Method Statement-HDPE-MWSP
Method Statement-HDPE-MWSP
Rev No: 00
Date:
Prepared by Reviewed by Approved by
Kumar Abhishek
REVISION HISTORY
Date of
Rev. No. Description of Change Author Reviewer
Revision
Page |1
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 2 of 16
Republic of Maldives.
Content
2.0 Scope
3.0 References
4.0 Responsibilities
5.0 Resources
6.0 Procedure
10.0 Attachments
Page |2
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 3 of 16
Republic of Maldives.
2.0 Scope
This procedure covers the detail work methodology and guidelines for HDPE pipe
laying, jointing, testing and commissioning activity in all type of strata such as soil,
soft murrum as well as hard rocks. General requirements for stacking, excavation,
laying, jointing, testing & back filling reinforcement at site to be under taken as per
approved drawings.
3.0 References
General Contract Requirement
Contract Specification
Approved Drawings
IS 4984:1995 (Reaffirmed 2002) High density Polyethylene Pipes for water supply
– Specification
IS 7634 - Laying and Jointing of Polyethylene Pipes – Specification
IS 5382: 1985 Specification for rubber sealing rings for gas mains, water mains
and sewers (first revision)
IS 8008 Injection moulded/machined high density polyethylene (HDPE)
Page |3
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 4 of 16
Republic of Maldives.
5.0 Resources
Materials: HDPE Pipe & Fittings
Manpower: Site Engineer, Site Supervisor, HSE Engineer, Quality Engineer
Equipment: The following equipment’s shall be used in order to execute the
HDPE Pipe laying work.
Fusion Welding Machine & Accessories
New Generation Hydra Crane with hook latch.
Belt type lifting sling with sufficient capacity
Measuring steel tape,
Truck or Trailer,
Calibrated Level instrument etc.
6.0 Procedure
6.1 Routing:
The choice of pipe line routing shall be governed by economic considerations and
other factors such as overhead and underground cables, existing pipelines and
traffic flow.
Page |4
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 5 of 16
Republic of Maldives.
The pipeline may be laid alongside of the trench and jointed there. There after the
jointed pipeline shall be lowered into the trench carefully without causing undue
bending.
Polyethylene pipes conforming to IS 4984, being black in colour, when subjected
to direct sunlight or warm ambient temperature may become warmer than the
ground temperature. When placed inside the trench, the pipe will contract in length
as it cools to the surrounding soil temperature. If the pipe is connected to sub-
surface structures (such as preset valve, etc) before it is cooled sufficiently,
excessive pull forces could develop. Allow the pipe to cool to ambient temperature
prior to making a connection to an anchored joint.
Trench Bedding
Polyethylene pipe requires no special bed preparation for laying the pipe
underground, except that there shall be no sharp objects around the pipe.
Page |5
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 6 of 16
Republic of Maldives.
However, while laying in rocky areas suitable sand bedding should be provided
around the pipe and compacted.
Trench Depth
The minimum cover depth to be maintain as one-meter for laying pipes and fittings.
The initial back fill up to 150 mm above the crown of the pipe should be compacted
with screened excavated material free of sharp stones or objects or with fine sand
where no such material is available.
A. Butt Welding
Butt welding (or butt fusion) jointing is a thermofusion process which involves the
simultaneous heating of the ends of two components which are to be joined until
a melt state is attained on each contact surface, thereby producing a permanent,
economical and flow-efficient connection.
Page |6
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 7 of 16
Republic of Maldives.
The two surfaces are then brought together under controlled pressure for a specific
cooling time and homogeneous fusion is formed upon cooling. The resultant joint
is resistant to end thrust and has comparable performance under pressure to the
pipe.
Pre-welding procedure
Welding Process
Place the pipes in clamps with ends against the trimming tool and pipe
markings aligned
Align and level components using support rollers
Tighten the pipe clamps to grip and re-round the pipes
Use the trimming tool to ensure continuous shavings are cut from each
surface
Check that there is no visible gap between the trimmed faces
Place the heater plate in the machine and close the clamps so that the
surfaces to be joined are touching the plate
Using the hydraulic system, apply the pressure previously determined
Page |7
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 8 of 16
Republic of Maldives.
Maintain the applied pressure until the pipe begins to melt and uniform bead
of 2-3mm is formed on each end
Check that the pipe does no slip in the clamps. The pipe ends must maintain
contact with the heater plates. Once the heat soak time is completed, remove
the heater plate, ensuring that the plate does not touch the melted surfaces
Immediately close the clamps and bring the melted surfaces together at the
previously determined pressure
Hold under pressure for the appropriate cooling time.
B. Electrofusion
This jointing process uses heat generated from electricity to melt both the pipe wall
and the pipe surface, creating a completely homogenous joint that is stronger than
the pipe itself. Thanks to its versatility, electrofusion can be used to weld together
pipes or fittings from different PE materials and different thicknesses as long as
there is compatibility of melt flow index and raw material density.
A typical electrofusion weld is carried out by a trained welder and includes the
following steps:
Pre-welding procedure
Page |8
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 9 of 16
Republic of Maldives.
Welding Process
C. Flanged Connections
Page |9
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 10 of 16
Republic of Maldives.
