Method Statement for DOCUMENT CHEC-JECCP-80-GE-

JEC Commercial NUMBER MST-0018

Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 2 / 34

NOTE: This document and all its contents is the property of CHEC. It is confidential
and is given to you for a limited purpose and must be returned on request. Neither this
document nor any information concerning it can be copied, exhibited or furnished to
others without the consent of CHEC

Table of Contents
1. Purpose of the Method Statement ................................................................................ 4

2. Scope of the Method Statement .................................................................................... 4

3. Referenced Document ................................................................................................... 4

4.Welding procedure.......................................................................................................... 4

4.1General Description ............................................................................................. 4

4.2 Welding Preparation for the internal&external Electrofusion couplings ......... 6

4.3 Welding preparation for the socket/spigot ..................................................... 14

5. Welding ..........................................................................................................................17

5.1 Welding Control ................................................................................................. 17

5.2 Welding area cleaning ....................................................................................... 18

5.3 Set of the welding equipment ........................................................................... 18

5.4 Extrudor Welding............................................................................................... 19

6.Testing of the weldings .................................................................................................21

6.1 Welds performed by electrofusion ................................................................... 21

6.2 Welds Performed bu Socket-Spigot ................................................................. 21

7.Second Phase Casting ..................................................................................................24

8.Recommendations to Comply .......................................................................................27

9. Resources .....................................................................................................................28

10.Quality Control .............................................................................................................30

11Healthy and Safety ........................................................................................................31

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 3 / 34

11.1General Preventive Measures .......................................................................... 31

11.2 Safety At Work Procedure:Cutting,Grinding and Pipe Welding ................... 32

11.3 Considerations On Work Completion ................................................................ 34

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 4 / 34

1. Purpose of the Method Statement

The purpose of this document is to describe the procedure to perform the

electrofusion welds of the HDPE DN1600/DN1800 pipes to be installed for
the seawater Intake and Outfall marine pipelines of Jazan Desalination Plant
and Sewage Treatment Plant and the second phase concreteing of the
ballast.The construction team shall follow this method statement strictly and
ensure it complies with IFC Specification and Drawings during the
construction.

2. Scope of the Method Statement

This method statement is intended to detail the procedure of HDPE

Intake and outfall pipes welding and second phase casting.The methods of
quality checking, which are mentioned in this method statement, shall be
followed under welding supervisors’ instruction.

3. Referenced Document

➢ T50-L-DOC-VE-024224 Specification for HDPE pipe

➢ Codes and Standards:

Saudi Aramco Construction Safety Manual (CSM)

4.Welding procedure

4.1General Description

All the connections of the HDPE pipes and fittings will be performed by
electrofusion welding.

Two different connection systems will be used for the project depending
of the type of the pipes to be connected:
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 5 / 34

▪ The SQ profile pipes (smooth external surface) will be welded by using

Internal/External electrofusion couplings.

Picture 1. Section of a weld performed with internal/external electrofusion

couplings.

All the project stub ends will be welded by using Intern al/External
electrofusion couplings.

▪ The PR profile pipes (corrugated external surface) will be welded

by welding the pipes socket-Spigot connections.

Picture 2. Section of an electrofusion weld performed with socket/Spigot.

All the pipes including fittings (elbows, diffusers and manholes)

connecting with PR pipes will have apart from the socket/Spigot connection
an internal electrofusion coupling.
The electrofusion process works by introducing a controlled electrical
voltage to the heating coil (electrofusion wire), which in turn generates heat
to melt the fitting and pipe surfaces. As the polyethylene surfaces melt they
also expand in volume to close any gaps between the pipe and fitting. After
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 6 / 34

the gaps are closed, the continued melt expansion gene rates pressure within
the heated zones.

Picture 3. Electrofusion wires

The electrofusion wires will be installed on site in order to avoid the wire
corrosion or wire damages which could happen during the materials transport
to the site or during the pipes & fittings storage and handling.

4.2 WELDING PREPARATION FOR THE INTERNAL&EXTERNAL ELECTROFUSION

COUPLINGS

The SQ profiles (smooth external surface) will be welded by using HDPE

Internal & HDPE External electrofusion couplings.

