The document is a method statement for proposed pipeline works for a water and irrigation pipeline network project in Danet Abu Dhabi. It outlines the procedures for excavation, pipe laying, pressure testing, backfilling and other construction activities. Responsibilities of the contractor's surveyor, foreman, site engineer and quality assurance personnel are defined. The method statement also provides details on pipe wrapping, joint protection, and cable/pipe connections to complete the pipeline installation.
The document is a method statement for proposed pipeline works for a water and irrigation pipeline network project in Danet Abu Dhabi. It outlines the procedures for excavation, pipe laying, pressure testing, backfilling and other construction activities. Responsibilities of the contractor's surveyor, foreman, site engineer and quality assurance personnel are defined. The method statement also provides details on pipe wrapping, joint protection, and cable/pipe connections to complete the pipeline installation.
Method Statement MS 04 Proposed Pipeline Works (Pressure Lines)
4 16/03/08 Engr. Ehab Hassan Pr.Engr. KN N.S.Vijayakumar QC Engr. KN Engr. Mohamed Ashraf Ahmed Sr. P.M. KN 3 08/03/08 Engr. Ehab Hassan Pr.Engr. KN N.S.Vijayakumar QC Engr. KN Engr. Mohamed Ashraf Ahmed Sr. P.M. KN 2 16/03/07 Engr. Sanjaykumar Sr. QC Engr. KN Engr. Amr Fikry C.M. KN Engr. Mohamed Ashraf Ahmed Sr. P.M. KN 1 05/03/07 Engr. Ricky Khosla (OE) ADMAC Engr. Khalid Assaf (PM) ADMAC Mohamed Al Shabasy (SM) KN 0 30/09/06 Najjar (QS) ADMAC Engr. Khalid Assaf (PM) ADMAC Mohamed Al Shabasy (SM) KN Revision Submitted Date Prepared by Checked by Issued by
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 2 of 14
REVISIONS
4 16-03-08 Consultant, PMT comments incorporated and resubmitted for approval
3 08-03-08 Red sand Bedding and Wrapping Tape Systems Included
2 16.10.07 Consultant, PMT comments incorporated and resubmitted for approval 1 05.03.07
Comments incorporated and resubmitted for approval 0 30.09.06 Issued for Approval Revision Date Description of Modifications
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 3 of 14
1.0 SCOPE
3.0 REFERENCES
4.0 DEFINITIONS
5.0 RESPONSIBILITIES
6.0 GENERAL
7.0 INSPECTION & TESTING
8.0 HEALTH & SAFETY
9.0 ATTACHMENTS
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 4 of 14
1.SCOPE
This Method statement covers Pressure Pipeline works for Water and Irrigation Pipeline network for Danet Abu Dhabi Infrastructure Works project. which include dewatering, excavation/formation, bedding of granular material, pipe laying, pipe surround with gravel/red sand and Wrapping tape for Water pipe line Network. 2. REFERENCES - Material Approval Requests : Ms-29/Danet-100/KN/RS/06 MS-07/Danet100/KN/RS/06 Rev2 Ms-28/Danet-100/KN/RS/06 Rev 3 - Drawings : Water Pipeline -Danet/KN/W/2000 Danet/KN/W/PR/2001, 2002, 2003 Irrigation Pipeline Danet/KN/IM/5000, 5001, 5002, 5003, 5004, 5005, 5006 & 5007 - Specifications : Volume 2A, Section 3, 4.21 & 6 - ADWEA Specifications for water works - RFI/CIVIL/044 Rev. A dated 24 Feb. 2007 for Working and Test Pressure 3. TOOLS & EQUIPMENT Typical Equipment
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 5 of 14 4. RESPONSIBILITIES
contractor surveyor has to issue and record data such as levels, alignment, coordinates, existing utilities value for clearing, grading, excavation, formation, pipe bedding, pipe laying, surround backfilling and other activities and to ensure that the work is carried out according to site engineer instructions. Contractor Foreman has to supervise/organize the clearing, grading, excavation, formation, pipe bedding, pipe laying, wrapping, surround, backfilling and other activities and to ensure that the work is carried out according to site engineer instructions. Contractor Site Engineer for raising/requesting inspections, monitoring the works, Coordinate with the Laboratory and site team for conducting all the tests at various stages and to coordinate with consultant inspector for inspection. Contractors QA/QC, receives request from site engineer and issues to consultant further on agreeing about the time, Date and to ensure that the quality of the work is as per specification. contractors site Laboratory Technician, to provide the laboratory all samples required at various stages according to instructions from laboratory manager and consultant. contractors Laboratory Engineer/Manager, to ensure that all samples provided at various stages are tested according to specification and certified prior to forwarding it to the consultant (Engineer/QA-QC) for approvals.
