Method Statement for The Testing & Commissioning of Domestic Pumps

1.0 SCOPE :

This Method Statement describes/defines the procedures involved in the testing and
Commissioning of Domestic Water Pumps & Booster Pump Sets and Accessories in order to
confirm proper operation.

2.0 PURPOSE :

This Work Method Statement (WMS) is to ensure installation of Water Pumps Sets is correct and
as per agreed procedures and that working of the system is correct and as per client
requirements and to check is work is carried out as per the regulations.

The aim and /or benefits of complying with this WMS include: Program Compliance, Health,
Safety and Quality and Environmental company policy compliance.

3.0 REFERENCES

3.1 Mechanical Approved materials & equipment (Data sheet/Submittal)

3.2 Approved Project Drawing( Plumbing)

3.3 Project Specifications,

4.0 DEFINITION

None

5.0 RESPONSIBILITIES
5.1 Project Manager will be responsible for the following:

5.1.1

Overall responsible for the implementation of this method statement.

5.1.2

Responsible for ensuring that the work is performed in accordance with the specification and
with the time & constraints.

5.1.4

Ensure that all required submittals i.e. test reports, T&C reports are made available in timely
manner.

5.2 QA/QC Department will be responsible for the following:

5.2.1 QA/QC Department will perform all preliminary checks prior to the commissioning of
the system.

5.2.2 Ensure all installations are as per approved shop drawings and as per approved
material submittals.

5.2.3 Ensure the works comply with the contract requirements to serve the purpose.

5.2.4 Ensure the work is completed as per quality requirements. Contractor shall inspect the
same work to initiate ITR for company approval.

5.3 Commissioning Team:

5.3.1 All Pre-Commissioning and Commissioning activities are the responsibility of

5.3.2 Pre-commissioning and Commissioning shall be carried out by Specialist Contractor

5.3.3 Contractor Commissioning manager shall check the commissioning works prior to
submission to the Commissioning Agent for witnessing and approval.
5.3.4 In case of failure in any test, the Specialist Contractor will rectify, and MEP
Commissioning team to re-offer the test to Commissioning Agent for re-witnessing and
approval.

5.3.5 Final Testing & Commissioning Report shall be submitted to consultant for approval.

5.4 Safety Officer/ Engineer will be responsible for the following:

5.4.1 Tool Box talk has to be conducted and all the hazards have to be identified before
starting the commissioning.

5.4.2 To make sure that the Personnel Protective Equipment (PPE) are used by the Task
Force during executions of work at site.

5.4.3 Risks related to the activity shall be assessed and addressed as required.

5.4.4 To provide training for the work force in order to execute the activity safely.

6.0 METHOD OF WORK

6.1 Equipment/ Tools

6.2.1 Calibrated Flow Meter

6.2.2 Calibrated Pressure Gauge

6.2.3 Hand Tools

6.2.4 General Tool Box

6.2.5 Spanner Set

6.2.6 PPE's

7.0 PROCEDURE / EXECUTION OF WORK

7.1 WATER FILTERED TRANSFER PUMPSET

7.2 EQUIPMENT DATA

Duty :

No. of pumps :

Qty :

Pump model :

Motor details :

7.3 PRE-COMMISSIONING CHECKLIST

7.3.1 Check pump set installation completed

7.3.2 Check suction & discharge pipework /valves/fittings free of leak.

7.3.3 Check suction strainers clean

7.3.4 Check float switch installed in the suction tank and roof tank and cable properly
marked and connected to control panel (For auto operation & dry run prevention)

7.3.5 Check if the mains power supply is available at the socket.

7.3.6 Check incoming mains for proper earthing and neutral line

7.3.7 Check whether electrical control panel properly wired and connected with pump
motor.

7.3.8 Check whether water available in the suction tank

7.4 METHOD OF COMMISSIONING

7.4.1 The Water Transfer Pump Set are controlled by float switches in discharge tank.

7.4.2 Check if the mains power supply is available at the socket.

7.4.3 Connect the power supply and start the trail operation.

7.4.4 Direct the float downward in the overhead tank.

7.4.5 First raise the float switch in upward direction. This will cause pump 1 to start

7.4.6 Next, return the float switch to the original position. This will cause pump P1 to stop.
7.4.7 Perform the above steps consecutively two or more times to verify the operation.

7.4.8 Allow the pump to operate a minimum of 10 seconds for each trial operation. The trial
operation must be completed within 2 minutes.