Picture 4. Electrofusion couplings

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 7 / 34

4 x Electrofusion welds will be performed through each coupling.

Picture 5. Scheme of and Electrofusion weld performed with couplings

To weld by using electrofusion couplings require the operations described

below:

▪ Pipe dimensions and reference control

There are different pipe profiles of each diameter, therefore the welding
supervisors shall identity the pipes to be welded before starting any operation
ensuring that the right pipes are selected.
Before starting the welding operations the welding supervisors shall review the
pipes dimensions (internal/external diameters) in order to select the most similar
pipes to be connected.
Apart from the standard marking, the supplied HDPE pipes incorporate a ‘colour
code’ in order to make easier the pipe identification on site.

▪ Pipe ends milling and cutting

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 8 / 34

The SQ pipes (smooth external surface) are supplied providing an extra

thickness at both ends in order to allow the milling of the pipes ends on site
without affecting the pipes wall thickness. The aim of milling on site the pipes
ends are to adjust the diameters of the pipes to be connected and to clean
the pipe external surface to be welded.

Picture 6. Pipes to be welded by couplings extra-Thickness.

The welding supervisors shall assess which are the grinding

requirements (pipes external diameter) for each end of each pipe, after
checking on site the dimensions of the pipes to be connected.

The pipe’s inner diameter will be taken as the reference for the pipe milling
control. The welding supervisors shall also determine whether is required to cut or
not some pipe end (in case the pipe end is damaged or in case it had lost its
perpendicularity).
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 9 / 34

The placement of the pipe on the grinding machine shall be done taking care in
order to avoid damaging the support wheels of the milling station which will support
the HDPE pipes.

The pipe shall be positioned properly centred in the machine. This task can be
performed with the help of a forklift or of the gantry cranes.

Picture 7. Placing the pipe on the grinding machine

In case the pipe cutting is required, the circular saw shall be placed in the
‘cutting position’. For the right positioning of the saw it is required to check the
parallelism between the circular saw support and the pipe support.

Once the saw is switched on, a full turn of the HDPE pipe will be performed in
order to mark the position where the cut will be made, subsequently beginning to cut
the section ensuring that the saw maintains the perpendicularity with the pipe.

Both the speed and movement of the saw will be regulated as per the welding
supervisor instructions.
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 10 / 34

Picture 8. Cutting a DN3000 pipe

Once the cutting of the pipe is finished, the pipes ends milling may start.To
perform a proper grinding of the pipe ends, the reference support shown in the
picture included below, which takes into account the pipe’s inner face as a
reference.

Picture 9.Grinding process

The speed and the movement of the grinder tool will be adjusted in order to
mill 250mm pipe length (extra-thickness length).
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 11 / 34

▪ Placing the grinded pipe to be welded in the ramp

Once the pipe ends are milled and cut (if required) they are placed on the
concrete launching ramp.

The pipes are supported over provisional removable (two halves) and
adjustable in height supports.

Picture 10.Pipe milled in the ramp

The pre-casted concrete ballasts have been previously placed over the
concrete ramp.

Picture 11.Concrete ballast

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 12 / 34

The two pipes ready to be welded will be placed in front one of each other on
the ramp. Once supported and aligned they will be approached.

Picture 11. Pipes ready to be welded

▪ Cleaning of the areas to be welded with a PE cleaner (isopropyl alcohol

or similar / ethyl alcohol with or similar). Water shall not be used for this
task.
▪ Internal tensioning ring, external clamp and electrofusion couplings
The HDPE Internal and External electrofusion couplings are installed on the
pipes to be welded by using the electrofusion welding tools:

- Internal electrofusion hydraulic ring.

Picture 12. Internal hydraulic rings

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 13 / 34

The purpose of the hydraulic internal ring is to keep in contact the surfaces
to be welded. These tools are able of re-rounding the pipe keeping the couplings
and the pipe ends in contact. As the polyethylene surfaces melt they also expand in
volume to close any gaps between the pipe and fitting. After the gaps are closed,
the continued melt expansion generates pressure within the heated zones.

- External clamp.