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 6 of 14
5. Procedure The work will be carried out accordingly in the following phases:
- Dewatering (If required) (Method Statement MS 02)
- Excavation/Formation (Method Statement MS 03)
- Bedding Red sand (Water Pipeline) (Method Statement MS 03)
- Bedding Red Sand (Mar/Ms/104/Danet/100/KN/Mas/08/0)
- Pipe Laying
- Pipe Wrapping
- Hydrostatic Pressure Test (in accordance with Contract specifications Clause 4.21 and RFI / 044 Rev. A)
- Pipe Surround Red sand (Water Pipeline) (Method Statement MS 03)
- Pipe Surround Red Sand (Irrigation Pipeline, Ms-044/Danet-100/KN/RS/07)
- Backfilling (Method Statement MS 03)
- Embankment (Method Statement MS 03)
5.1 Surveying will be conducted according to MS-01. 5.2 De-watering (if required) will be conducted according to MS-02. 5.3 Excavation (including trial holes) will be conducted to the proper formation level according to MS-03. 5.4 The soil at the formation level will be compacted as per MS 03. 5.6 After formation compaction is confirmed, compliant bedding will be prepared using approved material (i.e. Red sand for Water pipeline Ms-05/Danet-100/KN/RS/06 Rev1 & Redsand for Irrigation pipeline Ms-044/Danet-100/KN/RS/07) according to the specifications and as indicated in the approved shop drawings.
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 7 of 14 5.7 Pipe Laying a. Pipe shall be laid after the Wrapping tape System according to clause 6.0 by lowering it manually (for light weight pipes) or by crane (using nylon slings to hold, for heavy weight pipes) on the Red sand bedding. b. The socket of the previously placed pipe will be cleaned, lubricated by putting the rubber ring in the socket and applying liquid soap on the rubber rings, spigot and socket as per specifications. c. The spigot side will be pulled into the socket with the come-along jack until it is impeded to the end of the socket. d. After the pipe has been released to rest on the bedding, the joint gap, line and level are checked.
6.0 Procedure for Anticorrosive pipe Wrapping Tape Systems a. Ensure the outside of pipe and fitting is clean and dry. b. Nylon brushes to be used for any cleaning. c. Ensure the primer is thoroughly mixed and stored in clean containers. d. Using the clean dry brush. Pre measured quantity of primer will be used for each pipe length and applied evenly to achieve the coverage specified by the manufacturer. e. When the primer is nearly dry (tack to touch) wrap the pipe using approved self adhesive wrapping tape securing the required overlap securing sufficient tension. f. Wrapping tapes shall be applied with 55% overlap and ensure the least 150mm overlap when splicing the roll ends. Spigot ends of pipes will be free from wrapping for the length required for connection purposes. No air pockets or separation underneath the wrapping tape is allowed. g. During the pipeline installation, the pipeline is covered with polyethylene sleeving as per the specification. Joints and all uneven surface shall be covered with approved non shrink non-drying mounding mastic filler compound compatible with tape to form a smooth R4
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 8 of 14 surface. For tape application the maximum slope of profile is 45 degree. Application of filler will be on dry and clean surface and manufacturers recommendation will be applied. 6.1 Protection of flanged Joints in Buried Conditions a. Lines area to be wrapped is extended 400mm on both side joint i.e.(800mm total length irrespective of the diameter of the piping) b. Clean and dry the outside surface. c. Use clean dry brush apply the primer evenly on the prepared clean area. d. Uneven surface of all joints and fitting shall be filled with approved non-shrink, non drying mounding mastic filler. e. Wrap the prepared joint with self adhesive tape of 55% overlap. The pipeline is covered with polyethylene sleeve as per specification.
