QUALITY MANAGEMENT SYSTEM

MS for Installation of Fire hydrant

system
DOC.No: VKBS/HPCL/FPS/002

HPGRDC
PROJECT

EMPLOYER HPCL

PMC EIL

CONTRACTOR VK Building Services Pvt Ltd

METHOD STATEMENT FOR INSTALLATION FIRE

HYDRANT SYSTEMS

VKBS EIL

Signature:

Date:

Name: Lingeswaran Binod Davis Mohan

Organization: VKBS VKBS VKBS

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 QUALITY MANAGEMENT SYSTEM
MS for Installation of Fire hydrant
system
DOC.No: VKBS/HPCL/FPS/002

METHOD STATEMENT FOR INSTALLATION

OF
FIRE HYDRANT SYSTEM /
HOSE REEL / FIRE SHAFT

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MS for Installation of Fire hydrant
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DOC.No: VKBS/HPCL/FPS/002

TABLE OF CONTENTS

ITEM DESCRIPTION PAGE NO.

1 OBJECTIVE 4

2 SCOPE OF WORK 4

3 REFERENCES 4

4 RESOURCES 4

5 MACHINE and TOOLS 4

6 MAN POWER 5

7 SAFETY TOOL 5

8 HANDLING and STORAGE. 6

9 WORK METHODOLOGY 6

10 ROLES AND RESPONSIBILITIES 18

11 INSPECTION AND TESTING: 19

12 ATTACHMENTS AND RECORDS 21

1. OBJECTIVE:

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MS for Installation of Fire hydrant
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DOC.No: VKBS/HPCL/FPS/002

The purpose of generating this Method Statement is to define the procedure step
by step to implement the correct practices for Installation of Fire hydrant valve, Hose reel,
and fire hydrant accessories drum through the guidelines so as to ensure that the job
execution complies with the requirements of contract specification & serves the
intended function to satisfactory level.

2. SCOPE OF WORK:

 Erection of FIRE HYDRANT SYSTEMS, HOSE REEL and FIRE HOSE CABINET
 The scope of work includes providing, installing and commissioning of FIRE HYDRANT SYSTEMS, HOSE
REEL DRUM and FIRE HOSE CABINET.

3. REFERENCES:

 HPCL project quality plan

 HPCL Health & safety plan
 Contract specification no
 Approved Technical data sheets
 Design Intent Drawings & Approved Shop Drawings
 Manufacturers Catalogues & Recommendations

4. RESOURES:

Following tools & materials shall be used for this activity.

 Tools listed in tb-1 below.

 Pipes and accessories , fittings as per approved drawings

5. MACHINE AND TOOLS:

Site engineer and supervisor shall ensure all necessary tools & tackles are available at site prior to
commencement of work. All tools to be tested by client before start the work.

Sl.No Tool/ Equipment Quantity

1 Pipe cutting machine 01 No

2 Welding machines 01 No

3 Grinding machine 01 No

4 Half round file 02 Nos

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5 Pipe Wrenches 02 Nos
01 No
6 Hacksaw
01 No
7 Drilling machine
01 No
8 Gas cutting set
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MS for Installation of Fire hydrant
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DOC.No: VKBS/HPCL/FPS/002

6. MAN POWER:

The following list of people who will be the responsible for the installation works. Tool box
meeting to be conducted to the workers before start the works. All workers to be inducted by safety
personnel, all workers must understand the safety signage and concept of works.

No of
Sl.No Designation
Personnel
1 Project Engineer 01
2 Quality / Safety Engineer 01
3 Fitter 01
4 Welder 01
5 Helper / Rigger 03

7. PERSONAL PROTECTIVE EQUIPMENTS:

All the Personal Protective Equipment must be used at the time of execution.

Item Description
1 Safety Helmet
2 Safety Shoe
3 Goggles / welding shield
4 Hand Gloves
5 Reflective Vest

8. HANDLING and STORAGE:

 Prepare delivery schedule and check site conditions as well as storage capacity.
 Prior to delivery of material to site do a site survey and make all necessary co-ordination with the client
representative as regards to access for the save transportation of the said material to the designated
location.
 On delivery to site the materials shall be stored indoor or suitable arrangements have to be made to
protect the materials.
 Material shall be kept in dry, well ventilated, dust free, non corrosive atmosphere
 The unloading of material shall be done manually.

