ms for installation of grp ug piping for 533_esa103

8/19/2019 MS for Installation of GRP UG Piping for 533_ESA103

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P u b l i c W o r k s A u t h o r i t y

DRAINAGE AFFAIRS

DOHA WEST SEWAGE TREATMENT WORKS

EXTENSION 05

CONSULTANT

egis

CONTRACTOR

Suez Environment- Marubeni JV

SUB CONTRACTOR

Gulf East Engineering, Contg. & Trading Co.

Method S ta tement fo r the Ins ta l la t ion & T ie - In o f UG-GRP

Pipe- 533__ESA103_

00 15-03-2016 21 AJIT CHACKO ANISH DEV SHASHI PILLAI

REV. DATE PAGES PREPARED CHECKED REVIEWD APPROVED CLIENT APPRD


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DOHA WEST SEWAGE TREATMENT WORKS EXT#5

METHOD STATEMENT FOR THE INSTALLATION &TIE-IN OF UG-GRP PIPELINE – 533__ESA103_

Doc No: GE-SUEZ-MS-002

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Page 2 / 21 Date: 15/03/2016

TABLE OF CONTENTS

1. PURPOSE

2. SCOPE

3. APPLICABLE CODES, STANDARDS AND REFERENCES

4. DEFINITIONS AND ABBREVIATIONS

5. RESPONSIBILITY

6. TRAINING

7. MATERIALS HANDLING AND STORAGE

8. MANPOWER, TOOLS AND EQUIPMENT

9. PROCEDURE

10. SEQUENCE OF INSTALLATION

11. SAFETY PRECAUTIONS

12. LIFTING PLAN

13. ATTACHMENTS


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1. PURPOSE

This Method Statement is prepared to define the procedures that Gulf East Engineering will implement in

process of Tie-in Connection (Tie-in No.38 & 39) for line no. 533__ESA103_. These Tie-In’s are done to

avoid clash with the pipes 539__EFI018_ & 589B_ETT001_, which shall be laid in future.

Where and when required, all the revisions, modifications and additions to this Method statement shall be

submitted to the consultant for information and/or approval.

Area highlighted yellow in Fig 1. below shows the area of work.

Fig 1.

2. SCOPE

The scope of this method statement covers the minimum requirements, Procedures and Standards that

must be adhered to while installing the UG Pipelines. The activities include material reception from Stores,

Loading, Shifting the material to area of work, Unloading and Installation.

The Scope is limited to the following category of pipelines identified as listed hereunder.

a) 533__ESA103_ - Dirty Water from Existing UF to inlet works.


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3. APPLICABLE CODES, STANDARDS AND REFERENCES

3.1. DOCUMENTATION1. QCS 2010

2. PROJECT HSE PLAN

3. PROJECT QUALITY PLAN

3.2. INTERCONNECTING PIPE DRAWINGS1. DGT-M-DR-000-801-C

2. DGT-M-DR-000-805-C

3. DGT-M-DR-000-821-C

4. DGT-M-DR-000-827-A

3.3. ISOMETRIC DRAWINGS1. 533__ESA103_ Rev 2

3.4. FLOWTITE Installation guide for buried pipes –AWWA.3.5. Pipe List DGT-X-LT-000-801

4. DEFINITIONS AND ABBREVIATIONS

4.1. Definition

Pipes : Circular tubes through which fluid can flow

Installation : Material transport and handling, pipe laying including the complete operationof laying, jointing and testing pipes in trenches.

Pipeline : long, continuous line of pipes and fittings including valves and ancillary structures

Plant : Doha West STP

Client : Suez Environment Marubeni JV

Consultant : Egis.

