SITE : : MEP,INTERIOR WORK

METHOD STATEMENT FOR CPVC & UPVC PIPING

 CONTENTS
1 INTRODUCTION................................................................................................................................................................................. 3
1.1 Purpose.........................................................................................................................................................................................................................3
1.2 Scope.............................................................................................................................................................................................................................3
1.3 Abbreviations and definitions....................................................................................................................................................................................3

2 SEQUENCE OF ACTIVITY................................................................................................................................................................3
3 PREPARATION.................................................................................................................................................................................... 4
3.1 General installation Procedures..................................................................................................................................................................................
3.2 Installation ....................................................................................................................................................................................................................
3.3 Erection .........................................................................................................................................................................................................................
3.4 Flushing,Testing & Commissioning ...........................................................................................................................................................................
3.5 Safety..............................................................................................................................................................................................................................

4 EHS RISK ANALYSIS......................................................................................................................................................................... 6

5 TRAINING MATRIX......................................................................................................................................................................... 10
6 PREPARATION.................................................................................................................................................................................. 11
6.1 General precautions......................................................................................................................................................................................................
6.2 Crucks of method statement .......................................................................................................................................................................................

7 CONTIGENCY PLAN........................................................................................................................................................................ 11
8 REQUIRED QUALIFICATION........................................................................................................................................................11
9 TOOLS REQUIRED........................................................................................................................................................................... 12
10 LOGISTIC, TRANSPORT AND MATERIALS HANDLING.......................................................................................................13

(Method Statement for CPVC & UPVC piping) Page 2 / 14

1 INTRODUCTION

1.1 Purpose
This document describes the Method Statement for CPVC/UPVC piping installation testing &commissioning.

1.2 Scope
Supply and Installation of CPVC/UPVC piping works.

1.3 Abbreviations and definitions

Abbreviation Definition
EHS Environmental Health and safety
SIG Signalling

2 SEQUENCE OF ACTIVITY

Inserting/ joining
the UPVC & CPVC
CPVC UPVC PIPING pipe by using paste
and ensure the leak
free joints after join-
ing.

Checking area and

visual inspection be-
fore starting work

1 2 3 4

Cutting of pipe
according to size.

Hold the pipe and

fix the clamp for the
UPVC & CPVC pipe
connection

3 PREPARATION

3.1 General Installation Procedure:

- Ensure that the proper clearance is available from civil side before commencement of works

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 - Ensure that the work area is clean and safe for carrying out the activities
- Prior to start of works, it shall be ensured that the relevant shop drawings and coordination drawings are approved
and issued for construction.
- It shall be ensured that no contraction with other previously installed services, and if there is any shall be cleared.
- It shall be ensured that the material issued is as per the approval material submittal.
- Check proper supports for the erection is available (if applicable).

3.2 Installation:-

3.2.1 Cutting:-
- Take the required size of the pipe and mark the required length.
- Cut the pipe according to the required length by using pipe cutter.
- It is necessary that the cut is always at the right angle.
- While cutting ensure burr free cutting.

3.2.2 Inserting/Jointing:-
- Clean the internal and external surface of pipe to be installed so that it is reasonably free from burr, dirt, mud,
gravel, or other foreign material.
- Clean the internal and external surface of the fitting to be used.
- Apply paste on the surface of the pipe and inside the fitting to be used.
- Ensure that the paste is spread evenly throughout the surface.
- The pipe is to be pushed inside the fitting and it is to be held tightly until the paste has dried.
- This procedure will ensure leak free joints.

3.2.3 Clamping:-
- Use proper clamps as prescribed
- Maintain the clamping distances as per supplier table.
- Always support the fitting at all the joints.
- The clamp should not be tightened too much, to avoid deformation of pipe section.
- Don’t use sharp objects such as nails and steel wire for holding the pipe.

3.3 Erection:-
- Before erection the work area is to be checked for obstructions.
- Sufficient skilled labour, competent supervisors, safety personnel and proper tools and tackles shall be used during
erection.
- All required permits shall be obtained before erection.

3.4 Flushing, Testing & Commissioning:-

- Flushing of Industrial Water pipe line shall be done by Water.
- Flushing shall be done by as per flushing procedure.
- All piping shall undergo hydro test for the required pressure.
- Moreover, hydrostatic test shall be done 1.5 times of operating pressure.
- All necessary arrangements via temporary piping, supports, vents, drains to be provided before test. Subcontractor
QC Engineer and client QC Engineer shall witness this test.
- All lowest and highest points of the line test pressure gauges to be mounted those should have valid calibration
records are produced to client for review.