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MS for Installation of Fire hydrant
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DOC.No: VKBS/HPCL/FPS/002

 The materials shall be placed above the floor level in order to prevent corrosion.
 According to the actual site requirement, the material will be transferred to
assigned location.
 All materials have to be entry – checked at the security gate and a copy of inward
documents must always be available at the site office.
 Ensure that the material approval and completion of IMIR before issue to site installation.

9. WORK METHODOLOGY:

INTRODUCTION

1) HYDRANT AND HOSE REEL SYSTEM& FIRE HOSE CABINET INSTALLATION

 Ensure availability of work front

 Ensure Availability of approved shop drawing, material, manpower and tools & tackles to
complete the work for the specific area shall be checked before proceeding with work.

2) WET RISERS/ DOWNCOMERS

 Ensure the completion of wall painting in Fire Shaft.

 Location of Wet riser/Down comer (pipe) shall be marked as per approved drawings in their
respective fire shafts. Ensure that, the center line of the hydrant riser pipe shall be in line with
the center of shaft opening.
 The MS channel supports touching the back wall of shaft shall be marked at intervals as per
approved shop drawing vertically and anchor bolts. Note that, the anchoring shall be done on
the concrete wall of the shaft.
 Pipes shall be carried through the shaft / stairs properly using required manpower and by
chain pulley.
 Vertical rise of the pipes shall be erected using chain pulleys.
 These pipes shall be fixed rigidly to the channel support by ‘U’ bolts.
 Tapping piece with slip on flange (80 mm dia for single & 100 mm dia for double headed
hydrant) of appropriate length shall be welded on the wet riser pipe. Ensure that correct size of
hole is cut on the riser pipe.

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MS for Installation of Fire hydrant
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DOC.No: VKBS/HPCL/FPS/002

 Ensure that the orientation of flange holes shall be in line with that of
hydrant valve position.
 Ensure that the center line of tapping is 1000 mm above the FFL as per
approved shop drawing. And also, ensure for getting the required radius when we insert the
fire hose to the hydrant valve for free flow of water.
 Provide temporary blind flange at the outlet of flange.
 Hose reel drum shall be fixed using the holes provided on them by using anchor fasters in RCC
wall or grouting angle frames with bolts in Brick wal. Ensure that, the center line of the hose
reel is approx. 1500 mm above FFL and free swinging without fouling with hydrant valve and
fire hose cabinet door.
 A 25 mm dia tapping shall be taken from the hydrant valve tapping piece. Provide a 25 mm dia
gate/ ball valve, hose adaptor of 25x19 mm. Then connection shall be made to hose reel either
through rigid pipe or same rubber/ flexible hose as applicable to the project. Ensure the
provision of screwed union after the gate valve for maintenance purpose.
 Proper provision shall be made inside the fire shaft for fixing branch pipe and fire hoses.
 Fire hose cabinet door shall be fixed after completion of all civil works to avoid damage.
M8Coach screws or anchor fasteners can be used to fix the door.
 Second coat of paint shall be applied after completion of entire civil works and welding works.

3) ABOVEGROUND PIPING

 Ensure the availability of work front.

 The horizontal above ground pipes shall be supported from the Pedestals by means of MS
supports (using U bolts) or structural steel supports (using channels, angles and U bolts) and
Spectacled as per approved shop drawings.
 Ensure the piping work is coordinated with other services to avoid re work later on.
 As for as possible piping network can be fabricated at floor level and minimize the field joint to
the possible extent.
 Pipes shall be welded with proper fit out and making V groove.
 Ensure completion of hydro testing before apply paint on welding joint

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MS for Installation of Fire hydrant
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DOC.No: VKBS/HPCL/FPS/002

 Hydrostatic testing shall be done as per tender specification and shall be

notified to the concerned authorities before start and finish of the testing.
Test reports in the proper format as attached shall be made for these and
signed and accepted by the concerned authorities.
 During commissioning stage, flush entire piping network with pressurized water by means of
fire pumps and ensure no foreign particle is left inside.

