Document Type

Royal Commission for Jubail and Yanbu

Method Statement

METHOD STATEMENT

RAWABI FAYFA CO.

DEVELOPMENT OF JALMUDA SHORELINE

692-C03R

Installation of Potable Water distribution system Piping

Method Statement No: 03

Issued by:

Rev.No. Date Description Prepared Checked Approved

0 23 March Installation of Potable Water Piping Mohamme Raoofuddin Yazid Nofal
2015 d Arshad Mohamme
d

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 Document Type

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Method Statement

TABLE OF CONTENTS

1. TITLE.

2. SCOPE OF WORK

General description.
Plant and equipment.
Materials.
Site planning & preparation
Work methodology.
Organization, Responsibilities & Supervision.
Work Force.

3. HEALTH & SAFETY

Risk assessments
Jubail ES & H Contractor Requirements
Protective & Safety Equipment.
Contractual Requirements.
Information to personnel.
Emergency Procedures.
Permit Requirements.

4. ENVIRONMENTAL ISSUES

Environmental Impact assessment.

Jubail ES & H Contractor Requirements
Contractual Requirements.
Emergency Procedures.

5. QUALITY ASSURANCE

Contractual Requirements.
Critical works.
Inspection & Testing.
Follow up & Evaluation.

6. APPENDICES

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Method Statement

1.0 TITLE

Installation of Under Ground Piping for Potable and Fire Water.

2.0 SCOPE OF WORK

General description

This method statement is intended to outline the ways, procedures and the
proper execution in the installation of RTR and UPVC pipe installation for the
above mention contract.

Plant and equipment

To execute the job below listed plant & equipment shall be used but not limited
to the following:

 Crane
 Generator
 Hand Tools
 Sling/Belt
 Shackle
 Chain Block or Come along
 Grinding and Cutting tools

Material

The material used shall be in accordance with the specification and contract
drawings such as RTR pipe and fittings, adhesive, UPVC pipe and fittings,
gasket, Lubricant, and Heating blanket from manufacturer of RTR pipe.
UPVC pipe CL-5:-
Φ32mm,
Φ40mm,
Φ63mm,
Φ75mm,
Φ90mm,
Φ110mm,
Φ160mm
RTRP pipe:-
Φ 200mm,
Φ300mm
Gate Valve:-
Dia. 25mm,32mm,50mm,65mm,80mm,100mm,150mm,300mm
Butterfly Valve
Fire-Hydrant

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Method Statement

Transportation and handling

 Pipes shall be stored on a plain ground in the wooden timbers or on sand

mounds with adequate chokes to prevent from movements.
 From the lay- down area to the trench site, it shall be transported by trailers.
 Prior to unloading of pipes from trailers, all items shall be inspected for any
visual / transportation damages.
 Care shall be taken to prevent pipes from rolling or falling from flat bed trailer
and this shall be attained by using proper supports, chocks.
 The rubber gaskets received along the pipes and fittings shall be stored in
shelter with original packing until it is used at site.
 The supplied lubricant is special vegetable soap (free from grease /
petroleum products). Only the supplied lubricant shall be used. The lubricant
paste shall be mixed with equal ratio of water (1:1) while using it.
 During handling, measures shall be taken to avoid touching or contaminating
the pipes ends.
 Adhesive kit should be stored at temperatures 5 to 35 C degree.
 Make sure adhesive should not be used after the expiry date.
 All materials shall be handled carefully at all times.

Site Planning

Before starting the installation, coordinates and elevation of the center line of the
bedding are established as per the latest revised IFC drawing inside the trench
construction area as a reference points. The surveyor writes down the drawing
number and revision of the drawing into the survey report. IFC drawing shall be
attached to the survey report.

Work Methodology

Trench Excavation:

 The width of excavation shall be made minimum to comfortably contain the space
of worker standing on either side or sufficient to work.