Picture 13. External clamp

The external clamps work together with the internal ring in order to re-round
the pipes to be welded, ensuring that the parts to be melt are in contact.

Once the internal tensioning ring, the external clamp and electrofusion
couplings are placed in its final welding position the tensioning tools shall be
adjusted (centring and tightening). If necessary, wooden or metal wedges may be
used to help in this task.

Once the internal ring is pressurized, the couplings installed and the external
clamp is tightened, the welding process may start
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 14 / 34

4.3 WELDING PREPARATION FOR THE SOCKET/SPIGOT

The PR profile pipes (corrugated external surface) will be welded by welding the
pipes socket-Spigot ends. Every PR pipe is supplied including one spigot end (male)
and one socket end (female).
The pipes & fitting´s socket incorporate integrated electrofusion wires. With the
tension transmitted by the welding machine, the electrofusion wire generates the
needed heat to melt together the material of the socket and the spigot end.

Figure 13. Socket – Spigot

The socket and the spigot ends have a specific ‘taper’ to improve the connection
between them.
One electrofusion wire will be installed on every socket end. This wire will be
composed by two halves, requiring therefore using simultaneously two welding
equipments to perform each welding.
The internal tension ring keeps in touch molten material of the male (spigot) and
the female (socket) ends during the welding process.
We describe below the steps required to perform an electrofusion welding of
every socket / spigot connection:
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 15 / 34

▪ To face the pipes / fittings to be welded keeping a separation between

them of about 1 m.
▪ Check that the ends of the electrofusion wires that will be connected to
the electrofusion welding machines will be in an accessible position (not
in the bottom of the socket).
▪ Check visually that the electrofusion wires are in good conditions. Check
the resistance´s continuity with a tester or multimeter to ensure that the
wire is not damaged.
▪ Clean the socket and the spigot to be welded with a PE cleaner (isopropyl
alcohol or similar / ethyl alcohol with 99.8% concentration or similar).
Water shall not be used for this task.
▪ Place inside the pipe close to the socket end, the ‘inner tension ring’
mentioned in the chapters included above.
▪ The function of this tool once placed in its final position is to ensure the
contact between the socket and the spigot ends.
▪ The final position of the internal should be as is shown in the following
sketch:

EXTERNAL CLAMP
WELDING ADAPTOR

SOCKET END

ELECTROFUSION
WIRE

SPIGOT END

INTERNAL TENSION RING

Figure 14. Socket – Spigot connection scheme

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 16 / 34

▪ Connect the socket and the spigot ends to be welded.

▪ Install the external clamp. It is important to note that the external clamp
shall not be installed before connecting the socket and the spigot, as the
clamp could reduce the socket internal diameter making difficult the
connection.
▪ Connect the electrofusion welding machines to the electrofusion wires
using an adapter similar to the one shown below.

Connect to the welding

machine.
Connect to the
wire ends

Figure 15. Welding adaptor

▪ The function of this adapter is just to allow the connection between

welding machine and electrofusion wires.
▪ Connect the electrofusion welding equipments to the electrofusion wires.
▪ As each welding is composed by one wire with two halves, every weld
has 2 x closed circuits. One electrofusion equipment shall be connected
to each circuit (To both ends of each wire).
▪ Connect the electofusion welding machine to the power supply. Turn on
the electrofusion equipment. The switch is located on the rear of the
machine
▪ Set the welding parameters and start the welding process.
▪ The cables can be removed after the machine has been switched off. The
joint can only be moved after it has cooled down.
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 17 / 34

5. Welding

5.1 Welding Control

Each weld must be numbered in order to control its traceability and that
the welding procedure has been accomplished d*uring its execution. The way
of numbering the welds shall ensure that:

▪ Each weld is own number and that this number is not repeated in the
project.
▪ The numbering of the welds shall not affect the welding execution. It must
be noted that the welds will be performed in the ramp or in the stock in
order to store 12/18 meters welded pipes.

The project requires performing DN1800 welds for the intake pipelines
and DN1600 welds for the outfall pipelines. Each Intake pipeline is split in 8
sections and each outfall pipeline is split in 9 sections. The DN1800 intake is
composed by two pipelines and the DN1600 outfall by other two pipelines.

