JV.

of The Arab Contractors and Elsewedy Electric Julius Nyerere Hydropower Project

EMPLOYER

THE UNITED REPUBLIC OF TANZANIA

TANZANIA ELECTRIC SUPPLY
COMPANY LIMITED
EMPLOYER REPRESENTATIVE

TANROADS ENGINEERING CONSULTING UNIT

(TECU)
EPC CONTRACTOR

JOINT VENTURE OF

PROJECT

Julius Nyerere Hydropower Project - JNHPP

Internal Review Document Release

A 12-08-2022 For Review 00 12-08-2022 For Review JVP JVP JVP

Ver Date Version Detail Rev Date Revision Details Checked Approved Approved

Scale: 1/100 Type: A4/Black Phase: Construction Discipline: Mechanical Contract / PO No: 7000

Originator Title

Method statemet & Risk Assesment

HDPE Fire fighting Network in EOV

Copyright © JV. of The Arab Contractors & Rev/Ver

Document No.
Elsewedy Electric All rights reserved. The
reproduction, disclosure or use of this document or 00
its contents is forbidden without express written 7000-JVP500-UZW-&MDC070-000001 Page
authority from The Arab Contractors & Elsewedy
Electric. 1/21
Purpose

This document defines specific guidelines that shall be considered while installing & testing HDPE firefighting Network at
operation village area

The method statement also communicates and defines the risks that may be involved during the activities, to ensure the highest
safety level required.

All Activates shall executed in accordance to the IFC drawings or layouts

1‐ Description of Work:

Civil Electrical √ Mechanical

Other (Please specify)

Location of Work: Operation Village Area

/

Brief Description of Work:

This Method of statements describes the installation procedures for the Installation & testing of HDPE
Fire fighting Network at operation village area

2. Erection sequence

2.1 Activities General Considerations

• Prior to the stage of fabrication and erection of any Activity, all Related Isometric (ISO)
drawings/layout to be issued as “For Construction”. ‐ Spools drawings, if applicable, to be
produced in accordance with ISO drawings/General Arrangements drawings/layout.
• Materials indicated in the drawings must be available with required size, quantity and quality
that confirm the requirements given in the related drawings.
• All materials to be used in the fabrication and erection shall be visually examined for no damage
and assure internally cleanness.
• Handling of pipes shall be by slings. Soft‐faced hooks, may also be used for lifting.
• After welding, “Visual Inspection” shall be done
3.0
Scope

• The scope of this method statement is to covers the Method Statement for Underground High Density
Polyethylene Pipes installation
• The purpose of this method statement is to detail the methods required to execute the Under Ground High
Density Polyethylene Pipe piping systems with the appropriate quality according to international standards.
• Butt Fusion Welding of HDPE Pipes Work Procedure
• The principle of butt fusion is to heat the pipe ends to a designated temperature (200-230 C deg.) under
pressure for a specified amount of time, then the pipe ends are fused together under pressure for a period of
time

WORKING PROCEDURE

1. •
• Preparation of welding: before you start the operation, it is
important to prepare the work area.
• Select the operation area that is suitable for the work.
• Install the protection tent or other equipment to protect the
welding zone against rain, sunshine or bad weather (if required)
• Set up the welding machine with all the accessories according to
the welding pipe size. Check if the machine is functioning.
• All of the problems or missing parts must be fixed prior to the
start of the welding operation.
• Welding machine must be calibrated before using
• Pipes to be cut with Over length for shaving and heat fusion
• Using suitable equipment for loading and downloading pipes ,
shaving tool & Heating plate such as ( forklift , boom truck & Mobile Crane )

2.

• Insert two pipes ends on both side of the machine clamps, protrude approx. 3-5 cm. from each shell side,
clamping and adjust the pipe or piping part, the surfaces to be welded should be parallel to each other.
• Adjust the alignment of pipe line by tightening or losing bronze nuts on the top aluminium clamps.
• Secure longitudinal movement of the parts to be welded by taking appropriate measures.
• Clean outside and inside pipe surface.
3.

• Insert the shaving tool or trimmer between the two pipe ends into
the lock position on the welding machine.

4.
•
Start the shaving tool or trimmer by turning on the
control switch.
•
Slowly approach the pipe ends towards the shaving tool
or trimmer by controlling the directional valve on
hydraulic control unit while keeping control pressure a
little higher.
The cutter will cut the surface of both pipe ends making
them clean, plane and parallel.