7.4.9 The operating current and the flow are to be measured and readings noted down.
These are compared with the design values. The actual values should match the design values or
should be within acceptable tolerance

8.0 SOFT WATER TRANSFER PUMPSET

8.1 EQUIPMENT DATA

Pump : Soft water transfer pump set

Duty :

Qty :

No. of pumps :

Pump model :

Motor details :

8.2 PRE-COMMISSIONING CHECKLIST

8.2.1 Check pump set installation completed

8.2.2 Check suction & discharge pipework /valves/fittings free of leak.

8.2.3 Check suction strainers clean

8.2.4 Check float switch installed in the suction tank and roof tank and cable properly
marked and connected to control panel (For auto operation & dry run prevention)

8.2.5 Check if the mains power supply is available at the socket.

8.2.6 Check incoming mains for proper earthing and neutral line

8.2.7 Check whether electrical control panel properly wired and connected with pump
motor.
8.2.8 Check whether water available in the suction tank

8.3 METHOD OF COMMISSIONING

8.3.1 The Water Transfer Pump Set are controlled by float switches in discharge tank.

8.3.2 Check if the mains power supply is available at the socket.

8.3.3 Connect the power supply and start the trail operation.

8.3.4 Direct the float downward in the overhead tank.

8.3.5 First raise the float switch in upward direction. This will cause pump 1 to start

8.3.6 Next, return the float switch to the original position. This will cause pump P1 to stop.

8.3.7 Perform the above steps consecutively two or more times to verify the operation.

8.3.8 Allow the pump to operate a minimum of 10 seconds for each trial operation.

8.3.9 The trial operation must be completed within 2 minutes

8.3.10 The operating current and the flow are to be measured and readings noted down.
These are compared with the design values. The actual values should match the design values or
should be within acceptable tolerance

9.0 HOT WATER RETURN PUMPSET

9.1 EQUIPMENT DATA

Pump : Hot Water Return pump set

Duty :

No. of pumps :

Qty :

Pump model :

Motor details :

9.2 PRE-COMMISSIONING CHECK LIST

9.2.1 Check pump set installation completed

9.2.2 Check suction & discharge pipework /valves/fittings free of leak.

9.2.4 Check dry run prevention of pumps provided.

9.2.5 Check if the mains power supply available at the socket.

9.2.6 Check incoming mains for proper earthing and neutral line

9.2.7 Check whether electrical control panel properly wired and connected with pump
motor.

9.3 METHOD OF COMMISSIONING

9.3.1 The Hot Water Return Pump Set will be equipped with 24hr timer to circulate the
water in the hot water system.

9.3.2 Check if the mains power supply is available at the socket.

9.3.3 Connect the power supply and start the trail operation.

9.3.4 Set the operating time of pump via 24 hr. timer .

9.3.5 Start the pump in auto mode and verify that the pump stops at the set time and
change over to stand by pump.

9.3.6 Perform the above steps consecutively two or more times to verify the cyclic
operation. The operating current to be measured and readings noted down. These are
compared with the design values. The actual value should match the design values or should be
within acceptable tolerance.

10.0 COOLED WATER CIRCULATION PUMPSET

10.1 EQUIPMENT DATA

Pump : Cooled water circulation pump set

Duty :

No. of pumps :

Pump model :

Motor details :
10.2 PRE-COMMISSIONING CHECK LIST

10.2.1 Check pump set installation completed

10.2.2 Check suction & discharge pipework /valves/fittings free of leak.

10.2.3 Check suction strainers clean

10.2.4 Check dry run prevention of pumps provided.

10.2.5 Check if the mains power supply available at the socket.

10.2.6 Check incoming mains for proper earthing and neutral line

10.2.7 Check whether electrical control panel properly wired and connected with pump motor.

10.3 METHOD OF COMMISSIONING

10.3.1 The Cooled Water Circulating Pump Set will be equipped with 24hr timer to circulate
the water.

10.3.2 Check if the mains power supply is available at the socket.

10.3.3 Connect the power supply and start the trail operation.

10.3.4 Set the operating time of pump via 24 hr. timer

10.3.5 Start the pump in auto mode and verify that the pump stops at the set time and change
over to stand by pump.

10.3.6 Perform the above steps consecutively two or more times to verify the cyclic operation.

10.3.7 The operating current to be measured and readings noted down. These are compared
with the design values. The actual value should match the design values or should be within
acceptable tolerance.