The simplest way of numbering the welds considering the points

mentioned above it would be as follows:

FOR THE OUTFALL WELDS COUNTER

O O1, O2, O3, ...
STARTING FROM
FOR THE INTAKE WELDS 1I (1,2,3,4,….) I1, I2, I3, I4, ….

Figure 16. Welding reference number

During the sections execution a ‘welding map’ shall be prepared by the

welding supervisors in order to know which welds have been incorporated to
each section.
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 18 / 34

For every weld, a welding control sheet shall be fulfil by the welding
supervisors in order to record the weld traceability.

5.2 Welding area cleaning

All items involved in the welding shall be perfectly cleaned by using

isopropyl alcohol or similar (ethyl alcohol with 99.8% concentratio n or
similar), the pipe area to be welded, the internal and external electrofusion
couplings, the socket area to be welded and the electrofusion wire.

The cleanliness is one of the critical points of any weld therefore special
care is required to perform this task. The use of water to clean is not allowed
as the water could remain affecting the welding. The cleaning of the surface
areas to be welded shall be performed by using isopropyl alcohols or similar
as the alcohol will be evaporated avoiding any rest of it affecting the welding.
Rags or paper (materials which do not leave residues) shall be used to wipe
the surfaces to be cleaned.

5.3 SET OF THE WELDING EQUIPMENT

Once the welding adaptors are connected to the brass wire to be

welded and to the welding equipment, the welding equipment shall be
manually set with the required welding time and voltage (see the table
included below):
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 19 / 34

Figure 17. Welding parameters

The welding supervisor might vary, particularly times depending on the

specific conditions of each welding. Variations of this parameter, or any
other, such as the voltage, must be approved by the welding supervisors.

5.4 Extrudor Welding

Once the electrofusion welds are finished (including the cooling times )
the internal extrusion welds shall be done.
The purpose of the internal extrusion welds is to allow testing the
electrofusion welds but these welds provide additional advantages as to
minimize the hydraulic losses of the connections softening the weldi ng
surfaces.
For the electrofusion welds performed with electrofusion couplings,
the below listed internal extrusion welds shall be performed:
- Where both faces of the internal electrofusion fitting meet
- Where both faces of the external electrofusion fitting meet
- In the ends of the internal electrofusion fitting around the entire
circumference.
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 20 / 34

Figure 18. Hand extrusion welding for the electrof. couplings

For the electrofusion welds performed by socket – spigot, only one

hand extrusion weld shall be performed in the pipe internal surface over the
gap between the socket and the spigot connection.

HAND EXTRUSION WELD

Figure 19. Hand extrusion welding for the socket/spigot connections.

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 21 / 34

6.Testing of the weldings

6.1 Welds performed by electrofusion

Each weld tightness will be checked by using a high frequency spark

tester. The spark test is a non destructive test which would find any pore in
the extrusion welds.

Figure 20. High frequency spark tester

The spark produced by the high frequency tester detects the conductive
material installed on the electrofusion internal coupling ends in case there is
any pore in the weld.

By performing the above mentioned test, it is checked that the hand

extrusión welds are ensuring that the connection is water tightness.

6.2 WELDS PERFORMED BY SOCKET-SPIGOT

The particular configuration of the socket/spigot electrofusion welds

allows carrying out a leakage tests of the electrofusion welds.
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 22 / 34

Figure 21. Test chamber of the electrofusion welds.

To perform the test, it will be necessary to perform a manual extrusion

welding inside the pipes, over the gap between the socket and the spigot
ends to generate a ‘chamber’ between this welding and the electrofusion
welding.

The inner surface of the spigot end of the pipes to be tested will be
drilled on site with two holes (ᴓ 12-14 mm). These holes will communicate
with the air camera generated in each electrofusion welding, as represented
below.

Figure 22. Drilling of the holes to access to air chamber

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 23 / 34

In one of the holes a valve will be screwed. This valve will allow
introducing air inside the chamber generated between electrofusion welding
and the extrusion welding.