5.
•
When the pipe ends had been trimmed squarely and with an even thickness, slowly decrease the
pressure before switching off.
•
Remove the shaving tool or trimmer from welding machine to the support frame and clear the facing
scraps from pipe ends.

•
Inspect the ends, they must be clean and plane; otherwise repeat the step 3 – 5 again.
•
During the clearing and inspection, avoid any contact with the surface of pipe ends.

6.
•
Recheck the alignment of the pipeline by bringing the pipe ends closely together and measure the actual
tolerance.
7.
•
Bring the pipe ends apart, to clean both pipe ends using coat with suitable cleaning agent and avoided any
contact to the surface after cleaning.
•
Repeat the cleaning process, if necessary.

8.
•
To start with the welding process, begin with the alignment stage by inserting the heating plate between the
two pipe ends, moving both pipe ends close together until contact with the heating plate.
•
Start the build up pressure, maintain the pressure until there are welding seam appear.

9. Open both pipe ends, carefully remove the heating plate without touching the melted area and see to it that
• the removing time should not be longer than permissible time, insert heating plate to the support.

10.

Immediately increase pressure up to the joining pressure level within the joining pressure built-up time
• Uniform beads must be created throughout the whole circumference of the pipe joints.
 • Maintain or Keep the joining pressure constant throughout the cooling time or until the welding joint cools
down. Avoid forced cooling down by applying water.

11.

• Remove the clamps after the cooling stage is complete.

• Welding bead of each jointing has to be visually inspected and measured based on the following:
o Both ends should be almost equal in dimension o
The bead surface should be smooth and do not shine.
o Bead width must be according to the limit dimension

• Possible differences in the formation of the beads may be justified by different behavior of the joined
materials.

12. Pipe laying

Installation Guidelines for PE Pipe
The engineer must evaluate the site conditions, the subsurface conditions, and the application objectives to
determine the extent of support the pipe may need from the surrounding soil. Where the pipe burial depth is
relatively deep, where subsurface soil conditions are not supportive of pipe, where surface loads or live loads
are present, or where the pipe DR is high, the engineer will generally prepare a specific installation
specification.

Trench Length
The length of open trench required for fused pipe sections should be such that bending and lowering the pipe
into the ditch does not exceed the manufacturer ’s minimum recommended bend radius and result in
kinking.
Trench Width
The trench width should allow sufficient room for joining the pipe, if required, snaking small diameter from
side to side along the bottom of
 Trench Construction
Principal considerations in trench construction are trench width, length, and depth; soil stability; and
groundwater accumulation in the trench. Unstable soils or wet conditions should be controlled by sloping or
bracing the trench walls, de-watering the trench bottom, and/or other measures.
Placing Pipe in Trench
Place HDPE pipe up to 1600 mm diameter in the trench Using equipment to lift, move, and lower larger
diameter pipe into the trench. Pipe must not be dumped, dropped, pushed, or rolled into the trench.
Backfilling
Backfill the pipes with recommended soil and compaction to be done with suitable equipment

Hydro static Test

Why wo do H.T
T o uncover any faults in the pipeline joints - for example, electrofusion, butt fusion or mechanical joints.

T o reveal any faults in the assembly of fittings, including valves, hydrants, bends, tees, branch saddles,

and flanges. T o check that the pipeline will handle pressure greater than its design pressure without

leaks.

A fully fused pipe string for installation by a trenchless method such as Horizontal Directional Drilling, may have a pre-
commissioning test, above ground.

Generally check that the complete pipeline has no leaks and is ‘good to go” into service.

But... A test may not uncover damage to pipes, that’s your job…you must check for damage during construction.
Pre-commissioning testing is not intended to supplement or replace the test requirements of the pipeline product Standards.
What you need to know
You’ll need to choose an appropriate Test Method, with consideration for:
(a) Pipe diameter, PN class and length to be tested. (b) Length of time for the pressure test itself.
(c) Magnitude of the test pressure and rate of pressurization.
(d) Removing all air from the pipeline during filling with water
(e) Prevent movement of thrust restraints, and have in place all permanent or temporary anchor block supports.
(f) Be sure your test gauges are accurate.
YOUR
(g) BeTEST EQUIPMENT
aware of ambient temperature changes during testing.
(h) Prevent
Test Manifoldleaks
& theinPump
all test equipment and the pipeline.
.
.
PRE‐TEST PROCEDURES

Before you begin testing...

• Be sure that all Anchor blocks are installed
• Install blank temporary end

When the pipe is pressurized, visually inspect all the exposed joints to be sure they have no leaks. Avoid testing against any closed isolation valves as these
can leak slightly and upset the test.