4) UNDERGROUND PIPING

 Obtain the clearance from the authority before execution.

 Mark the stretch to be excavated with lime powder as per approved drawing
 Excavate the pipe trench in trapezoid cross section to avoid collapse of trench with means of
machine or manual and trim the trench for exact height and even surface as per standard code
of practice.
 Barricade the area for unauthorized entry.
 Initially, dump the excavated earth near to the trench. If feel more, excess earth shall be shifted
to the designated destination.
 Shift the pipes & fittings, wrapping coating materials and tools & tackles next to the trench.
 Temporary supports shall be made available to rest the pipes very close to the trench.
 Check the inside the pipes for any foreign materials and ensure free from it.
 The pipes shall be flushed to remove any foreign material / welding flux trapped in the pipe
during fabrication
 Pipes shall be welded with proper fit out and making V groove.
 Anticorrosive wrapping coating shall not be carried before hydraulic testing. This is to ensure
no defect in pipe (viz, seam joint) and weld joints.
 Wherever field joints are to be done, a spacious pit shall be excavated for quality fitment &
welding.
 Hydrostatic testing shall be done as per tender specification and shall be notified to the
concerned authorities before start and finish of the testing. Test reports in the proper format as
attached shall be made for these and signed and accepted by the concerned authorities.
 Pipes shall be applied with anticorrosive wrapping materials. When bituminous primer is dry

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MS for Installation of Fire hydrant
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DOC.No: VKBS/HPCL/FPS/002

wrapping materials (generally 4 mm thick) shall be wrapped on the pipe

using hot flame. Maintain 25 mm overlap. Ensure tight wrapping without
any gap between pipe and wrapping sheet.
 Pipe length shall be lowered in the trench manually or by using tripod. Ensure no damage done
to the pipe and wrapping coating.
 Check the pipe is rested on even surface.
 After completion of hydro testing and wrapping coating of weld joint, refill the excavated earth
up to FGL and consolidation & compacting may be done, if contract says so.
 During commissioning stage, flush entire piping network with pressurized water by means of
fire pumps and ensure no foreign particle is left inside.

5) ANTICORROSIVE TREATMENT FOR UNDERGROUND PIPING

 Before fabrication, the pipes shall be cleaned for rust, oily, dirt surface and other defects.
 Anticorrosion treatment for underground piping will be as per IS: 10221.The pipes will be
applied with one coat of bituminous primer, on drying of which, a 4 MM thick HMHDPE
Polyethylene tape will be wrapped by hot flame.

6) Pipe Supports for Above ground pipe

 Supports for the pipes which are laid overhead (i.e. bellow the ceiling) shall be of universal
clamp using anchor fastener and hanger rods of appropriate size.
 Supports for the pipes which are laid vertically (i.e. parallel to wall, column etc.) will be of
bracket using MS ISMC Channel or ISA Angle and ‘U’ bolts of appropriate size.

Table: 1
Overhead Hanger Supports- Maximum
Pipe Dia Hanger Rod Dia
Spacing as per NFPA

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DOC.No: VKBS/HPCL/FPS/002

3.6 Mtrs 9.5 mm / (3/8”) dia

25 mm dia
3.6 Mtrs
32 mm dia 9.5 mm / (3/8”) dia
4.5 Mtrs
40 mm dia 9.5 mm / (3/8”) dia
4.5 Mtrs
50 mm dia 9.5 mm / (3/8”) dia
4.5 Mtrs
65 mm dia 9.5 mm / (3/8”) dia
4.5 Mtrs 9.5 mm / (3/8”) dia
80 mm dia
4.5 Mtrs
100 mm dia 9.5 mm / (3/8”) dia
4.5 Mtrs
125 mm dia 12.7 mm (1/2”) dia