Flanges and gasket should be centered, supporting one or both halves of the
joint if necessary
The end surfaces of the stub-ends must be close to each other before the
bolts are tightened to avoid elongation of the pipe during joint assembly
Bolts are tightened crosswise in at least six stages, starting with finger
tightening, and consequently using a torque wrench
Additional tightening to the recommended torque should be carried out
several hours later and also on the next day
As a rule of thumb, the sealing pressure should be at least twice the maximum
internal pressure in the pipe.
P a g e | 10
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 11 of 16
Republic of Maldives.
Compression fittings are popular because they do not require soldering, so they
are comparatively quick and easy to use and require no special tools or skills to
operate. Because compression fittings are not permanent, they are especially
useful in installations that may require occasional disassembly or partial removal
for maintenance.
The pipeline to be tested shall be filled with water slowly allowing for splurging the
entrapped air. Air valves at high points should be open to allow air to escape while
water is being filled. Before pressure is applied, the pipeline section under test
shall be restrained against movement.
P a g e | 11
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 12 of 16
Republic of Maldives.
If the test is not complete because of leakage or equipment failures, the test
section shall be depressurized and allowed to relax for at least 8 h, before
starting the next testing sequence.
Testing outside the trench is to be avoided, as pipe rupture may involve safety
issues.
Hydro Test shall be checked asp per approved drawing, specification and code.
Trench cover should be ensure 900-1100 mm.
The initial back fill up to 150 mm above the crown of the pipe should be
compacted
8.0 Health and Safety
The health safety and environment Management plan institutes the overall
mechanism for the risk management process with regard to the project. As an
integral part of the planning process prior to commencement of any operational
activity a suitable and sufficient specific assessment of risk associated with the
works should be taken
8.1 Training
Quality orientation training, Pep talk training and HSE Induction training based on
site requirement is given to all personnel to work in the site.
Job specific further Training must be provided to the working personnel like
JCB operators
Pipe Laying team
Hydro Test team
All work force related to the Activity
First aiders
8.2 Risk Assessments
HSE Hazards involved in the activities, tasks, tools & equipment pertaining to
this job has been assessed through Hazards & Effects Management Process
(HEMP) for each and every activity
The contents in HEMP Register shall be disseminated within the crew by the
shift supervisor / foreman, through Toolbox Talk.
Any new hazards & controls identified with reference to site conditions change
shall be briefed to the crew by the supervisor / Foreman, prior to
commencement of any activity
Following control measures generally apply to all hazards that shall be adopted
as a proactive measure in addition to the specific controls identified in the
HEMP Register:
Availability of First Aiders (with ready access to first aid boxes) shall be ensured
at each worksite. A first aid box with recommended items shall be kept at the
work place for use in case of requirement.
Medical facility for the crew when in need, shall be utilizing the clinic / hospital
identified for the purpose.
List of First Aider/Fire Fighting Team will be displayed.
An exclusive Emergency Vehicle will be provided, for any eventuality.
Saw dust and concrete wastage collected in Designated – marked container for
disposal at designated waste disposal facility.
Washed water from hard surface floors shall not be sent to sewer and to be
collected in a plastic container, labeled & stored for suitable disposal action.
Safe Storage System will be practiced & Handling is ensured by trained
personnel only.
Appropriate PPEs (Rubber gloves etc.) shall be used while doing handling,
cleaning activity.
To help, minimize the spread of viruses / dermatitis and upkeep of good health
of the employees, it is important to follow proper hygienic practices some
practices and procedures that will help reduce risk include:
Wash hands frequently. This is one of the most basic and important
preventative measures could be taken against the flu and some other viral
diseases. Use warm soapy water and wash hands for 15-20 seconds,
P a g e | 14
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 15 of 16
Republic of Maldives.
The MSDS shall be kept at site for reference and use in case of emergency.
Adequate signage shall be ensured related to the task performed.
Chemical exposed personnel shall be moved out of the spot to a safe location.
First aid shall be given in line with the MSDS guidance.
If required, body wash shall be given within the site using copious amount of
water.
In the event of contact to Eyes, the Portable eye washer shall be used to wash
the eyes.
Call for help within the worksite by calling the 24 Hrs. Emergency no.
Respond to the emergency of containing the spill, etc.if trained and if safe to do
so. Else call for help through 24 Hrs. emergencies and wait for further help from
external assistance.
Remove the affected personnel from the location to a fresh air place & call for
assistance to shift him / her to the nearby identified Hospital for further
treatment.
The Crew in-charge shall ensure that crew members have ready access to the
telephones for use during emergencies and the emergency contact numbers
are displayed in the site.
The emergency actions to follow to be disseminated to the work group through
daily tool box talk and ensured of the understanding by one and all.
Extreme requirements, call “XXXX” for POLICE/Emergency Response Team /
Ambulance assistance.
P a g e | 15
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :26.11.2020
JMC-MWSP-W-HDPE-MST-R00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 16 of 16
Republic of Maldives.
10.0 Attachments
Procured Material MTC from Vendor/Supplier
Inspection Request (RFI)
Pipe Laying Recorded with chain age in register.
Hydro Test Report
P a g e | 16
Project Name: - MWSP - Maldives
DOC No: - JMC-MWSP-W-HDPE-MST-R00