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Method Statement

 The side slope of trenches shall be at the angle of repose of the excavated
material.
 Shall be ensuring that all the excavation is safe to work around throughout
construction activities until backfilled.
 Excavated material to be placed at safe distance from the edge of the excavation.
 Ladders access to trench must be secured at their highest point.
 The necessary service access with slope shall be provided as required.
 The trench width shall be extending to minimum half of the pipe diameter at each
side.
 The width of steps shall be 1.2 meters or greater.

Trench De-Watering (If Required):

 In case of high ground water table, adequate dewatering shall be requiring through
suction pumps or well-point system depending on the ground water condition.
Pipe Laying Procedure:

 Position the crane (If it is needed) near the trench in a safe distance.
 Unload the pipe and lower into the trench.
 Make sure that the bedding is mechanically compacted prior to pipe laying as
per the required specification.
 After placing the first pipe, bring the second pipe near the pipe earlier placed
and install it with clamps, chain blocks/pullers.
 Release pipe from the crane, remove the slings and the clamps.
 Make sure that pipe is firmly supported.

 Pipe haunch is the most important part of the initial back filling except joints.
 Haunch the bottom of the pipe with the correct material to be used.
 Carry on the same procedure for the rest of pipes.

RTR Pipe (As per AMIANTIT BONDSTRAND Procedure)

 Install the band clamps on both components keeping sufficient space for the
winches when pulling the joint together,
 If the relative humidity is higher than 75 % or if the bonding surfaces are wet they
should be dried. (A hot air blower or heating blanket can be used).
 Pre heat or cool down the bonding surface, it is recommended to keep the
bonding surfaces between 15 and 45 C degree, by using the heating blanket, and

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Method Statement

if the sun will heat up the bonding surfaces to above 40 C degree, keep them in
the shade if possible.
 Re-sand the surfaces; if the sanded surfaces have been contaminated, or if initial
sanding took place more than 2 hours before assembling, the surfaces should be
re-sanded.
 Clean the sanded surfaces, Use a clean dry cloth or brush to remove sanding
dust, never touch the sanded surfaces after sanding and cleaning.
 Select the proper size of adhesive kit, it is recommended to use the pipe
manufacture table to know the quantity of the adhesive kit needed for one joint.
 Never split a package, always prepare complete kits (do not use damaged
or leaking adhesive kits)
 Prepare the adhesive, add the curing agent to the resin.
 Stir thoroughly until no streaks are visible and mixture has an even color(after 2
to 3 minutes)
 Make sure that before mixing the adhesive, all preparations have been done and
all parts to be bonded are ready for assembly, because mixed adhesive has a
limited pot life subject to the ambient temperature.
 Apply the adhesive immediately after mixing.
 Never use adhesive that has started to cure, this is the case when the mixture
gets
clotted and toughens.
 Assembling the adhesive bonding joint, insert the spigot in the bell, when
inserting the spigot pay attention to the marks end position and keep the join
together, letting the spigot dip back or turning the spigot after complete insertion
may result in a bed joint.
 Hook the 2 winches in the band clamps and start pulling the joint further together
in a smooth movement until the joint is firmly fixed together and there is a 50 mm
between the bell end and the mark, pull both winches at the same time.
 Check alignment during pulling and after joint make up.
 Do not remove the winches until the adhesive has fully cured.
 Remove excessive adhesive, also from the inside if possible (flanges), a spatula
may be used.

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Method Statement

 Apply the heating blanket; wrap the required size as per the pipe manufacturer
recommendation, around the joint keeping the power supply cable free from the
blanket, make sure the voltage is correct.
 Determine the curing time, curing is mainly subject of the distance (= Wall
Thickness) between blanket and adhesive, and it must be done regarding to the
pipe manufactures instruction.
 Activate the heating blanket, by applying the electrical power to the heating
blanket and check if it heat up, write down on the pipe next to the heating blanket
starting time, during the time of the curing with the heating blanket, it should be
checked regularly.