(Method Statement for CPVC & UPVC piping) Page 4 / 14

 - Clean water should be hydrostatic testing. Test pressure and holding time are followed as per
specification/Drawing, approved by client Quality department.
- When draining the test liquid, the pipe line vent shall be opened to avoid vacuum. If any leakage is found it shall
be rectified and re-tested.
- All test reports and certificates will be maintained for records and produced to client QC for review.
- After hydro test and flushing, box up the entire system. It has to be commissioned as per requirement without any
leak/problem up to the satisfactory level.

3.5 Safety
- Head Protection: - Hard hats or helmets should be worn where there is the possibility of injury from falling
objects. All time mandatory.
- Foot Protection: - Safety shoes should be worn if there are hazards from falling objects or when handling heavy
crates or equipment. All time mandatory.
- Hand Protection: - Gloves should be used while handling Earth flat to avoid cutting. All time mandatory.
- Eye and Face protection: - Eye glasses, nose mask, or face shields should be worn.
- Ear Protection:-It may be necessary to wear ear plugs or muffs when noise levels surpass 85 decibels.
- Shoulder protection: - Shoulder pads should be worn, if in case of manual straddling.
- Height work area shall be hard barricaded and only authorized persons will enter inside the earthing works
- Proper housekeeping should be done daily after finishing of works in the evening.
- As we are all aware regarding the COVID-19, we should take our own precautions to control the spreading rate
while activities going at site, so compulsory masks & sanitizers should be used at workplace.

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 4 EHS RISK ANALYSIS
- Hazard identification and risk assessment procedures should be carried out for the fixing activities, in order to develop, implement and maintain control measures.
5 0 5 10 15 20 25
4 0 4 8 12 16 20 Likelihood SEVERITY
3 0 3 6 9 12 15
Rating 0 = Zero to very low
Severity

2 0 2 4 6 8 10 Rating 1 = Very unlikely Rating 0 = No injury or illness

1 0 1 2 3 4 5 Rating 2 = Unlikely Rating 1 = First aid injury or illness
0 0 0 0 0 0 0 Rating 3 = Likely Rating 2 = Minor injury or illness
0 1 2 3 4 5 Rating 4 = Very likely Rating 3 = “3 day” injury or illness
Likelihood Rating 5 = Almost certain Rating 4 = Major injury or illness
Rating 5 = Fatality, disabling injury, etc

Risk = Likelihood x Severity

Acceptable Further review Unacceptable Risk
SI ACTIVITY HAZARD CONSEQUENC MINIMIZE RISK TO ACCEPTABLE RESPON

RATING

RESIDU
AL Risk
PROBA
BILITY

PROBA
BILITY
Severity

Severity
. INVOLV E LEVEL BY SIBLE

rating
RISK
N ED PERSON
O
1. Checking area Slip, Trip & 5 5 25 1. Proper housekeeping shall be maintained in the 4 1 4 Safety
and visual Fall The person may get work area. officer, Site
personal injury or
inspection before 2. Appropriate type of PPE such as eye protection Engineer.
fatal Property damage
starting work shall be worn along with hand and foot protection.
3. Adequate access to the work location be
provided or should be available.

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2. Cutting of pipe Rotating A worker may be 5 5 25 1. All rotating and moving parts shall be guarded. 4 2 8 Site
according to size. parts injured by back-and The operators shall not wear any loose clothes. Engineer,
forth or up- and-down 2. The guard shall be in place after the
site
motion when struck maintenance work is carried out.
by or caught between 3. TBT shall be given before the execution of the supervisor
moving and work
stationary parts 4. Adopt safe permit to work system.
5. Adhere to the safe operating procedures.
6. Appropriate information, instruction and
supervision shall be provided to workers Use of
appropriate personal protective equipment.

Breakage of The person may get 4 5 20 1. Grinding machine shall be operated keeping the 4 1 4 Site
grinding injuries or fatal and wheel guard in position. Engineer,
property damage 2. The maximum speed marked on every wheel
wheel site
shall never be exceeded. Rated speed of the wheel
shall be equal to or greater than the maximum supervisor
speed of the grinding machine.
3. The Operator shall inspect the wheels for
cracks and defects before mounting. Only the
wrench supplied by the manufacturer shall be
used and over tightening shall be avoided.
4. The operator shall keep the machine away from
his body at least for 30 seconds while starting
grinding machine.