6.2 Cable / Pipe Connections Welded stud and soldered cable / pipe connections shall be coated to the same standard as the pipe to which it is attached. After completion of cable connection, the cable tail shall be secured to the pipe with a lap of tape. The cable connection shall be cleaned, primed and profiled with mastic before tape wrapping. Cleaning and priming shall be as detailed above. The tape wrap shall have a minimum of three and a half circumferential overlap. 6.3 Bonding / Overlap of Backing Where required the tape shall be capable of being cigarette wrapped around the pipe and with the adhesive removed, the PVC backing shall be bonded over its full overlap to PVC layer beneath with suitable PVC adhesive.
6.4 Inspection a. Inspection of coated pipe joints, fittings etc. shall be visual for satisfactory adhesion and 100% holiday inspection by a holiday detector set at the working voltage. Third party is the responsible for carrying out the holiday detection test for the pipe wrapping. R4 R4
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 9 of 14 a. The applied tape shall be inspected to confirm that effective bond is formed between the pipe surface and the tape. This inspection shall be carried out not less than 24 hours after application. The working voltage shall be set at least twice per working day. b. Specific inspection upon completion of works may be required by certain project specifications.
6.5 Points To Note a. Wrapping must be done in shaded area and wrapping should not be done under direct sunlight. Whilst this may not affect the products performance properties, this makes the SBS modified bituminous compound extremely sticky and cumbersome to handle. Workers may also find difficulty in peeling off the release film in high ambient temperatures. b. Wrapping by hand or machine must be undertaken by experience personnel under proper supervision. Unsatisfactory workmanship shall be rejected especially where overlaps are not consistent and where rucking is evident. c. Rucking, especially at in-situ joints is to be avoided. Awkward and abrupt changes in shape shall be the subject of special attention and care during wrapping, ensuring elimination of entry paths for ground water and ground salts. Angle and speed of automated machines should be agreed upon (for necessary overlap as per specification) and locked to ensure continuity and uniformity of wrapping. d. Handling after wrapping, Cotton belts shall be used for lifting purpose. e. Wrapped joints shall not be subject to pressure from lifting devices. All skis used to support pipes shall be thoroughly padded. f. Wrapped pipes must be supported on unwrapped ends of pipe and not laid on the ground except as necessary in the trench for final positioning and laying. g. Wrapped pipes shall be protected from direct sunlight at all times and laid in the trenches as far as possible immediately after wrapping procedure is completed, and necessary inspection / checks done.
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 10 of 14 h. All Polybit Bitutape Pipe Wrapping Tape and its ancillary products (Bitutape Primer, Bitutape Moulding Paste, Bitutape Outer Wrap) should be stored in cool, dry / conditioned stores, covered, away from sunlight, at less than 30 deg. C temperature. Stocks should be rotated on a first in / first out basis. i. Tapes should be taken out from the conditioned stores just prior to application. Storing of tapes at project site / wrapping yard without proper storage facility is not acceptable and may affect application performance of the tape.
6.6 Backfilling a. Once several pipes have been laid and checked for alignment and level, pipe surround (Red Sand surround for Water pipeline & sand dune surround for Irrigation pipeline) shall follow in layers of 150 mm thickness (compacted with hand rammers) until the required level is reached as per the approved shop drawings. b. Testing of laid pipe shall be carried out prior to the placement of pipe surround in accordance with Contract specifications Clause 4.21 and RFI/44 Rev. A for pressure test for water line and according to Contract specifications Clause 6.60.8.1 for Irrigation line. c. Subsequent to pipe surround, backfilling will be done in accordance with MS 03. d. Followed by the backfilling, embankment construction will be carried out as per MS 03. 7.0 INSPECTION & TESTING:
7.1 Hydrostatic Pressure Test Testing of laid pipe shall be carried out prior to the placement of pipe surround in accordance with Contract specifications Clause 4.21 and RFI/44 Rev. A for Water line and according to Contract specifications Clause 6.60.8.1 for Irrigation line. Pressure and Leakage Test of Water Supply Network & Irrigation Pipeline Preparation before commencing the Test a) Each section of pipe under test will be properly sealed off and stop ends temporarily anchored. b) The pipeline to be partially backfilled with all joints and sockets to be exposed.