UPVC Pipe (Gasket joint)

 Clean the bell end thoroughly from inside, specially the internal groove, from
dirt, grease or any material deposition.
 Fix the rubber gasket in the bell groove.
 Mark the pipe around the circumference at the spigot end as per manufacture
recommendation.
 Apply thin film of lubricant on spigot and bell end pipe.
 Use two nylon slings and fix the come-along jacks (pullers) at each side of the
pipe spring line.
 The beveled end of the spigot and the gasket in the bell grove are first
cleaned and cleared of any foreign particle.
 By using the lubricant (use the same lubricant which is recommended by the
PVC pipe manufacture) applied to the spigot end.
 The lubricated spigot is then pushed past the gasket into the bell until the
guide mark on the spigot is flush with the lip of the bell, with the rubber joint; It
is usually possible to manually insert the spigot into the bell for pipes of
nominal diameter 100mm and smaller; for larger diameter mechanical
assistance may be needed for insertion.
 Using the bar and block method is recommended as field technician is able to
feel the amount of force being used and whether the joint goes together
smoothly.

UPVC Solvent Cement Joint

 Cut the pipe square: - Pipe ends must be cut square; using a when type cutter
or saw, fixed grinder machine with a stand or base can be used.
 Deburr and bevel pipe: - Regardless of cutting method used in the previous
step, burrs are created which must be removed from both the pipe I.D and O.D
before joining; all pipes ends should be beveled 10-25 degree. Commercially
available debarring and beveling tool is recommended, or a mill file may be
used also.

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Method Statement

 Clean joint components:- Wipe away all loose dirt and moisture from the pipe
O.D and fitting I.D with a clean, dry cotton rag, do not attempt to join wet
surfaces,
 Check joint interface fit: - An interference between pipe and fitting socket is
necessary for proper fusion of the joint, to check lightly insert the pipe into
fitting socket, do not force, inference between pipe and fitting should occur
between 1/3 to 2/3 of the socket depth (full interference fit) and socket bottom
(net fit), do not use components which improperly mate.
 Apply the primer:- Primer is necessary to penetrate soften both pipes to be
joining or pipes to fittings socket surface in order for the solvent cement to
properly bond, the most frequent cause of joint failures is inadequate solvent
penetration and softening of bonding surface during the joining operation.
 Apply the primer to pipes/fittings in the same manner, extending application
area to slightly more than the insertion depth into the pipe/fitting socket.
 Apply the second coat to both the pipe/fitting socket and pipe.
 Apply the solvent: After primer is dry, apply a layer of solvent in the same
manner.
 Insert the pipe/fittings in the socket before solvent gets dry and rotate to
clockwise direction slightly for better joint.
 Leave the joint for getting solvent to dry hard without any movement.
Thrust Block/Concrete Pouring
 All the dimensions are as per contract drawings.
 The area where the concrete is to be cast bottom shall be well compacted
and the polyethylene sheet shall be laid over the compacted area.
 The thrust blocks shall be cast in place concreting method.
 The dimension, size, Fabrication, bending details and placement details of
epoxy coated reinforcement steel bars are as per contract drawing.
 Thrust block shall be casted no less than 7 days before the initial test is
carried out..
 Polyethylene sheet shall be installed between the pipe and concrete.

Preparation prior to Hydro Testing:

 Prior to hydro testing, underground piping shall be partially back filled to the
required height with all joints exposed during the hydro test to detect any
possible leakage.
 All pipes end must be sealed off with test plug or blind flange.
 Test pump shall be placed on a firm ground away from the piping system to
be hydro tested.
 Before the hydrostatic test is carried out, permanent and temporary Supports
shall be installed.
 All pressure gauges to be used for hydro testing must be calibrated.
Hydro test Procedures:

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Method Statement

 Inspect the completed installation to assure that all requirements have been
met.
 Fill the line with potable water at the lowest point with open valves and vent
so that air will be expelled from the line to avoid pressure surges during the
pressure build up.
 Once the water comes out on the highest point of the vent close the valve.
 Pressurized the line slowly.
 Wait until the pressure is stabilized.
 If no sign of pressure drop disconnect the pump from manifold.
 Check all joints for possible leak.
 If no leak found, continue the test to the required period of at least 2 hrs to complete
test.
 Open slowly the valve to release the pressure inside the pipe located near the vent
 Drain the line to approved location to complete the testing.
 Pressure at each test gauge shall be checked and recorded on inspection sheet
 The length of the piping being tested shall not be more than 1 km.
 Ensure the gauge location will read the highest line pressure.
 Fill up the inspection sheets accordingly.
 The test shall be considered as “pass” if no sign of leakage is observe at the
permanent joints and there is no pressure drop.
 The inspection sheet(s) shall be signed by the RC representative.
 Upon satisfactory completion of the test and acceptance the system shall be
depressurized gradually.
 After completion the test, the water shall be transfer to the tanker or any
pond.
 Remove all temporary items installed for testing purposes.
 The trench shall be backfilled with sand to 300 mm above the pipe and
compacted in accordance with specification.

Pipe Backfilling upto Grade

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Method Statement

 After the pipe joint hydrotest,the pipes can be backfilled and compacted in
lifts of 150mm upto warning tape and thereafter in lifts of 300mm upto FGL.
 The backfilling should be compacted to 90% max dry density as per RC spec.
No. 692-320-20TR-CE-211.
 Sand shall be used for backfilling free of any contamination.

Responsibility
 The Project Manager and Construction Manager are responsible for the proper
implementation of this Procedure.
 QA/QC Manager is responsible for the implementation of all required Quality
Control Activities such as Test and Inspection.
 QA/QC Engineer is responsible for the proper carrying out of the inspection
and Testing details as per Specification and Procedure.
 Field Engineer and Piping Superintendent and supervisor responsibilities are to
manage all the everyday activities as per plan and schedule. They Coordinate
with the HSE Department to ensure that Proper Safety Implementation
respective to Personnel, Equipments and Environment are strictly adhered.
Piping Supervisor responsibility is to monitor everyday field activities, assuring
that implementation is as per this Method statement.

3.0 HEALTH & SAFETY

Risk assessments

Basic job steps Risk Safe job procedure

Check work permit Excavating without Accomplish safe work, plan, excavation trenching permit.

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Method Statement

system approved excavation Safety officer assigned in the area to check safe work
plan/excavation prior to actual excavation, sign board display
at work site.
Equipment operation Failure of equipment Designated equipment spotter defined access for heavy
operation equipment backup/reversing alarm. Must be always in good
condition.
Task Assignment Use of defective equipment Competent/ certified operators for the equipment inspected to
& tools use, hand tools of carpenters, mason & others crafts must be
inspected.
Access barricading No proper access or Provide adequate and appropriate access for personnel,
barricading barricades and install safety signs.
Sloping Collapsed excavation Sloping / stepping of excavation Installation of sheet piles, and
maintain de-watering system.(as required)

Transportation of soil Accumulation of excavated To designate stock pile area, spoil one meter away from edge
soil /spoil near the edge of of excavation.
excavation would result on
failure of the vacation

4.0
Environmental Safety& Health Contractor

 All Environmental and Health shall be taken care

 Execute periodic cleaning to keep site.
 Adjacent properties free of accumulations of waste materials, debris, rubbish,
and windblown debris resulting from construction operations.
 New water pipes shall be kept isolated from existing water distribution
pipes for bacteriological samples and tests.
 Store volatile wastes in covered metal container remove from premises daily.
 Prevent accumulation of waste which creates hazardous condition.
 Collect and remove waste materials, debris, and rubbish from site periodically
until execution of final cleaning and dispose off site in lawful manner.
 Conduct cleaning and disposal operations to comply with local environmental
laws.