(Method Statement for CPVC & UPVC piping) Page 7 / 14

 Guard Debris or hot 5 5 25 1. Never remove guards. 4 1 4 Site
has been sparks fly back at 2. Ensure guards are fitted securely in the correct Engineer,
removed the operator, position before use and are resistant to bending
site
or causing burns or and twisting.
incorrect lacerations. 3. Ensure the thickness and diameter of supervisor
ly Operator’s hand attachments is within the angle grinder ratings.
positione makes contact with
d (eg moving parts,
removin resulting in
g amputations or
the guard lacerations.
to use
a larger
attachment)
Workers are 5 5 25 4 1 4 Site
1. Ensure workers wear hearing protection.
exposed to The person may affect 2. Ensure workers have audiometric testing when Engineer,
with temporary or
extended assessed as necessary site
permanent hearing
periods of loss such as noise supervisor
noise induced hearing loss
from
grinders
Flammable 5 5 25 Ensure flammable substances are not placed or 4 1 4 Site
substances The person may affect stored in areas where grinders are used. Engineer,
with burn injury or
near site
fatal
grinders supervisor
Property damage

Dusts or 5 5 25 1. Ensure the work area is adequately ventilated 4 1 4 Site

vapours The person may affect (this may require natural airflow or extraction Engineer,
with skin diseases or
remain in the units). site
respiratory problem or
work area fatal 2. Ensure the work area is regularly cleaned and supervisor
when using dusted.
grinders

(Method Statement for CPVC & UPVC piping) Page 8 / 14

3 Inserting/ joining Trap, fall of Abrasions, fingers 4 3 12 1. Explain the safe working procedure to the 2 1 2 Site
the UPVC & objects, numbing, skin Engineer,
workers in tool box talk before the
damage, back ache
CPVC pipe by impact, commencement of work Site
using paste and chemical 2. Ensure the workers are competent for the job supervisor
ensure the leak hazards and ensure the equipment’s are in good condition
free joints after (fixing to use.
joining. paste),
3. Fixing paste must be used in safe condition and
musculoskel
explain the hazards in the fixing paste to the
etal
workers and clearly read the fixing paste
disorders
ingredients and method statement.
4. Job change should be required and gives
information, instruction about the good posture.
5. Ensure the personal protective equipment’s like
hand gloves, safety shoes are suitable to use
during working and appropriate for the workers.
4. Hold the pipe and Sharp edges, Cut and abrasions, 4 3 12 1. Don’t use sharp objects such as nails and steel 2 2 4 Site
fix the clamp for trap, back ache due to poor wire for holding the pipe Engineer,
posture to hold the
the UPVC & entanglemen 2. Ensure the materials ( UPVC & CPVC pipe) Site
pipe, bone fracture.
CPVC pipe t, impact. quality, the clamp should not be tightened too supervisor.
connection. much, to avoid deformation of pipe section
3. Ensure the workers are competent for the job
If possible barricade the work area avoid
unnecessary disturbance.
4. Ensure the workers are wear properly the
personal protective equipment’s such as hand
gloves, safety shoes etc.,
5. Conduct training and gives information,
instruction about the hazards in the work and their
control measures should be explain the safe
working procedures for the tasks.

(Method Statement for CPVC & UPVC piping) Page 9 / 14

 5

Electricians

Security Staff
Project Manager
-

Warehouse Manager
Sr. OHS&E Managers
Chief OHS& E Manager

Sub-contractor Personnel
GC/PMRC Representative
OHS&E Induction

OHS&E Leadership
TRAINING MATRIX

OHS&E Plan

(Method Statement for CPVC & UPVC piping)

Alstom EHS Passport

High Risk Activity

Management
Applicable Statutes &
Management

Regulations
OHS&E Audit & Inspection

Day to Day Risk Management

First Aid & CPR

OHS&E Emergency Response

& Preparedness
Safety Training Observation
TRAINING MATRIX

Programme (STOP)
Power Tools and Equipment
Inspection
Housekeeping and waste
Supervisor

management
Incident / Accident
Investigation & Reporting
Page 10 / 14 Co-Current Permit to Work
System
Confined Space Working

Working at Height

Working Near adjacent railway

or Live Electrical atmosphere
Heavy Lifting Operation
Specific

Electrical Safety & Power

operated Portable tools
Manual Material Handling

Scaffold Erection/ Dismantling

Total Hours
6 SAFE OPERATING PROCEDURE (DOES AND DON’T)

