apply new pipe Teflon tape, and reinstall.
 Hand tighten the sprinkler into the fitting using the proper size of wrench.

 To install the escutcheon plate, align it with and press it over the sprinkler body until the outer
edge of the escutcheon meets the mounting surface.

 The distance between a hanger and the center line of an upright sprinkler shall not be less than
76mm.

 Note: Step wise methodology as recommended by the Approved Sprinkler Vendor to be followed.
8.10 Identification

 Identification shall be in English and/or Hindi in accordance with requirements of the

local authority having jurisdiction, including, but not necessarily limited to the following.
 Sprinkler piping and standpipes.
 Control valves and test valves
 Fire suppression Systems and devices
 Control panels
 Hose, valve and extinguisher set.
 Valve and alarm device schedules
 Firefighting Pumps

8.11 a. Plant and Pipe Identification:

 Stencil 40 mm high white enamel block type characters on each item of Plant for
identification purposes.
 Also, provide a complete system of pipe identification stencils or labels adjacent to each
valve and branch take-off, and at not over 15 m intervals along runs of pipe, with flow
arrows at each marking.
 Use a contrasting colour to the finish coating of the piping, either white or red, for pipe
identification stenciling or labels.

8.11 b. Valve and Device Identification

 Tags and Signs: Identify valves in main and riser piping, floor and sectional control valves,
and alarm devices with 25 mm diameter brass tags, secured to valve or device with brass
S-hook or jack chain, and numbered consecutively.
 Identify control, drain and inspector’s test valves with porcelain enameled signs, secured
to valve with brass jack chain.
 Note: TDS including samples shall be submitted towards Identification label and
Tags approval
8.12 Application of Pypkote (Pipe Wrapping)

8.12 A Surface Preparation:

The pipe Surface shall be cleaned by a wire brush to remove any foreign
particles.

8.12 B Application of cold stick (Primer):

 Cold stick is to be applied over the pipes immediately after cleaning. This is to
prevent any further accumulation of rust on the pipe.
 The primer tins are rolled on the floor to allow the primer to mix well before the
tins are opened.
 Cold stick/ Pypstik is a cold applied primer and is applied by brush (Paint brush/
Roller).
 The cold stick/ Pypstik is allowed to become touch dry (15- 30 Minutes) after
primer application.

8.12 C Application of Pypkote 2mm /4mm tape:

 After the surface is coated with Primer, Pypkote tape is applied over the pipe in
Spiral or circumferential fashion by thermos - fusion process.
  Flame through LPG heating torch is applied onto the lower face of the tape till
the tar mix attains a shiny appearance.
 The primer coated surface may be gently heated by a run of LPG torch and the
tape is then adhered to the primer coated surface spirally / circumferentially.
 Tapes are then pressed with a piece of cloth to ensure proper adhesion to the
pipe surface.
 The overlaps are maintained at a minimum of 2 cm to 5 cm. The overlaps should
be sealed with the help of a hot trowel.

8.13 Handling of wrapped Pipes:

 The coated pipes are to be lowered inside the trenches as early as possible. The
coated pipes are to be lowered into the trenches and back filled within 7 days
from coating.
 Care to be taken while lowering the coated pipes so as not to damage the
coating.
 Chains, cables, or other equipment which are likely to cause damage to the
coating shall not be permitted and dragging or skidding of the wrapped pipe to
be avoided.

8.13.A Repair of damaged coating:

  The area where the coating is damaged is patched up with Pypkote tape by
flame bonding with a piece slightly larger than the area of damage.
 The sagged and air pocket portion of Pypkote tape observed if any should be
removed. Before fixing a new tape, the primer should be applied, and new tape
fixed by following regular application procedure.
 An Overlap of 2 cm to 5 cm should be provided between old and new tapes only
on the top connection.

8.13.B Field Joints:

 After welding visual inspection and testing is completed, the area of the field
joints is to be cleaned.
 The cleaned joint area to be coated with primer and allowed to dry to reach
touch dry condition.
 Tape should be applied over the coated primer with overlap of 3 cm to 5 cm on
both sides of the applied tape.
 Procedure as per 6.6.3 to be followed.

12. Organization & Responsibility

The following are the responsibilities of personnel involved in the scope of this
procedure.