Figure 23. Inlet valve

The second perforation, it will work as an air outlet. Before fil ling the
chamber with air, a properly screwed manometer will be installed. This
manometer will verify the pressure to be applied and it will close the
perforation.

Introduce pressurized air using the inlet valve with the manometer
installed. Increase the air pressure up to 1 Kg/cm 2 .

Keep the system pressurized for about 20 minutes. During this time the
joint shall be inspected looking for any leak or defect.
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 24 / 34

Figure 24. Left - Air chamber Inlet valve and manometer. Right pressure
test.

Keep the staff informed about the work scheduled. Avoid the presence of
non-specialists in the work environment.

In the case that pressure test detects any problem in the electrofusion
welding. The welding can be repeated as defined in electrofusion welding
procedure.

After repeated the weld it the pressure test can be repeated. If the
results are successful the leak has been solved. Otherwise proceed with the
installation of an internal electrofusion fitting inside the pipe over the joint.

7.Second Phase Casting

Once the extruder weldings have been performed the second phase casting
of the concrete ballasts should proceed.The process shown as following.
(1) Place the concrete ballasts on the steel rollers suitable for the movement
over the rail of the ramp. Check that the concrete ballasts are centered over
the rails.
(2) Shifting the concrete ballasts over the rails to center them on the axis of
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 25 / 34

the pipe weldedjoints. Use tools to perform this operation to facilitate the
maneuver.
(3) Place the formwork for the second phase cast. The formworks will have
an octagonal shape, as shown in the photograph below.

Figure 25 Formwork for second phase casting

(4) Two workers will be at the top of the pipe pouring the second phase
concrete with a concrete bucket through the prefabricated hole located on
the top part of the concreteballast, arranged for this purpose. The concrete
will be poured from the casting tank or concrete bucket into the ballast filling
hole using a funnel
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 26 / 34

Figure 26 Process of second phase casting

(5) Once the setting time of the second phase concrete has finished,
remove the formworks.

Figure 27 Excellentquality of mass concrete

(6) The finished ballast will be marked with a spray of bright color in its upper
par with its corresponding number, to enable viewing once the pipe is
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 27 / 34

beneath the water level.

(7) The control points for the manufacture and assembly of the concrete
ballasts will be included in the programme of concrete ballast control of this
project. All checking items to be performed shall be recorded in this control
sheet.
(8) This process will be the same for all the concrete ballasts delivered on
site.

8.RECOMMENDATIONS TO COMPLY

1. It is recommended to check the good state of the equipment, making sure

that the jack has oil, the inner tensile ring is not damaged as to assure an
homogeneous tightening around the full circumference.
2. Before starting the welding process it is recommended to verify the
continuity of the resistance or brass wire. This test can be made using
the electrofusion equipment itself. If there is no continuity; there is no close
circuit, the machine will give an error sign and will not start.
3. The ends of the brass wire should not be in contact during the electrofusion
welding. It is recommended to separate them with insulating material (wood,
fiber, sleeves, etc.).
4. The welding and cooling times shall be followed in order to obtain a proper
connection.
5. It is advisable to avoid staff transiting in the pipes during the welding and
the cooling time.
6. If the surfaces to weld present moisture or are wet somewhere in the area,
they should be properly dried up. The presence of water in the welding may
cause internal pores.
7. We will not dismantle the internal tensile ring and the external tensioning
tool until the welding and the cooling time has totally finished, thereby ensuring
the correct welding of the pipes.
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 28 / 34

8. Even though in Jazan the temperature is hot throughout the year, in

adverse weather conditions (below 5°C) it is recommended to preheat 200
seconds the defined voltages.
9. Once the welding process has started it is not recommended to leave
without monitoring the electrofusion equipment, because errors may occur
during the execution (shortcuts) which have to be solved immediately.
10. To perform a proper welding it is recommended to work on levelled surfaces
with the aid of steel supports for pipes.
11. All Electrofusion welds require the pipe to be restrained or sufficiently
supported on each side of the pipe to restrict movement during the fusion and
cooling process, and to alleviate or eliminate sources of stress and/or strain
until both the fusion cycle and the cooling cycle are completed.
12. The electrofusion fittings can be re-fused in the event of an input power
interruption, i.e. fusion leads were detached during fusion, generator runs out of
gas, processor malfunction, or other circumstance that results in processor input
power interruption. The recommended procedure for re-fusing fittings is: Fitting
should remain in clamped position and be allowed to cool to ambient tem-
perature. The fitting should be reconnected to the processor and fused for the
entire fusion time.
13. The clamps and the interior rings will remain in its place until the weld area
to cool. This process can take around 40 minutes.
14. Do not move or manipulate the pipes during the cooling time.