Contractor : Gulf East Engineering, Contracting & Trading

4.2. Abbreviation

SUEZ : Suez Environment

GE : Gulf East Engineering, Contracting & Trading

HSE : Health, Safety & Environment

BLDG. : Building

GRP : Glass Reinforced Plastic

UG : Under Ground

PTW : Permit To work

QA/QC : Quality Assurance / Quality Control


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5. RESPONSIBILITY

GUILHEM JOLY

HSE MANAGER

MATTHEIU PILLOT

CONSTRUCTION

MANAGER

AHMED SHAWKY SITE

ENGINEER UNDERGROUND

NETWORK

KHALED YOUSSEF

GRP ERECTION PIPING

SUPERVISOR

MANDAL JAGESHWARQC INSPECTOR

SUEZ

SAISH K PILLAI

PROJECT MANAGER

SHASHI KUMAR PILLAI

CONSTRUCTION

MANAGER

PLANNINGENGINEER

AJIT CHACKODOC.

CONTROLLER

ANISH DEV.SPROJECT ENGINEER

QA/QCSITE SUPERVISORS

WORKERS

VISHNU K.VHSE OFFICER

GULF EAST


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The Project Manager- GULFEAST

a) Supervise and coordinate between the project teams.

b) Attend site meetings on regular basis.c) To ensure the effective implementation for the Quality management system

d) Coordination and comply with project work program.

e) To ensure the overall progress of project to the agreed program.

f) To ensure availability of the required resources on time.

g) To supervise the Project engineers.

The Construction Manager- GULFEAST

a) Manage and oversee the day to day construction management of the Project.

b) Plan, Develop and Organise the construction effort to formulate the most effective plan for the

timely completion of each activity and in effect the Project.

c) Responsible for implementation of scope of work – fabrication, erection, testing, hook-up in

conformance with the project requirements.

d) Monitor and report to PM the project details including progress, risks, Pull backs and Open

opportunities.

e) Investigate reasons for unsatisfactory performance and provide recommendation and institute

measures for improvement.

The Project Engineer- GULFEAST

a) Act as the main contact for the Construction Manager

b) Ensure the progress of Project to agreed Program

c) To coordinate with the design team dedicated to the Project

d) To check all technical details in liaise with the QA QC.

e) To Supervise the Site in all.

QA/QC Engineer/Inspector- GULFEAST

a) Ensure work has been done as per the specification and drawings, inspections are done as per

Quality Control Procedure and the Inspection and Test plan are up to date.

b) Prepare all quality documents and procedures as required.

c) Perform random site inspections on regular basis.

d) Raise RFI’s through Site Query (SQ) systems.

e) To raise non- Conformances for any deviations in the materials, installation procedures,

workmanship.

f) To follow up all non-conformance notices till the closure and maintain logs of all these items.

g) Ensure that the latest approved drawings are being used by the site personnel.

HSE Officer- GULFEAST

a) Confirm that all people working at site are safety inducted.

b) To make sure that all personnel’s are wearing the proper required PPE’s

c) Identify the hazards involved in each work activity and advice the workforce the correct safety

measures to be followed.

d) Perform routine checks for validation of Certificates of trained Manpower and machines utilized


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e) Attend weekly meeting with the Client HSE Manager.

f) Observe that the working hours are strictly followed during Summer.

Construction Manager –

SUEZWill be in charge to ensure that the works are done in accordance with the project

requirements. He will also make sure about proper between site engineer carrying out simultaneous

activities such as Piping , Equipment etc.. He will be attending the construction meeting with the client

representative and will report to his team the client expectation.

Site Engineer –SUEZ

Shall be responsible of the coordination of the works. He will be the one making sure proper

interfaces with civil work partner as well as with the client representative. He will also check and solve the

technical concerns.

Site Supervisor -SUEZ

Is responsible to follow the work at site and to make sure that works happen

according to method statement and project requirements. The site Supervisor will attend to all site

inspection.

QC Inspector -SUEZ

Is responsible to organize and attend site inspection in accordance with the project

specification, QCS and ITP. He will be responsible to follow the inspection up the issuance of the

inspection report dully signed.

HSE Manager -SUEZ

Will make sure that safety requirement as HSE project plan and procedure are fulfilled.

6. TRAINING

6.1. Safety Induction shall be provided to any employee/ Visitor entering the site. 6.2. Before start of any work, VIGIMINUTE to be performed by all work Crew members on a daily basis.6.3. Only trained and certified personnel’s shall be engaged in activities demonstrating high risk rate or in

situations where the presence of a trained personnel is mandatory.