[Link] Category Responsibility

.
1. Project Manager Shall be responsible for overall implementation. Shall
be responsible for overall monitoring, compliance and
control of manpower, equipment, safety & transport
facilities etc.
2. Site In-Charge Shall be responsible for control, supervision, and
direction for implementation of this procedure.
3. Site Engineer Shall carry out the work as per the drawings and
specifications.
 Shall give required line and level, cross check and
record it as applicable.
4. QA/QC Engineer Responsible for overall monitoring and control of QC
activities, shall visit the site as and when required.
5. Safety Officer After getting information for starting a specified work,
the Safety Officer shall inspect the work area &
machinery involved in the said activity. If the Safety
Officer finds any deviation/deficiency, he shall inform
the Construction Manager for compliance as and when
required.
1. Shall frame safe rules and safe working practices in
consultation with Construction Manager.

13. Workforce/Training
 All personnel shall undergo site-specific safety induction, toolbox talks, and
task-based training prior to commencement of work.
 Training shall include safe handling of pipes and fittings, use of tools and
equipment, working at height (if applicable), hot works (where required), and
emergency procedures.
 Only trained and authorized personnel shall operate power tools, lifting
equipment, and pressure testing pumps.
 Continuous supervision and periodic refresher training shall be conducted to
ensure compliance with quality, safety, and environmental requirements
throughout the execution of the work.

14. Quality requirement

1. Quality assurance and control shall be as per Inspection and Test Plan (ITP).

11.1 Hydro-testing and Inspection

 It shall be ensured that the area taken up for hydrostatic testing is highlighted in the drawing.
location of vent/ drain valve, plugged connections and water pressure pump connection has been
indicated on the drawing.
  Make sure the Hydrotest scheme with drawing to be discussed and approved before the start of
hydrotest.
 Place safety warnings at all points where personnel may pass through within the vicinity of
testing.
 All piping and attached appurtenances subjected to system working pressure shall be
hydrostatically tested at 200 psi (13.8 bar) or 50 psi (3.5 bar) more than the system working
pressure, whichever is greater, and shall maintain that pressure at ±5 psi (0.35 bar) for 2 hours.
 The piping system and components shall be capable of withstanding 150% of the working
pressure including water hammer effects.

 Plug all the openings.

 Close all the drain valves.

 Connect the test pump to the pipe work at the filling location, bleed all air from the pipe work.
 Connect a calibrated pressure gauge and fix an isolation valve from both sides of the pressure
gauge.

 Two no of pressure gauges to be provided at the start and end of sprinkler zones for hydrotesting.
 Fill the complete pipeline with water avoiding any air column. (For this purpose, keep the air vent
valve at the highest elevation slightly open, while filling water when line is filled with water close
the valve)

 On the pump, pressurize the line to an intermediate pressure, say 100 psi. Wait for 5 minutes;
check all major joints for any visible leak.
 If the system is OK, pressurize the system to 150 psi and wait for 10 minutes for any drop in
pressure or leakage.

 If the system is found to be leak proof, pressurize the line to the required testing pressure and
keep for 2 hrs.

 Hold the piping under pressure for duration of 2 hours and observe for any leakage or pressure
drop, if the pressure gauge shows a steady reading after 2 hours; notify the client/consultant to
get the test witnessed by the consulting engineer.

11.2 High voltage holiday detection test:

 All tape coated pipes and joints shall be tested with an approved high voltage holiday detector.
 The tester to be equipped with an audio visual signaling device to indicate any faults, holes,
breaks or conductive particles in the protective coating.
  While selecting test voltages, consideration shall be given to the tolerance on coating thickness
and the voltage should be selected based on maximum coating thickness.
 For 3 mm to 4 mm thick coating a max test voltage should not exceed 12kv as per OEM
recommendations.

11.3 Inspection

 Inspection request shall be raised stagewise for the Inspection of Main Contractor and Client
 Upon the arrival of Pipes to site the Material inspection shall be inspected by FPS contractors
QA/QC engineer for visual and dimensional checks

 The in-process work shall be monitored for quality of workmanship and installation against
approved shop drawings.
 All the works shall be inspected for the conformance towards project specifications.

 After contractors QA/QC inspection the inspection request shall be officially submitted to
engineer for inspection and approval

 All comments raised during inspection shall be recorded and closed prior to proceeding with
subsequent activities
 Final acceptance and clearance for handover will only be provided after satisfactory completion
of all inspection stages submission of test reports and closer of all punch points.

11.4 RECORDS:

 All inspection formats and other records shall be as per project approved forms.
 The Approved copies shall be part of the final Package closure documentation.

15. Health, Safety & Environment

 Workers shall be using proper PPE, and the lifting area shall be barricaded to prevent
unauthorized access.

 Weather, ground condition, and equipment shall be verified before operations

 Environmental impacts such as noise, waste, and spills shall be controlled and minimized.

 All HSE procedures and policies shall be followed as per the approved HSE plan and the HIRA submitted.