150 mm dia 4.5 Mtrs 12.7 mm (1/2”) dia

200 mm dia 4.5 Mtrs 15.9 mm (5/8”) dia

4.5 Mtrs
250 mm dia 15.9 mm (5/8”) dia

Fig 1. Riser Support Detail for Vertical Piping

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DOC.No: VKBS/HPCL/FPS/002

Fig 2. Ceiling Support Detail

 Install the assembled pipe length directly below the actual position using manpower, nylon
rope, ladder, vertical lifts and other necessary tools as per requirement
 Proper care will be taken while lifting the materials
 The pipe will be checked for correct level and position and if necessary adjusted
 Bottom of the Pipe will aligned for the pipes running horizontally. For this
eccentric reducers will be used for size variation.
 Centre line of the pipe will be aligned for the pipes vertically. For this concentric
reducers will be used for size variation.
 Then pipe field joints will be made by threading or welding method as per material
specification.
 Before joining the joints, pipe line shall be cleaned for foreign materials inside it. Proper
temporary caps will be installed to all open ends.
 Work location will be cleaned after completion of day’s work.

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MS for Installation of Fire hydrant
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DOC.No: VKBS/HPCL/FPS/002

7) INSTALLATION OF HYDRANT & FIXTURES:

 Identify the installation materials (like hydrant valves, hose reel etc.) and
accessories required as per approved drawing and confirm the availability of material before
the installation.

 After completion of hydrostatic testing and complete flushing of the piping network, prior
permission will be taken for installation of the hydrants & fixtures

 Required materials along with necessary tools & tackles and accessories will be shifted to the
work site as per programmed schedule.

 Before installation of any equipment, the same shall be checked for foreign materials inside it
and proper operation of the equipment.

 Hydrant valves will be installed by the means of bolting with the mating flange with insertion
of rubber or CAF gasket in the flange joint. Fasteners shall be of MS Galvanized. Note that
fasteners should not be painted.

 Hydrant valves shall be at 1000 mm above FFL.

 Fire Brigade Inlet connections shall be installed at approved location

 FBI connection (to system) post shall be with butterfly valve and check valve.

 Hose reel drum will be mounted on the wall as per approved shop drawings.

 Rubber hose will be reeled on the drum by using worm hose clips. One end of the hose will be
connected to the incoming main of 25 mm dia pipe with isolation gate/ ball valve. Other end of
the hose reel will be connected to spray nozzle by means of worm hose clips.

 Ensure the proper installation of isolation valve (with/without tamper switch) and flow switch
on the inlet side of hose reel system as per the approved shop drawings.

 Fire hoses and branch pipes will be placed in the fire hose cabinet as per the approved shop
drawings.

 A proper protocol will be prepared for the installation which will be signed by the concerned
authorities.

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DOC.No: VKBS/HPCL/FPS/002

CHECK LIST
PIPING FOR FIRE HYDRANT & HOSE REEL SYSTEM
LOCATION:
DATE

Sl. No. Activities / Items to be inspected Remarks

1 Pipes, fittings and other accessories like valves, supports etc. received are to be
checked for make and technical specifications as per the approved submittals.

2 Check the quantity and quality of the materials received. Ensure the received materials
are conforming to the relevant standards for type, size, model and dimensions.

3 Check the received materials for transit damage, if so, return the materials.

4 Ensure the proper storage of materials as per manufacturer recommendations and

applicable standards.

5 Ensure the availability of approved latest shop drawings, manpower, tools equipments,
materials, site clearance before the commencement of installation.

6 Ensure Builders work drawings and shop drawings are

Coordinated & approved.

7 Check for proper working of welding machine and all other equipments.

8 Check the pipe joint fit-up for proper gap and groove.

9 Check the root welding for slag, blow holes, excess/ lack of penetration, cracks etc.

10 Check the final run of welding for correct workmanship.

11 Ensure the removal of temporary locks (like tack welding) and burrs by the means of
grinding after the final run of welding.

12 Ensure the inside of the pipe is free from foreign materials before starting the fit-up.

13 Check the supports for proper spacing and type as per approved drawings and ensure
it can bear the designed load of piping and accessories.

14 Check the erected pipes as per approved drawings.

15 Ensure the installation of pipes for proper gap from adjacent sides i) to carry out field
welding.

ii) To install valves and other accessories.

iii) To operate tightening tools and equipments.
iv) Proper operation and maintenance of the piping and equipments.
16 Check the valves and other accessories for manual operation, free from foreign

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DOC.No: VKBS/HPCL/FPS/002

materials inside it and maintaining proper direction of flow mark

while installing.