• Leave all bolted or flanged joints exposed, to allow for re-tensioning during or after testing.
• Leave all fusion joints, service connections and valves exposed, wherever possible to check for leaks.

Filling the pipe…

• Always, slowly fill the pipeline with water from the lowest point – this will allow for air to migrate to the high point and allow it to
bleed off through an air valve, hydrant or service connection located at a high point.
• Be sure to remove all air out of the line during filling, and before you apply the test pressure. Air trapped in the line, can make the test
appear like you have a leak, (when there actually is no physical leak) and give a false result.
• T he availability of water for testing is important….
you’ll need a clean acceptable supply and don’t forget you’ll need an approved location to discharge it after the test.
• As the pipe slowly fills with water, allow a stabilization time-period for the air to escape and water temperature in the pipe to stabilize.
T he length of the stabilization time period will depend on the pipe diameter, and ground gradients or profile - overnight is preferred but
should be at least 3 hours. Any trapped air must be bled off before you start your pressure test.

H.T Pressure value: 13.6 bar

H.T Duration: 2 HRS
 RISK ASSESSMENT FORM

Cost Center Name : JNHPP Cost Center No. : RA No. :

7200/
Risk Assessment for Method Statement No. : Contractor Name : JV AC/EE Revision No. : 00
MSRA-00018
Method Statement Title : UPVC Piping System. Date : 12 /02/2021

Probability (P) Severity (S) Risk level P/S S1 S2 S3 S4

(R)
1 = Very Low 1 = Light P1 - - D C
2 = Low 2 = Medium B B - P2 A = Risk reduction urgently necessary
- D C
3 = Medium 3 = Severe P3 A D - C = Risk needs to be reduced
4 = High 4 = Extreme A - P4 D C B - = Risk is acceptable
D B A

Assessment Assessment
Task/Activity / No Control With Control
Ser. Hazard Hazard Effect Control Measures
Operation
P S R P S R
 RISK ASSESSMENT FORM
Assessment Control Measures Assessment
No Control With Control

Ser. Task/Activity / Hazard Hazard

Operation Effect
P S R P S R
Transfer and D Material shall be properly packages and tied.
Storage of
D Materials’ shall be appropriate to the truck load.
Equipment and
D Truck movement shall be only through designated
Materials D Fatality routes
D Medical D The driver/operator shall be trained and has a proper
Treatment license for the used truck
D Equipment D Truck speed shall not exceed 15kmh
D Unstable loads damage D Trained banksmen used in the loading, unloading and
D Falling loads D Fuel/Oil Leak movement of truck.
D Heavy loads and D Environmental D Area entrances shall be wide and sufficient.
01 3 4 A 2 3 C
overloading. issues D Unloading area shall be barricaded
D Fire D Disruption to other D Forklift shall be inspected and be operated by competent
D Incompatible materials operations person.
D D Sufficient space to be available for the forklift
D movement.
D Loaded material shall be suitable for the forklift design.
D Ensure that erection pay area ground is level and
compacted with proper drainage incorporated.
D Ensure all materials are correctly stacked.

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D Ensure that materials are correctly supported on timber

or metal dunnage.
D Ensure that loads on pallets are correctly positioned and
strapped
D Assess weight of loads prior to placing
D Store heavy loads at low storage heights
D Ensure incompatible materials are correctly segregated.
D Store flammable materials away from heat and ignition
sources.
D Ensure dangerous goods and chemicals are stored as per
manufactures requirements.
D Appropriate PPEs shall be provided and used.

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Ser. Task/Activity / Hazard Hazard

Operation Effect
P S R P S R
D Exposure to UV D Wear correct PPE
radiation D Provide localized shade (nonflammable fabrics)
D Glare D Provide sunscreen
D Exposure to D Eye injuries
D Workers to wear long sleeved shirt and long trousers
D Burns to skin
temperature extremes
D Carcinomas D Provide shade where practical
D Wing D Fatigue D Provide clean, cool drinking water
D Rain D Heat stress D Ensure regular/short rest breaks
D Dust exposure D Dehydration A D Provide insect repellant
Working
02 D Poor visibility 4 3 1 3 D
Outdoor D Hyperthermia D Wear gloves when handling or picking up items of
D Insect bites D Hypothermia equipment from the ground
D Stress
D Ensure grass is kept low
D Provide wing protection where practicable – fire proof
tarpaulin
D Provide dust suppression in the form of water.