7. MATERIALS HANDLING AND STORAGE

7.1. All materials shall be inspected for any fabrication defects, In-transit defects such as deep scratches,cracks etc.. prior to reception of materials from Stores. Further the person in charge for accepting thematerials should assure that the permanent identification tags denoting the nominal diameter, name ofmanufacturer, Spool number etc. are present on each material received.

7.2. Any Visible defects beyond the agreed tolerances shall not be accepted and the anomaly shall beimmediately reported to the concerned Engineer.

7.3. Coordination with the installation team and logistics should go hand in hand to avoid trouble handlingand reduce unnecessary material transfer and time wastage.

7.4. Transportation, Handling and Storage shall be strictly in accordance with the manufacturer’srecommendation.

7.5. During Transporta) Pipes and fittings shall be well secured and adequately supported along their length.

b) Nesting of pipes may be permitted.

c) No pipe shall overhang the end of a vehicle.

7.6. Handling shall be carried out as follows:a) Pipes should be lifted singly and not handled as bunches


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b) Pipes shall be handled only by means of approved hooks or fabric slings

c) Use of wire ropes, chains will not be permitted.

d) Pipes and fittings of diameter smaller than 300mm may be handled manually.e) Pipes and fittings shall not be dropped or bumped.

f) Pipes shall not be dragged over the ground.

6. Storage of jointing material shall be as follows:

a) Under cover

b) Rubber ring gaskets shall be stored in their original packing and not be exposed to sunlight.

c) Rubber ring gaskets must be protected from exposure to grease and oils.

d) Gasket lubricant shall be stored in shade and in the original container.

8. MANPOWER, TOOLS AND EQUIPMENT

8.1. Direct Manpower

- Supervisor - 01

- Safety Officer - 01

- QA/QC Inspector - 01

- Surveyor - 01

- Fitter - 04

- Helper - 04

- Rigger - 01

8.2. Tools & Equipment

- Trailer / Truck - 01

- Crane 25T - 01

- Total Station - 01

- Hand Tools - Lot

- Chain puller - As per requirement

- Webbing slings - As per requirement

-


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9. PROCEDURE

9.1.1. Preparation for work

- Obtain PTW prior to start of any work.

- Barricade the area to avoid unauthorized/unwanted entry and encroachment.

- Conduct topographic survey of existing pipelines and mark the area for tie-in 38 & 39 asshown in Fig2.

- As-Built drawings shall be prepared based on this survey. Variations if any with theisometric drawings shall be noted down and the drawings revised accordingly. The newdrawing shall be submitted to the consultant for approval.

- Check the bottom level and width of trench and make sure it meets the requirements.

- List out the required tools and tackles to carry out the shutdown activity and accumulatethose items in the reserved tool box.

- When all the above requirements are met shift all pipes of portion A to A as shown in Fig3.

- The pipes and fittings shall be transported by using trailer/ Truck and will be offloaded tothe trench using crane in a safe and proper way.

Fig 2.


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Fig 3.

9.1.2. Joining of GRP pipes:

Joining of pipes shall be made as per the procedure and directions of pipe supplier. Thefollowing steps to be followed during installation of GRP pipes. There are different types methodof joining and the following joining method and procedure shall be applied;

All the pipes as per the required length shall be joined with coupling, which is called as double

bell coupling joint. The following steps shall be followed;

- Foundation & Bedding: The bed must be over excavated at each joint location to ensure

that the pipe will have continuous support and does not rest on the coupling. The

coupling area must be properly bedded and backfilled after the joint assembly completed.

- Cleaning of Coupling: All the coupling grooves and other parts shall be thoroughly

cleaned to ensure no dirt, presence of oil and any other unwanted particles inside the

coupling and its groove. (see below cleaning method)


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- Install Gaskets: Insert the rubber gasket in to the coupling groove leaping loops (typically

two to four) of rubber extending out of the groove. And it is restricted to apply any kind of

lubricants in the groove or on the gasket at this stage of assembly. Water may be used to

moisten the gasket and groove to ease positioning and insertion of the gasket. (See below

picture). Apply uniform pressure and push each loop of the rubber gasket in to the gasket

groove. After insertion pull carefully in the radial direction around the circumference to

distribute compression of the gasket.