17 Check the flange joints for proper sealing with rubber gasket.

18 Check the flange joints for proper tightening of fasteners

19 Check the pipe routing as per approved drawings.

20 Check the pipe installed for proper leveling and alignment and coordinated with other
services.
21 Check the drain valves installed and terminated to the location as per approved
drawings.
22 Check the height of the hydrant posts and Stand post for hose reel as per approved
drawings.
23 Check the hydrant post and Stand post for hose reel for exact location as per approved
drawings.

24 Check the sleeves provided to run the pipes through walls/floors or partitions are as
per approved drawings.
25 Check the sleeves are cut to length for mounting flush with both surfaces.

26 Check the opening around the pipes passing through walls / partitions etc. Are
properly sealed after completing the installation work.

27 Piping work is to be installed such that sufficient Spectacle is available for dismantling
of pipes, valves & accessories and re assembling at field location.

28 Ensure the satisfactory test result of the hydrostatic pressure test and maintaining the
test records duly approved by the concerned authorities.

29 Ensure the proper cleaning, degreasing & removal of rust before applying primer on
the pipe surface.
30 Check the application of primer for even thickness all around the pipe as per standards.
31 Check the dryness of the primer applied pipe surface area before applying first coat of
paint of approved color.
32 Ensure the completion of all installation, testing and commissioning activities before
applying the second coat of paint.

33 Ensure the piping and accessories installed are protected from any damages till the
handing over of the system to client.

34 Ensure the proper identification, flow directions and valve y\tags are provided as per
specifications.

35 Ensure the installation of piping work in coordination with other services.

36 Check the healthiness of the complete installation prior to commissioning.

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DOC.No: VKBS/HPCL/FPS/002

CHECK LIST

INSTALLATION OF FIRE HYDRANT AND HOSE REEL EQUIPMENT

LOCATION: DATE

Sl.No. Activities / Items to be Inspected Remarks

1 Check the Hydrant valves, branch pipes, fire hoses, hose reel etc. received for make and
technical specifications as per the approved submittals.

2 Check the quantity and quality of the materials received. Ensure the received materials
are factory tested and confirming to the relevant standards for type, size, model and
dimensions.

3 Check the received materials for transit damage, if so, return the materials.

4 Ensure the proper storage of materials as per manufacturer recommendations and

applicable standards.

5 Ensure the completion of hydrostatic pressure testing of the piping network where the
equipments are to be installed.

6 Ensure Builders work drawings and shop drawings are coordinated & approved.

7 Ensure the availability of approved latest shop drawings, manpower, tools& equipment,
materials, site clearance before the commencement of installation.

8 Check the following before installing the hydrant valves

i) Inside of the hydrant valve is free from foreign materials.
ii) Flange surface for proper even level.
iii) Flange dimensions of the hydrant valve are identical to the connecting flange which
is welded on the pipe.
iv) Check the gasket on the seat valve for damage by filling the valve with water, if so
replace it.
v) All parts like spindles, body disc etc. is undamaged.
vi) Free rotation of wheel.
vii) Free operation of instantaneous spring lock. and blank cap.
viii) Ensure the piping network is free from foreign materials.
ix) Adequate Spectacle availability for installation, testing and
Maintenance.

9 Check the following after installation of hydrant valve.

i) Proper tightening of fasteners.
ii) Provision of rubber gasket in the flange joint.
iii) Correct orientation of valve as per approved drawings.
iv) Ensure the testing and commissioning activity immediately after the installation.

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v) Installed equipment is protected from damage till handing over of

the system.

10 Check the following before and after the installation of hose reel
equipment.

i) Damage to the body, hub and spindle equipment.

ii) Collar is properly protected.
iii) Adequate Spectacle availability for supports, installation, testing and maintenance.