9. Resources

Main manpower and equipment are listed in table1 and table2: (tentative
quantity).Contractor shall work 2 shifts if necessary to increase production as
per schedule.

Table1 - Manpower list(1 shift)

 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 29 / 34

No. Position Unit Quantity Task

1 Construction Manager EA 1 In charge of

construction

2 Quality Assurance Manager EA 1 In charge of

Quality
Assurance

3 Quality Control Manager EA 1 In charge of

Quality Control

4 Quality Control Supervisor EA 1 In charge of Qc

inspector

5 Site Engineer EA 1 In charge of

construction at
site

2 Foreman EA 2 In charge of
construction
workers

Welding Supervisor EA 2 Technical

Support

3 QC Inspector EA 2 Mechanical
and Civil Qc
inspect at site

4 HSE Officer EA 1 Safety inspect

at site

5 Flagman EA 2 Guarding
Forklift

6 Gantry Crane Operator EA 2 Operate Crane

7 Trailer Driver EA 2 Operate Trailer

8 Welder EA 31 Welding
Activity

9 Form fixer EA 12 Second phase

concrete
Formwork
installation
formwork

10 Repair worker EA 8 Repairing

concrete
ballast
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 30 / 34

Table 2 - The quantity of Main equipment

Table 6-1 Equipment List
No. Equipments Spec Quantities Remarks

1 Welding Machine 8 Welding

2 Gantry Crane 20t 2 Transport

3 Forklift 12t 2 Transport

Transport,
4 Mobile Crane 50t 2
Casting

5 Trailer 120T 2 Transport

10.QUALITY CONTROL

A welding control check list including all the points described below will
be filled up for each and every welding performed which covers all the
technical data of each union:

RESPONSIBLE
CHARACTERISTICS FREQUENCY OF
ITEM TASKS DOCUMENT OF THE
TO CONTROL THE INSPECTION
INSPECTION
1 BEFORE WELDING OF PIPES
At the project Welding
1.01 WELDERS CERTIFICATE Document
beggining supervisor
As per method Welding check Welding
1.02 PIPE CUTTING Each welding
statement list supervisor

As per method Welding check Welding

1.03 PIPE GRINDING Each welding
statement list supervisor

Each welding Welding check Welding

1.04 LENGTH MEASUREMENT Measurement
list supervisor

CIRCUMFERENCE Each welding Welding check Welding

1.05 Measurement
MEASUREMENT list supervisor

Each welding Welding check Welding

1.06 PIPE CLEANING Cleaning
list supervisor
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 31 / 34

ELECTROFUSION FITTING
Each welding Welding check Welding
1.07 CLEANING INCLUDING BRASS Cleaning
list supervisor
WIRE
Each welding Welding check Welding
1.08 BRASS WIRE CONTINUITY Visual
list supervisor

