METHOD STATEMENT FOR INSTALLATION OF HDPE PIPES AND FITTINGS

TABLE OF CONTENTS

1. Scope / Objective

• Reference

• Access / Egress

• Health and Safety Hazards
  • Safety Lighting
  • Task Lighting
  • Emergency Arrangements
    • General
    • Fire Precautions
    • Communication
  • Risks Control
• Hazards / Risks
• Control Measures / Permits
• 3^rd Party Protection
• Environmental Considerations

• Definitions

• Responsibilities / Supervision

• Procedures / Method to be Employed

• Training

• Working Hours

1. House Keeping

1. Manpower Requirement & Supervision

1. Material Requirement

1. Plant & Equipment
   1. General
   1. Plant and Equipment Schedule
   1. Personnel Protective Equipment
   1. Power
   1. Working Platforms

1. Q.C. Approvals and other Documentation

1. Supporting Documentation

1. Distribution

1. Other Information

1. Site Safety Engineers Approval

1. Attachment – Sketches

1.0     SCOPE / OBJECTIVES

This Method Statement covers the installation of HDPE pipes and fittings for use with the domestic water transfer pipes. This procedure defines the method used to ensure the pipe and fittings installation has been carried out as per contract requirements and best commercial practices.

• REFERENCES

Contract document:           1105/SP/M-15100 Basic Materials and Methods

                                        1105/SP/M-15202 Plumbing – Pipes and fittings

                                        1105/SP/M-15301 Pipes, Fittings and Valves

Technical Submittal:           PD/14          Polyethylene Pipes and Fittings

Standards:                         ISO 4427:1996     Polyethylene (PE) Pipes for water supply – Specifications

Manufacturer’s Installation Instructions

Shop Drawings – Marked APPROVED FOR CONSTRUCTION

The Shop Drawings and Main Water Supply Pipework Details should provide adequate information for the installation to be carried out. Manufacturer’s instructions and relevant standards shall be referred to in the order shown.

• ACCESS / EGRESS

3.1     Work will be carried out only when all associated works of the Main Contractor have been verified that they have been completed.

3.2     Installation of the HDPE pipes will be carried out provided all the works in the risers and shafts are completed and access has been granted.

4.0     HEALTH AND SAFETY HAZARDS.

Implementation of Health & Safety mechanisms and checks as per Contract Agreement and the approved A&P Health & Safety Manual. The responsible Safety Officer for each building will conduct routine safety inspections.

1. Safety Lighting

     Safety lights will be used in case of power failure ensuring good illumination of the area for evacuation of personnel in case of an emergency.

• Task Lighting.

Adequate lighting will be provided to ensure the good illumination of the working area. Task lighting, where requires will consist of fluorescent lights mounted on tripods.

• Emergency Arrangements.

• General: Site general safety procedures will be followed. In case of emergency the Safety Officer or most senior A&P employee present will stop the work. He will put into action the emergency arrangements and report to assembly points as indicated during the Site Induction Course.

• Fire Precautions: No significant fire risk is associated with this activity but general fire prevention measures will be taken as per Arabtec instructions to A&P.

• Communication: Communication from work areas to Site Office shall be via mobile phones issued to Senior foremen. In emergency situations use hand-held 2-way radios if necessary to speed up notification of relevant personnel and/or the JBR01 Site Clinic.

• Risk and Controls.

1. Hazards / Risks

     Relevant Risk Assessments (See Section 19 Attachments):

              1.     PRT – 007 Hand Tools

              2.     WAH – 001 Ladders and Stepladders

              3.     WAH – 002 Mobile Elevated Working Platforms

              4.     WAH – 006 Working at Heights

              5.     MAT – 004 Disposal of Waste Materials

• 3^rd Party Protection: Applicable as per the contract only

• Environmental Considerations: After the completion of the works the working area should be cleared of any waste materials related to the performed work.

5.0     DEFINITIONS

                     As per specifications (see References).

6.0     RESPONSIBILITIES / SUPERVISION

• Project Manager – will have the overall responsibility of the Project for execution, quality and safety. Also he will maintain the planning progress and coordination of works with main contractor.

• Project Senior Mechanical Engineers / Site Mechanical Engineers – will be responsible for the day to day activities on site, for materials, drawings, testing & commissioning and allocation of Departmental resources to work areas on Site. The Project Senior Mechanical Engineer will report to the Project Manager.

• Supervisor – will be directly responsible for the day-to-day job on site, for coordinating work with the technicians or any other staff assign to his area.

• QA/QC Department – will oversee the quality requirements and quality control measures for the Project in coordination with the Senior Project Mechanical Engineer as outlined in the A&P QA Manual.

• Safety Officer – will be responsible for the Health and Safety aspects on site as per the Main Contractor and A&P Safety requirements.

• Manufacturer – will be responsible to provide trained personnel as well as supervise and provide technical advise during the installation procedure.

• PROCEDURES / METHOD TO BE EMPLOYED.

• Pre – Ordering:

Before ordering drawings must be prepared and approved. All relevant Technical Submittals will be submitted for approval by the Engineer and have been approved at least Code B.

• Ordering:

Standard A&P procedures for ordering of HDPE pipes, fittings and relevant materials will be followed

• Factory manufacture.

As per Supplier/Manufacturer

• Transportation to site:

Pipes will be transported to the site by the supplier.

Care must be taken to ensure the pipes are evenly supported throughout their length and should not overhang the vehicle bed. Pipes should be loaded with protective fittings at alternate ends.