- Lubricate Gaskets: Apply a thin layer of lubricant to the rubber gaskets (see below picture)

in order to get flexibility and easiness to insert the pipe.

- Clean and Lubricate Spigots: Clean thoroughly the pipe spigots to remove any dirt, grit,

grease and other unwanted/foreign materials (see below picture). Inspect the spigot sealing

surface for possible damage and apply a thin layer of lubricant to the spigots from the end to

the black alignment stripe. Keep clean both the coupling and spigot until completion of

insertion.


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- Coupling shall be mounted on one pipe, prior join two pipes together, by using clamp or

sling around the pipe at a distance of 1 to 2 meter from the spigot on to which the

coupling will be mounted.

- Make sure that the coupling as well as the pipe should have enough gaps from the

ground or at least 100 mm above the ground level to keep away from dirt. Other

techniques may also be used to joining the coupling/pipes.

- Fixing of Clamps: Clamp/slings shall be fixed on the first pipe or left in the position from

the previous joint. (See below pictures). Clamp contact with the pipe shall be padded or

otherwise protected to prevent damage to the pipe surface.

- Join Coupling: Come alone jacks or any other alternative mechanism placed on the pipe

and connected to the clamps. Pipe shall be pulled into position in to the coupling until it

reaches the home line or touches the centre register. Then it shall be moved on to the

next pipe to be joined.

Home line = (Width of coupling- Gap between adjacent pipes)/2.

Normally the pipes we are using at site have either single spigot (SP) or double

spigot (DSP). Refer the Table 1 below for spigot dimensions


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Table 1

The final spool or the closure spool to be installed will be DSP spools, in some cases it will be

the rocker pipes with DSP.

Select two couplings to be installed and place one coupling square onto the end of closure

pipe (with DSP) so that the gasket is in contract around its entire circumference. Push or pull

the coupling uniformly onto closure pipe until the entire coupling is resting on the spigot end. It

may be necessary to gently help the second ring over the chamfered end of the pipes. Repeat

with the second coupling on the other end.

Set the closure pipe (with DSP) in the trench aligned with the adjacent pipes and with equal

clearance on either side.

Keep the closure pipe centred and minimize pipe end contact. Pull the coupling till it touches

the home line of adjacent pipe.

All this have been shown in the drawing below.


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- Flanged Joints: GRP flanges shall be joined according to the following procedure;

1. Clean the flange face thoroughly and the O-ring groove as well

2. Ensure the sealing gasket / O-ring is clean and undamaged.

3. Position the sealing gasket/ O-ring in the cleaned groove and be secured with small

strips of tape or adhesive.

4. Align flanges to be joined and tightened with required bolts, nuts and washers.

5. Tighten all the bolts by using proper spanners/torque wrench and check the torque

value with Manufacturer.

6. Check all the bolts once again after one hour to ensure the bolts are properly tightened

or to adjust to get the required torque value if necessary.


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- Other Joining Methods: Mainly there are two kinds of other methods are there to join

two pipes or to join 2 different kind of materials. In this case we have to follow the below

mentioned procedure/steps.

Flexible steel Coupling method (See below picture): When a GRP pipe connecting to

other pipe materials with different outside diameter, the flexible steel coupling joining

method shall be applicable. These couplings consist of a steel mantle with an interior

rubber sealing sleeve.

It is important that to control the bolting torque of the flexible steel coupling. Do not over

tight/torque these coupling bolts and follow only manufactures recommended assembly

instructions, but with the pipe supplier’s recommended bolt torque limits.

Mechanical Steel Couplings: Mechanical couplings have been successfully to join pipes

of different materials and diameters, and to adapt to flange outlets. If a mechanical

coupling is used to join GRP to another pipe material then only mechanical coupling with

dual independent bolting system shall be used (see below picture). This allows for the

independent tightening of the GRP pipe side, which typically requires less torque than

recommended by the coupling supplier.