3.3 Protective and Safety Equipment

 All person at all time when on the site have to wear a protective helmet. It is
essential to be properly adjusted to the wearer’s head. Metal hard hats are
prohibited. “No holes in the helmet & not to be painted.
 Safety shoes/boots shall be issued to all personnel on the site. Safety shoes
complies with ANSI standards which should be oil, abrasion, and heat
resistant fully useful for the construction sites.
 Appropriate glasses and eye protection to be issued to workman as required.
Factors to be considered in selecting eye protection include the degree
required and the comfort provided as required by ANSI.

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Method Statement

 Rubber boots to be provided during concrete woks. These boots should be in

good condition in order to prevent any contact of concrete with workers foot.
 All workers as a requirement will use protective hand gloves to protect against
sharp or rough edges, chemicals, and hot or cold surface accordingly.
Contractual Requirements
 All safety and health which are required to fulfill by the contractor will be taken
care in accordance with the International EH & S Standards in junctions with
client’s Specification, Standards, and Instructions.
Information to Personnel
 Safety and Environmental education and information to be disseminated to all
the employees, in shape of seminars, safety tool box meetings and safety
refresher courses.
Emergency Procedure
 First aid clinic is available at site in the hour of need. Emergency Telephone
numbers are posted and displayed on site on appropriate locations.
 Rescue aids will be in place such as retrieval lines, safety harness, etc.
 In the event of heat stress and strokes a fully equipped ambulance is available
to transport the victim to the nearest hospital for treatment.

5.0 QUALITY ASSURANCE

Contractual Requirements
Contractor is bound to meet the requirement of Quality Assurance.
Critical Works
All critical activities will be performed in accordance with the clients
Specification, instruction as well as International standards.
Inspection & Testing
Inspection and testing to be carried out in accordance with the approved ITP
and RC Specification (Attached ITP).
Follow-up & Evaluation
Work executed shall be evaluated and followed up in accordance with RC
Specifications and International Standards.

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Method Statement

Acknowledgement Signatures
The personnel listed below confirm receipt of the method statement and have had the contents explained to them,
understand it and are aware of the site ES&H requirements.
Name Employer Date Signature

Note to FE, CS & FCS – Any significant change from this method statement requires it to be revised and resubmitted
to RC before work can commence.

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Method Statement

HYDROSTATIC TEST DATA SHEET

PRESSURE PIPELINES: PW

Line
No. From: To:
Valve No. Valve No.

Part I: Filling Pipeline Part IV: Refilling

When pressure has dropped 1 bar - 1.0

1 Water Source ________________________ kgf/cm2
(14.2 psi) or when 4 hours have elapsed the
line shall be refilled and the quantity accurately
measured as the pressure is restored to the
___________________________________ required test pressure.
2 Filling (time)
Begin ____________ Complete _________
3 Time Elapsed _______________________
Allow water to stand for 24 hours. 1 Pressure Reading
Begin ______________ End ______________
Part II: Attaining Pressure 2 Time
Begin ______________ End ______________
1 Pumping
= (Time) 3 Required water volume __________ liters
Begin ____________ Complete _________ 4 Actual Leakage in litre/hour
2
= Time Elapsed _______________________
3
= Pressure Attained ____________________ Part V: Calculation of Leakage
4
= Pressure Specified ___________________
No piping installation will be accepted until the
Part III: Testing actual leakage is less than the number of liters
per hour as determined by the
formula:
1 After the pressure has reached the speci-
L =
field test pressure, close the inlet valve and ND(P) X 0.5
wait for pressure to drop by 1 bar (14.2 psi) 1304.1
or four hours whichever comes first. L= is the allowable leakage in liters per hour.
N
2 Pressure Reading = is the number of joints in the length of
Begin ____________ Complete _________ Pipeline tested.
D
3 Time = is the nominal diameter of the pipe in cm.
is the average test pressure during
Begin ____________ Complete _________ P= the
leakage test in bars.
Should any test of pipe disclose leakage greater than that specified in the formula, the defective
joints shall be located and repaired until the leakage is within the specified allowance.

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