INNER TENSILE RING Each welding Welding check Welding

1.09 Placing
PLACEMENT list supervisor

EXTERNAL TENSIONING TOOL Each welding Welding check Welding

1.10 Placing
PLACEMENT list supervisor

INTRODUCTION OF WELDING As per method Each welding Welding check Welding

1.11
DATA IN MACHINE statement list supervisor

2 DURING WELDING OF PIPES

As per method Each welding Welding check Welding

2.01 CHECK VOLTAGE AND TIME
statement list supervisor

3 AFTER WELDING OF PIPES

Each welding Welding check Welding

3.01 VISUAL INSPECTION
list supervisor

Each welding Welding check Welding

3.02 RESPECT COOLING TIME
list supervisor

CHECK THE BEAD AT THE Each welding Welding check Welding

3.03
ENDS OF COUPLINGS list supervisor

11.HEALTH AND SAFETY

11.1 GENERAL PREVENTIVE MEASURES

- The work will be executed taking the appropriate safety precautions to avoid
an accident or incident when performing the activity.
- All personnel involved with the grinding and welding of pipes should use
their Personal Protective Equipment (PPE) consisting of helmet, goggles,
gloves, ear plugs, reflective vest and safety shoes.
- The working area should be defined and marked. Only authorized persons
who execute the activities described in this method statement are allowed
to enter the working area.
- Safety induction has to be done to the staff in charge of shifting the pipes to
the ramp (drivers, riggers, workers, etc.)
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 32 / 34

- The operator responsible of transferring pipes to the ramp must work in

coordination with the rigger.
- The workers involved in the pipes milling process should use earplugs due
to excessive and caused by the milling station.
- On the working area, there should be a first aid kit, with the aim of providing
first aid to injured personnel.
- A fire extinguisher will be located in the welding area.

11.2 SAFETY AT WORK PROCEDURE: CUTTING, GRINDING AND PIPE WELDING

MOVING AND PIPE PLACEMENT TO THE RAMP

- Only the staff responsible for the activity shall be found

on the work front.
- The staff responsible for performing the cutting and grinding must verify that
the supports of the saw blade and the grinder are well anchored to the
ground so that when moving and positioning the pipe the staff is not
exposed to blows or crushings.
- The operator responsible of transferring pipes to the ramp must work in
coordination with the rigger.
- Warning and prohibition signs shall be installed, indicating the
use of PPE, hazard suspended loads, moving forklifts, hazardous fall,
maximum speed at site, etc.

PIPE CUTTING AND GRINDING

- Workers involved in this activity and those who are close to the work front
should compulsory use their Personal Protective Equipment (PPE)
consisting of helmet, goggles, gloves, ear plugs, reflective vest and safety
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 33 / 34

shoes, due to excessive and harmful noise which exceeds the maximum
permissible limits and is harmful to the health of workers.
- The workers involved in the pipes milling process should use earplugs due
to excessive and caused by the milling station.
- The workers involved in the pipe grinding should compulsory use
disposable safety masks which will protect them from inhaling polyethylene
particles that may be harmful.
- It is mandatory to switch off the cutting and grinding machine for reviewing
and checking for any inconvenience to avoid incidents or accidents.
- Only the staff responsible to perform the activity will be found on the work
front.

PIPE WELDING

- It should be verified that all the equipment is in the welding area.

- For the electrofusion welding it should be verified that the welding
equipment
is located and in good conditions in the ramp before the activity begins.
- The worker must verify that the cables are made of vulcanized material,
which prevents its contact with water and possible electric shock risks.
- A fire extinguisher will be located in the welding area.
- Control measures must be taken to verify the operability of the welding
equipment and tools.
- It must be verified if workers involved in this activity have their appropriate
Personal Protective Equipment (PPE) and if they are in good conditions.
- The area must be clear of all combustible materials and chemical
flammable substances.
- On the working area, there should be a first aid kit, with the aim of providing
first aid to injured personnel in case there is an accident.
 Method Statement for DOCUMENT CHEC-JECCP-80-GE-
JEC Commercial NUMBER MST-0018
Port Project
HDPE Pipes&Fittings
Welding Procedure REVISION A01
ISSUED BY CHEC ISSUED DATE 4 Dec 2017 PAGE 34 / 34

11.3 CONSIDERATIONS ON WORK COMPLETION

- Promote training from the project manager to the last worker assistant, in
order to know the rules and always put priority on safety issues in their
work.
- For the selection of personnel to perform each task, it must be taken into
consideration the knowledge in health, safety and risk prevention, and
minimum requirements should apply.
- Continually develop staff training, in the theme of hazard identification and
risk assessment, until an acceptable standard of knowledge is achieved.
- Conduct safety briefings which are participatory and dynamic, so that
workers can take more emphatically security issues and may have greater
knowledge of the risks involved in each activity carried out in the field.