11.0 COOLED WATER BOOSTER PUMPSET

11.1 EQUIPMENT DATA

Pump : Cooled water booster pump set

Duty :

No. of pumps :

Pump model :

Motor details :
Pressure vessel :

11.2 PRE-COMMISSIONING CHECK LIST

11.2.1 Check pump set installation completed

11.2.2 Check suction & discharge pipework /valves/fittings free of leak.

11.2.3 Check suction strainers clean

11.2.4 Check float switch installed in the suction tank and cable properly marked and
connected to control panel (For dry run prevention)

11.2.5 Check pressure vessel pre-charge pressure

11.2.6 Check if the mains power supply available at the socket.

11.2.7 Check incoming mains for proper earthing and neutral line

11.2.8 Check whether electrical control panel properly wired and connected with pump motor.

11.2.9 Check whether water available in the suction tank

11.3 METHOD OF TESTING & COMMISSIONING

11.3.1 The Cooled Water Booster Pump Set will be controlled pressure transducer/switches
and operates based on demand of system pressure.

11.3.2 Connect the power supply and start the trail operation.

11.3.3 Set the cut in and cut off pressures in pressure transducer / switches.

11.3.4 Fill air in pressure vessel and this shall be 0.5 bar below the cut in pressure

11.3.5 First, open one or two taps. Now water will be released from the pressure vessel. Open
few more taps. Now the line pressure drops down and this will be sensed by the pressure
transducer and a command is send to PLC to start the lead pump. The PLC will start the duty
pump via VFD and VFD ensures that the pump will run only at the required frequency to
maintain the system pressure (cut off value in transducer).

11.3.6 Next, close all the taps and this will cause the pressure to build up in line and reaches
the system (Cut off pressure), which is set on the pressure transducer, and this will cause the
pump1 to stop.

11.3.7 Perform the above steps consecutively two or more times to verify the operation.
11.3.8 Allow the pump to operate a minimum of 10 seconds for each trial operation. The trial
operation must be completed within 2 minutes.

11.3.9 The operating current and the flow are to be measured and readings noted down.
These are compared with the design values. The actual value should match the design values or
should be within acceptable tolerance.

12.0 RAW WATER BOOSTER PUMPSET

12.1 EQUIPMENT DATA

Pump : Raw water booster pump set

Duty :

No. of pumps :

Pump model :

Motor details :

13.0 PRE COMMISSIONING CHECK LIST

13.1.1 Check pump set installation completed

13.1.2 Check suction & discharge pipework /valves/fittings free of leak.

13.1.3 Check suction strainers clean

13.1.4 Check float switch installed in the suction tank and cable properly marked and
connected to control panel (For dry run prevention)

13.1.5 Check pressure vessel pre-charge pressure

13.1.6 Check if the mains power supply available at the socket.

13.1.7 Check incoming mains for proper earthing and neutral line

13.1.8 Check whether electrical control panel properly wired and connected with pump motor.

13.1.9 Check whether water available in the suction tank

13.2 METHOD OF TESTING & COMMISSIONING

13.2.2 Connect the power supply and start the trail operation.

13.2.3 Set the cut in and cut off pressures in pressure transducer / switches.

13.2.4 Fill air in pressure vessel and this shall be 0.5 bar below the cut in pressure.

13.2.5 First, open one or two taps. Now water will be released from the pressure vessel. Open
few more taps. Now the line pressure drops down and this will be sensed by the pressure
transducer and a command is send to PLC to start the lead pump. The PLC will start the duty
pump via VFD and VFD ensures that the pump will run only at the required frequency to
maintain the system pressure (cut off value in transducer).

13.2.6 Next, close all the taps and this will cause the pressure to build up in line and reaches
the system (Cut off pressure), which is set on the pressure transducer, and this will cause the
pump1 to stop.

13.2.7 Perform the above steps consecutively two or more times to verify the operation.

13.2.8 Allow the pump to operate a minimum of 10 seconds for each trial operation. The trial
operation must be completed within 2 minutes.

13.2.9 The operating current and the flow are to be measured and readings noted down.
These are compared with the design values. The actual value should match the design values or
should be within acceptable tolerance.

15.0 SAFETY

15.1 All appropriate safety personal protective equipment shall be worn by workmen such as
Helmet, cover all clothing, safety shoes, goggles and gloves whenever required.

15.2 Approved tools and equipment will be used in lifting of heavy equipment.

15.3 During execution of hot works, a fire blanket & extinguisher shall be positioned at all times.