Larger pipes should be loaded first and if the vehicle is fitted with side supports, these shall be on height not greater than 1.5 m. Any supports must be free from sharp edges to prevent damage of the pipes during transportation/

7.5  Handling

Pipes should not be dropped onto hard surfaces and should not be dragged along the ground. Where possible the loading and unloading of pipes should be carried out by hand.

If mechanical lifting equipments are to be used, no metallic slings, hooks or chains should be used in direct contact with the pipes. Web slings are preferred, which will damage the pipe wall.

7.6  Storage

To ensure that deterioration of the pipes and fittings does not occur during storage, it is imperative that the following recommendations are adhered to:

• Bundled Pipe:

   Pipes supplied by the factory in bundles should be stored on a flat surface. Bundles should not be stored on top of each other.

• Loose Pipe:

   Pipes should be stacked on a flat surface free from sharp projections, stones or other protuberances likely to cause point loading or pipe deformation.

   Side supports should be provided in the form of stout timber posts, not less than 75 mm² placed at no greater than 1.5 m centres along the length of the pipe. The width of stacked pipes should not exceed 3 metres.

   The height of pipe stacks should not exceed seven layers or two metres maximum height.

   Stacks should be protected from weather elements by means of placing tarpaulins or similar sheets over them securely fixed to the timber support posts, in order to provide protected and shaded conditions and at the same time allow a free passage of air around the pipes.

• Fittings:

Fittings should be stored in sheltered conditions that are protected from the weather elements and accidental damage.

7.7     Inspection of Materials in Stores

7.7.1   Upon receipt of materials on site these will have to be inspected by the Storeman and Site Engineer or representative, to ensure correctness of materials and quantities.

7.7.2   A Material Inspection Request (MIR) shall be issued and all materials must be inspected and verified by the Engineer that they are correct.

• Pre Installation Checks

7.8.1   Before any materials are installed ensure that these have been inspected at site and have been approved as per the relevant MIR form.

7.8.2   Ensure that all drawings are current and marked “APPROVED FOR CONSTRUCTION”.

7.8.3   Inspect the site and ensure that all necessary sleeves and openings have been allowed for.

7.8.4   Inspect the relevant area for any possible clashes with other services.

7.8.5   Inspect all materials and verify that they are undamaged.

          7.9  Installation

                 7.9.1  Marking

Mark from approved drawings the position of all pipes as is possible by the programme / related progress on site.

       7.9.2   Marking of Supports

Mark all routes carefully using a marker as per the approved drawings

Anchor point brackets are to be installed at every 6m and sleeve type brackets at every 3m as recommended by the manufacturer for this project and as shown on drawings.

       7.9.3   Installation of Pipework

7.9.3.1   Electrofusion

The joining of the pipes (by means of couplings) will be carried out by electrofusion jointing machines operated by specialised personnel provided by the manufacturer.

7.10   Installation

Install using approved clamp and support as per approved technical submittals and related shop drawings.

Any open ends must be properly protected.

7.11     Visual Inspection

Once the HPED Pipes and Fittings are installed a Work Inspection Request must be issued and the units must be visually inspected to ensure that the correct installation procedures have been followed and that the units are properly installed in the prescribed manner.

7.12     Hydraulic Testing

(Please refer to Method Statement Ref No.: 4.0.0.2)

7.13     Disinfection of the pipe system

Before the piping can be used it must be disinfected and certified as such as per the Disinfection of Pipelines procedure. (Refer to Chemical Treatment Method statement – M.S.3.1.12)

• TRAINING

8.1  Tradesmen performing the described work will be experienced plumbers. If deemed necessary specific team / individuals will undergo further training and awareness programs for this activity by the Production / Quality Assurance Departments and the Manufacturer.

• Toolbox talks will provide general training and awareness for each activity and also in Health & Safety matters and precautions.

• WORKING HOURS

Normal working hours: 7.00 am to 5.00 pm

1. HOUSE KEEPING

          All work places where A&P personnel are working will be cleared of the waste materials derived from their work ensuring clean and healthy work environment as well as to maintain free access and egress in the event of emergency.

1. MANPOWER REQUIREMENT & SUPERVISION

Each team for this activity will consist of two Pipefitters/Plumbers and their helpers.

1. MATERIAL REQUIREMENT

1.      HDPE Pipes

2.      HDPE Fittings

3.      Anchor Bolts

4.      Supports

5.      Electrofusion Machine

1. PLANT & EQUIPMENT REQUIREMENTS

1.      Plumber’s Tool box

2.      Helper’s Tool box

Personnel Protective equipment:  All personnel should wear at all time safety shoes, helmet and overall.

1.    Working Platforms: Scaffolding as required within the specific work area.

1. Q. C.  APPROVAL AND OTHER DOCUMENTATION

1. SUPPORTING DOCUMENTATION

Shop drawings.

1. DISTRIBUTION

• Main contractor,
  • Project Senior Mechanical Engineer
  • Q.C. Engineer
  • Site Mechanical Engineer
  • Tower Health & Safety Officer

1. OTHER INFORMATION

No applicable

1. SITE SAFETY ENGINEER’S APPROVAL

Risk mitigation measures as identified in Risk Assessments in Section 19 to be inspected at regular intervals for Activity duration as identified in the approved Health & Safety Manual.

1. ATTACHMENTS

Quality Control Checklists:

                      HDPE Pipes and Fittings Quality Control Checklists

       Risk Assessment Forms:

PRT – 007 Hand Tools

WAH – 001 Ladders and Stepladders

WAH – 002 Mobile Elevated Working Platforms

WAH – 006 Working at Heights

MAT – 004 Disposal of Waste Materials