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 11 of 14 c) Any valve included in the section shall be set in the open position. d) Blank flanges shall be installed. e) All concrete anchors or thrust blocks included in the section must have reached their required 7 days strength. Testing Procedure a. The section of the pipeline shall be filled with normal drinking water or chlorinated water at the lower end. b. Pressure Gauge shall be fixed at the lowest point. c. During the filling operation care will be taken to ensure that there is no entrapped air in the section of the pipeline. It will be ensured that water cross section is fully flowing through the air valve / nearest fire hydrant units before closing the system and applying pressure. All peak points of the pipeline shall be adequately vented during the filling operation to expel as much air as possible. d. The pressure shall be raised to a test pressure of 13.5 bars and a graph of actual pressure against volume of water used at intervals of 0.5 bars will be prepared. The pressure at the lowest point of the section under test shall not exceed the above test pressure. e. The test pressure shall be maintained for a period of 1 hour (by pumping if necessary). f) The pump will then be disconnected and no further water be permitted to enter the pipeline for a further period of three (3) hours. g) At the end of this period the pressure shall be recorded and if the pressure is less than 12 bars, then pump shall be used and required quantity of water to be filled to restore the test pressure shall be measured in litres. h) The maximum acceptable leakages shall not exceed the following, - For Water Network Supply - 0.02 litres per millimetre of nominal pipe diameter per kilometre of pipeline per 24 hours for each bar head of test pressure applied. - For Irrigation line 3 litres per 1000m length per 25 mm nominal bore per 24 hours. - The test procedure will be carried out in full coordination with ADDC and will be according to ADWEA Specifications.
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 12 of 14 Leakage Repair a. Initially, locations of leakage (whether from the fittings used for testing or from the pipeline joints) will be confirmed. b. Once location of the leaks is/are confirmed, suitable measures will be taken to solve / repair the same. c. After repair works are completed pipeline will be re-tested according to the above mentioned testing procedure (Point No. 2 of section 6). Note: See attached (Sketch 1 & 2) as attached detailing the Testing Equipments for Water Supply Network & Irrigation line respectively. 7.2 Disinfection and Flushing (Only for Water Network Supply line) Introduction a. The quantity of water for flushing has to be calculated as 3 (three) times of volume of the pipeline, the quantity available chlorine for disinfection has to be calculated as 20 mg/l. b. Granular hypochlorite will be used with 62% available chlorine according to the required quantity of the available chlorine of 20 mg/l. Procedure a. The pipeline is disinfected at the same time as the hydrostatic tests performed. b. One end of the new installed pipeline has to be connected to the source of water (existing pipeline, all water used for testing shall be of drinking quality). c. The second end of the pipeline will be plugged with adequate flange, stop valve & discharge hose. d. Required quantity of granular hypochlorite is mixed with sufficient quantity of water. e. Water is started to fill from the source and at the same time hypochlorite mixture is injected from adjacent point to the source. f. When the chlorine reaches at the second end of the line, stop valve is closed and to stop further filling.
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 13 of 14
g. Leave the chlorine inside the pipeline for 24 hours after which the line is flushed and values for free chlorine and PH checked. h. Samples will then be taken to the laboratory for testing. i. The flushed water will then be discharged in to the Municipal Storm Water manhole through a flexible hose pipe after obtaining necessary approval from the competent local authority. Note: Acceptable value for free chlorine is 0.2 to 0.5 mg/l and for PH, it is 6.5 to 9.2 mg/l.
8.0 Prevention of fire Hazard a. Bituminous wrapping tape, primer, solvents etc are fire hazardous materials these shall be stored separately under closed store. b. Fire extinguishers shall be kept in vicinity of wrapping stores. c. No smoking sign/Fire hazard sign boards shall be visibly installed.
8.1 Confined Space
a. Continuous communication with the external outdoor personnel must be established.