6.1 General Precaution

- Safety Programme- All operations shall be carried out by qualified and competent supervisor. The supervisor shall
also be responsible for the safety arrangements at the worksite.
- Fencing shall be provided, wherever necessary, around the working area or watchmen provided to prevent
onlookers from trespassing into the construction sites. For work during the night lighting of at least 100 lux
intensity shall be provided at the work site.
- The working area shall be investigated to ascertain the presence of any buried-obstruction and actual position of
all service lines passing through the work site shall be known before the work commences. Particular attention
shall be given in case live electrical cables pass underground, which may interfere within the depth of foundation.
- The safety provisions shall be brought to the notice of all concerned and matters needing special attention shall be
displayed at a prominent place at the work spot.
- All necessary PPE identified as per Risk Analysis such as full body harness and safety helmets and safety shoes,
as considered suitable, shall be kept available for the use of persons employed on the site and maintained in
condition suitable for immediate use.
- A first-aid kit shall be maintained at the site near the place of work, to comply with the requirements and
provisions for the work.
- Those engaged in mixing and stacking of cement bags or any other material injurious to human body shall be
provided with protective wear suitable for the purpose. Welders engaged in the work of welding shall use eyesight
shields.
- Every crane driver or hoisting appliance operator shall be competent to the satisfaction of the engineer-in-charge
and no person under the age of 21 years should be in-charge of any hoisting machine including any scaffolding
winch, or give signals to operator

6.2 Cracks of Method Statement

7 CONTINGENCY PLAN
- For any unforeseen situations or uncertainties which could lead to unsafe situation, the supervisor should consider
the followings:
 Stop work and remove all tools and materials from location.
 Report to Engineers or raise any concern during meeting etc.

8 REQUIRED QUALIFICATION
- Work Authorization
 Permit to work on site need to be obtained before start of the installation activities and cancelled after completion
of the work. Permit to work system must be in accordance with employer requirements and ALSTOM EHS
policies/Procedures.
 Permit Issuer and Permit Receiver shall comply the guideline of PTW procedure.
 Competency assessment and work authorization is mandatory from Project Director and nominated Ones

- Manpower
 Operational Construction Supervisor (ALSTOM)
 Project manager ( Mr.sachin pmc pune) ELEMENTS

(Method Statement for CPVC & UPVC piping) Page 11 / 14

  Site Engineer (Sub-contractor)
 Quality Engineer (Sub-Contractor)
 Site Supervisor (Sub-Contractor)
 Electrician (Sub-Contractor)
 Safety Engineer (Alstom)
 Safety Supervisor (Sub-contractor)
 Workforce (15 No’s) for shifting and lifting Material as Required (Sub-Contractor)
The above listed team is a theoretical team, according to safety plan and working conditions.

(Method Statement for CPVC & UPVC piping) Page 12 / 14

9 TOOLS
Standard Tools
Tools Short Description Picture (For Illustration Purpose only)

Measuring Tape To do linear measurement markings

5m (1)

Spirit Level (1) To level the foundations, or beds of

machines to ensure the machine can
output work pieces to the accuracy
pre-built in the machine.

Hammer (1) To deliver an impact to a small area

of an object

Electrical Extension It is used as a Multi – plugger. Only

Leads (1) Industrial type Electrical distribution
board used for power distribution and
contain ELCB /RCCB. Sensitivity of
RCCB/ELCB should not more than
30mA and temporary distribution
board must be in accordance with
IP44 standard or above

Steel Rule 150mm To measure short distance

(1)

Knife (as per For cable stripping and termination

requirement) purpose

Insulated Step To work at height

Ladder (1)

(Method Statement for CPVC & UPVC piping) Page 13 / 14

 Tools for pipe For cutting, phasing
cutting (as per
requirement)

10 LOGISTIC, TRANSPORT AND MATERIALS HANDLING

- Equipment should be delivered to the work area from the stores by trolley on rail or road or any other suitable
means.
- Following inspection shall be carried out when collecting mounting stands/ bases:
 Shifting of material by trolley or manually to the exact location depending site conditions. (Weight less
than 40 Kg).
 Finish of Stand is in good condition.
 Fixing bolts and ladders (where applicable) are shipped together with stand.
 No visible damage
 Deliveries are consistent with drawings and associated drawings and documentation.
 Stored materials on site shall be properly secured well marked and covered

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