11 Check the rubber hose for any holes or cuts, before and after the installation.

12 Check the spray nozzle for any damage, free from foreign material and proper manual
operation before installation.

13 Ensure the proper tightening of rubber hose with hose reel, nozzle and incoming main.

14 Ensure proper tightening of flow switch on the incoming main and proper control
cabling to fire alarm panel.

15 Check the proper operation of hose reel and free flow of water through spray nozzle.

16 Check the healthiness of the complete installation prior to commissioning.

10. INSPECTION AND TESTING:

General:

All inspection and testing shall be carried out to satisfy the criteria that shall
Be evidence in the relevant inspection documents.

Procedure for Hydraulic Testing

 Maximum length of pipeline as per site conditions will be hydraulic tested to a pressure 1.5
times the system working pressure. Procedure of conducting hydraulic testing is as follows.
 Pipe interiors will be cleared for any foreign materials.
 Blank off all the open ends of pipes.
 Arrangement for filling the water inside the pipe line, proper venting of air and hydraulic test
pump connection with pressure gauges will be made.
 Pipeline will be checked for any leakage and if so that will be rectified immediately and above
said activities will be repeated.
 The pipe line will be pressurized through hydraulic test pump, which will be driven either by
electric motor or manual.
 During pressurization once again pipe line will be checked for leakages.
 After attaining the required test pressure, the running of the pressurizing pump will be made

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off and immediately the pressure reading of the pipe line will be noted. The
concerned approval authority for this test shall be present during testing
period at work location.
 After two Hrs. pressures reading will be noted. And the test result will be
certified by the approval authority. If the test result is not satisfactory, the above said exercise
will be repeated till test gets satisfactory result.
 Hydraulic Test Report will be prepared and get approved from the approval authority.
 Water will be filled in the pipe line by means of filling pump or facility available at site.
 Proper venting will be done so that all the air inside the pipeline by opening vents valve at all
high points. Water will be allowed to flow from all venting points for about 10 to 15 Minutes to
ensure that complete air has been removed.
 After the confirmation of removal of all the air, all vent valves will be closed.

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HYDROSTATIC TEST REPORT FORMAT FOR PIPING OF FIRE HYDRANT &

WET RISHER &HOSE REEL SYSTEM
TEST REPORT NO: : DATE

SYSTEM: :

LOCATION: :
………………………………………………………..

REF. DRG. NO ;
………………………………………………………..

SYSTEM WORKING PRESSURE :

……………………………………………………….. bar

HYDRAULIC TEST PRESSURE :

……………………………………………………….. bar

TEST DURATION AS PER SPECIFICATION ;

……………………………………………………….. Minutes

DATE OF TEST :
………………………………………………………..

TEST PARAMETERS

DATE TIME PRESSURE SIGNATURE

INITIAL READINGS

FINAL READINGS

TEST OBSERVATIONS ……………………………………..

TEST RESULT ………………………………………

ATTACHMENT 1) Sketch of pipeline network tested

COMMENTS:

Receiving Inspection and Testing:

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The receiving inspection is carried out to ensure that the incoming

materials will not be used until it has been inspected and verified for
conformance to specification, Inspection and verification shall be done
on the materials Delivery Order (D.O) and be evidenced by (IMIR) which
will be stamped on the D.O
In-Process and Final Inspection and Testing:

All the Devices and cable continuity to be checked for installation and commissioning check the proper
functioning.

Health, Safety, Security and Environment:

Only experienced and competent personnel are permitted to use machinery. A person is deemed to be
competent on the successful completion or relevant training in combination with their on-site performance.

 The suitable tonnage Hydra will be used to unload and Load in a safe place.
 At the time of erection the area will be barricaded for unauthorized entry of persons.
 Well skilled persons to use on erection. Workers to follow all the safety rules.
 Toolbox meeting to be conducted before start the work.
 Proper toolbox to be given to the workers before start the work.
 While working above 2 meters safety belts is compulsory.
 To give the proper signal to hydro and scissor lift operators.
 Hot work permit in place before commencement of welding works if any.

Item Work Process Risk/ Hazards Safety and Health Measure

1 Handling/Lifting Injuries caused by improper method Approved JSA to be followed

of lifting
2 Work at height Falls Approved JSA to be followed.

12. ATTACHMENTS AND RECORDS:

 Factory Test reports& Site Test Report.

 Installation Check list.
 Tool box talk.

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