8.2 Avoidance of eye and skin irritation
a. Wear eyes of face protection shield and hand gloves, Contact with the eye shall be immediately attend by medic as per manufacturer safety data sheet.
R4
Danet Abu Dhabi
Infrastructure & Roadworks Contract - 100
Method Statement Proposed Pipeline Works ( Pressure Lines ) Ref. : MS 04 Rev 4
2012/MS 04 Rev 4 16 th March 2008 Page 14 of 14
9. ATTACHMENTS a. Inspection & Testing Plan (ITP/Pipeline/P/04 Rev. 1) b. Complete safety shall be maintained during the execution of works as per reference "Safe/01" (as attached). c. Drawing No. DANET/KN/MISC/SK/302 - Water pipeline test method d. Drawing No. DANET/KN/MISC/SK/303 - Irrigation pipeline test method
e. Water Network Pressure Test Certificate f. Irrigation Line Pressure Test Certificate g. Material Acceptance Certificate Form No : Mar 05 h. Material Receipt Inspection Report Form No : MRIR/01 i. Certified Applicators, Letter Ref No:2012/A1-2/MAA/419-07 j. Wrapping Tape Check List Form No:19 k. Survey and Setting out Check List No.24 l. Bedding and Pipe Laying Report Check List No.01
ITP Reference Number: ITP/Pipeline/P/04 Rev. 3 Date: 16-03-2008 1 Establishing method statement Submit to Engineer Before work Approved document 1.37.2 (Volume 2A) H A R 2 Material submittal / approvals Submit to Engineer Before work Approved document 1.3 (Volume 2A) H H A S 3 Shop drawings Submit to Engineer Before work Approved document 1.5 (Volume 2A) H A R S 4 Material received on site verifying the compliance of received material For each Item Approved MAR & MRIR Form 1.3 (Volume 2A) H H S Att Form No.MIRIR/01 & MAR 05 5 Surveying ITP/Survey/01 Rev. 2 1.4 (Volume 2A) Att Form No.24 6 Excavation/Formation ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S Att Form No.24 7 Red Sand Bedding ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S S Att Form No.24 8 Anticorrosive pipe Wrapping Holiday Test ADWEA Spec w-p-ss-010 ADWEA Spec w-p-ss- 010 H W S S Att Form No.19 9 Pipe Laying Checking levels & Alignment For every length of Inspection raised Will be carried out according approved shop drawings Section 3 & 6 H H S S Att Form No.19, 24 10 Pipe surround and Pipe top Level ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S S 11 Hydro test of Pipe Hydrostatic Pressure Test For every length of Inspection raised Will be carried out according to specification & RFI/44 Rev A Section 4.21 & RFI/44 Rev A H H S S Test Certificates (E-07.56.017, Rev 0, MAR, Dated 05.01.2003 & Form: Danet/IRR/PT/01, Rev 0) 12 Backfilling ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S S 12.1 Placing of selected Backfill in Layers ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S 12.2 Field Compaction ITP/Earthworks/03 Rev 5 Section 1.28.3.2 (Volume 2A) H H H S 13 Disinfecation / Flushing for water Pipes Laboratory Test for chlorine and PH value Acceptable value for free chlorine is 0.2 to 0.5 mg/l and for PH, it is 6.5 to 9.2 mg/l Section 7.2 H H S S 14 Embankment ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S Att Form No.19 Consultant SIGN: SIGN: NAME: NAME: DATE: DATE: Contractor Contractor: Inspection and Test Plan for: Inspection Points: H= Hold Point, W= Witness Point, R= Review Point, S= Surveillance, A=Approval, WAT=Water Net Works Consultant Item No. Activity Description Project Managers: Engineer / Engineer Representative: Contract No: 100 KN Project No: 2012 Project Title: Danet Abu Dhabi Infrastructure Works ITP SIGN OFF POST COMPLETION OF WORKS Verifying Document / Report Contractor Consultant WAT Testing Laboratory Inspection Points Legend: ITL= Independent Testing Laboratory, ITP= Inspection and Test Plan, CI= Comments Incorporated Proposed Pipeline works ( Pressure lines ) Inspection and Test Activity Acceptance Criteria Frequency Specification Reference Location (for Post Completion signoff): PMT