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D Implement regular equipment inspections and logbook

D Pinch points system.
D Shear points D Medical D Equipment to be tagged with an “Out of Service” tag and
D Accidental start treatment isolated prior to being worked on and earthed if required.
D Equipment failure D Health effects D Equipment to be fitted with adequate muffler system.
D Noise D Stress D Personnel to wear hearing protection where warranted
D Vibration
Operation of D Property and D Equipment to be fitted with acoustic shielding
03 Stationary D Thermal 3 3 B D All hot pipes and surfaces to be correctly lagged/shielded 1 2 -
equipment
D Fire/explosion
Equipment damage D Ensure fire extinguisher is available within easy reach of
D Over rev/speed
D Over pressurization D Fire and equipment
D Limited or poor access explosion D Ensure proper refueling system is implemented
D Fuel spillages D Fueling only to be undertaken by trained personnel
D Machines to be fitted with removable covers for easy access
for maintenance purposes.

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Task/Activity / Hazard
Ser. Operation Hazard Effect
P S R P S R
D Avoid manual handling by using special beams.
D Heavy loads D Team lifting (e.g. several workers to handle large loads)
D Poor ergonomics D D Using manually operated load handling aids) e.g. trolley,
Slippery objects D Medical chain – block, forklift, wheelbarrow)
D Slippery surfaces Treatment
D All assist lifting equipment shall be maintained and
D Jammed objects D Chronic/Acute
Manual inspected.
D Unknown load weight disorder
Handling, D High frequency of D Dividing the load into smaller packages to reduce the
04 Pushing, D Equipment and 4 3 A weight. 1 2 --
lifting/action property damage
Pulling/ Bio-
D Pre-existing injury D Reduce duration & frequency of manual handling
Mechanics D Fatigue D Provide adequate breaks and recovery time
D Disease D Stress
D Shifting weight D Ensure provision of dry and anti-slip surfaces and access.
D Any leaks and spillage shall be corrected in accordance
D Bio mechanical
inefficiency with site instructions.
D Equipment failures D Ensure provision of adequate free space for
D equipment and worker’s movement without any

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D Equipment getting D obstacles.

stuck or high level of D If preexisting medical conditions are known by the
friction on moving employee, he must inform his supervisor.
parts D Rebar caps to be fitted to all exposed installed rebar
D Sharp edges D Dealing with jammed objects shall be executed by skilled
persons and under supervision from responsible engineer.
D Avoid stooping and twisting by modifying the workplace. D
All involved workers shall be physically fitted to the task.
D TBT shall be provided regarding safe handling technique
and dealt weights.
D Appropriate PPEs shall be provided and used.

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Ser. Task/Activity / Hazard Hazard

Operation Effect
P S R P S R
D Fatality D Ladders to be commercially built. No homemade ladders to
D Injury be used on the project.
D Equipment and D Personnel are not to work from ladders other than light duty
property damage tasks or inspection functions
D Personnel working at height (Above 1,8 Meters) on a ladder
D Fall from height must be tied off to a separate suitable anchor point/structure
D Failure of ladder D D Personnel working on a ladder are not to reach too far to
Electrocution either side of ladder. Both feet must be kept on the ladder
D Ladder struck by rung when working
05 Using Ladders 3 4 A 1 2 -
mobile equipment D Ensure ladders are fitted with anti-slip feet
D Incorrect erection of D Ladders to be free from damage or painting.
ladder D Head of ladder to exceed the working point by meter.
D Incorrect type of ladder D Ladders not to be used for any other purpose other than
access and light duty tasks
D Ensure ladder is placed on a stable none slippery surface D
Ladders to be positioned at correct angle to work.
D Ladders are not to be used to support loads other than the
weight of one person carrying very light hand equipment.

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D Tools to be inspected and color coded in accordance with

project color code system.
D Pre use Visual inspection shall be conducted to ensure good
insulation and that wiring and casing are free from damage.
D Hot work permit to be issued, if required.
D Tool/Equipment shall be able to withstand normal, overload
and fault currents and that it shall be used within
manufacture’s rating and in accordance with any
manufacturer’s instructions.
D Personnel working with electrical equipment at height where
D Electricity there is potential for “Kick Back” shall be provided with a
D High temperatures / D Fatality stable work platform
explosion D (electrocution) D Manufactures guards shall be fitted to all electrical
Using Electrical
D Falling from height D Injury D hand tools
Tools
06 D Exposed energized D Equipment 4 4 A D Guards are not to be removed under any D circumstance to 1 3 D
/ Equipment
parts damage perform work where the guard D might be a hindrance.
D Noise D Damaged or faulty electrical hand tools to be immediately
removed from use
D Safe correct routing of cables to avoid run over, trapped,
dragged over rough surface or getting in contact with
chemicals or hot surfaces.
D Avoid using equipment in wet conditions and use supply
cables are suitable for this.
D Avoid homemade or temporary connections.
D Avoid continuous flexing.
D Equipment and cable shall withstand exposure to water, solar
radiation, gnawing by rates and extreme heat.
D Use suitable protective systems (e.g. RCD & double isolation

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Task/Activity / Hazard
Ser. Operation Hazard Effect
P S R P S R

D Only competent workers who can use tools/equipment.