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- Joints shall be capable of withstanding the various tests specified for the appropriate class

of pipe. Joints shall withstand, while maintain the specified test pressure ,a deflection of

not less than 1.5% in any direction.

- After completing the pipeline installation the entire system shall be tested according to the

procedure submitted separately as well as pipe list DGT-X-LT-000-801 B.

- Clear the area and do the house keeping properly prior to handover to civil for backfilling.

- A joint inspection shall be made along with the consultant and main contractor Engineer

as per ITP/RFI for final approval and hand over to civil contractor.

10. SEQUENCE OF INSTALLATION

a) Pipe installation shall commence in portion A-B (Ref Fig 4) .Pipes shall be laid in

sequence as shown in fig 4. This installation shall be done without disturbing the

existing lines nearby.

b) Pre-assemble the spool from B to C and A to D (Ref Fig 4) . This is done to save time

during the actual installation process during tie-in.

Fig 4

c) Partial backfilling of portion A to B shall be done by the civil contractor. The joints shall

be exposed for detection of any leaks during operation.

d) Existing pipe shall be emptied of fluid and valves to be isolated shall be locked out.


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This shall be done in coordination with O&M.

e) Obtain PTW and LOTO before commencing any cutting or modification works on the

existing pipe. The Supervisor should confirm that the correct valves have been shut as

mentioned in the LOTO sheet.

f) Upon reception of the PTW, Cut out the existing pipe from the previously marked area

to a length favorable for the installation of new pipe. Two teams shall work

simultaneously for this activity.

g) Pre-assembled spools shall now be placed inside the trench. The connection at point

A & B shall be made via GRP Bell coupling and at point C&D where the connection to

existing pipe occurs, shall be done through Steel Coupling. The data sheet for steel

coupling is attached here with this MOS.

11. SAFETY PRECAUTIONS

a) Isolate the area with proper barrier and warning tape in order to control unauthorized entry to

the working area.

b) Provide common safety equipment at site (fire extinguisher, bucket with sand, fire watch etc.)

in accordance with fire and safety regulations.

c) Prior to start the activity; ensure that all work permit have been obtained from concerned

authorities as per the general site requirements.

d) Ensure that all lifting equipment shall be certified and the lift/drop zone shall be barricaded

with warning tape and sign boards.

e) Daily tool box talk shall be conducted by the supervisor prior to commencement of each day

activity.

f) Make sure that there shall be adequate air circulation or proper ventilation for the working

area.

g) A dedicated safety officer and supervisor shall be responsible to ensure all safety precautions

and requirements.

h) Ensure proper PPEs for all working groups at all time.


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12. LIFTING PLAN

The Lifting Plan describes the List of Equipments and Safety measures deployed for theinstallation of GRP underground Pipe identified as 533__ESA103_

As outlined in this method statement, any activity shall commence only after the receptionof a valid work permit.

The concerned Work Supervisor shall coordinate with the Lifting team in arranging allrequired tools and tackles for the work. He must ensure that the Crane Operator, Riggerand Banks man are competent and are holding a valid training certificate. It shall beconfirmed in advance that the crane and all associated vehicles have safe and unimpededaccess and egress to and from site.

Communication between the crane operator and Lifting crew shall be via hand signals.

The following Equipments are purposed for the activity

o Crane - 50 T Capacity, Model No. NK 500 E-V, Manufacturer - KATOo Trailer/ Truck

Once the approval for work is validated, Crane shall be positioned to Stages as shown inFig 5.

Fig 5.

The area shall be cordoned off with barrication tape and Proper Cautionary Signage. Thisstep shall be followed for positioning cranes in different stages based on the installationProgress.


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Loading Chart


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13. ATTACHMENTS

Isometric Drawings

ITP

Risk Assessment

Particular Technical Specification for Couplings

Crane Catalogue – KATO NK-500 EV

ms for installation of grp ug piping for 533_esa103

Documents