D Suitable PPEs shall be provided and used.
D TBT shall be conducted before commencing the activity.

D Fire / Explosion. D Eliminate the confined space entry by modifying it or have

D Acute/Chronic work done from outside.
D Flammable atmosphere. disorder. D PTW shall be obtained before entry.
D Noise. D Fatality. D Working alone is prohibited.
D Inadequate lighting D Infection. D Isolate all sources and use LOTO.
Confined Space D Electricity D Asphyxiation D Ensure suitable of entry, safe access and egress.
Entry e.g. pits, D Engulfment D Loss of D Conduct continuous testing of the atmosphere (Gas&
07 trenches, D Biological Hazards consciousness. 3 4 A Oxygen level). 2 3 C
D Oxygen
pipelines, etc. D Rescue difficulty. D Using suitable tools to confined space conditions.
deficiency/enrichment D Good ventilation and lighting shall be provided.
D Body temperature D Competent workers who are permitted to enter a confined
D Interior configuration space.
D Reduce duration and frequency of the work inside the
confined space.

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Ser. Task/Activity / Hazard Hazard

Operation Effect
P S R P S R
D Suffering exposure if ill D Fatality D Ensure that no personnel work alone after-hours D when site
or Injured D Injury is not occupied by other personnel.
D Being trapped for long D Stress D Ensure that security personnel have operational / functioning
periods of time D Property damage communication equipment when working alone.
08 Working alone 3 4 A D Security supervisor to call in to check on employee every two 1 2 -
D Psychological factors
D Communication issues hours and / or employee to radio into base every hour.
D Unable to satisfactorily
address

D Electricity D Electrocution D Electrical work to be performed only by qualified electrical

D Ground faults D Fatality personnel
D Non termination of D Injury D All electrical work to be strictly supervised and formally
cables D Property and quality checked
Temporary
D Exposed live wires D Equipment
D Electrical systems and cables to be protected D from
D Damaged equipment D damage
09 Construction 4 4 A damage from other construction processes, D i.e., welding, 1 3 D
Power and D Faulty work gas cutting, rigging, etc.
lighting D Faulty electrical D All components used in electrical work to be as
equipment D per design specifications
D Fire D ELCB’s to be fitted to electrical equipment
D Explosion D Electrical equipment not to pass through

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D explosive zones unless it is explosion protected

D All electrical panels to be locked and only accessed by
authorized. electrical personnel when work on electrical
components is required
D Project LOTO system to be employed.
D Failure of lightingD
D Low lighting levelsD
D GlareD
D ElectricityD
D Lighting design to take into account amount and quality of
D Poles damagedD
lighting
D TemperatureD
D Lighting maintenance schedule to be implemented
D Location of polesD
D Only authorized electrical personnel to work on lighting
D Falling from heightD
fixtures
D Bollards to be placed around base of lighting towers t o
protect towers from accidental damage from mobile plant and
equipment.
D Portable lighting masts to be extended to full height D Earth
leads to be connected.
D Specific training shall be conducted for all involved workers

Summary of Requirements:
1 Specific Training : Manual handling, Hot work, Electric hazard, Welding and cutting

2 PPE : Full PPE considering working in electricity, hot works,

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Task/Activity / Hazard
Ser. Operation Hazard Effect
P S R P S R
3 PTW required : Hot work and high risk activates permit and STARRT Cards.

4 Supervision Level : Fire watcher, HSE Officer and Construction Engineer.

5 Emergency Preparedness : Appropriate Fire Extinguishers, First Aid Box,

6 HSE Measurements : Gas, light, wind, heat and noise monitoring.

7 Isolation Requirements : As mentioned in above control measures such, Barricading system...etc.

8 Certificates, SDS or Data Sheets : This document shall be reviewed periodical in accordance with site conditions, change in work method and
used materials or failure in controls measures / Major accident or change.

Assessed by:

Name Position Signature Date

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