Document Type

Royal Commission for Jubail and Yanbu

Method Statement

METHOD STATEMENT

RAWABI FAYFA CO.

DEVELOPMENT OF JALMUDA SHORELINE

692-C03R

Installation of Sanitary Wastewater Piping

Method Statement No:01

Issued by:

Rev.# Date Description Prepared Checked Approved

0 23 mar15 Installation of sanitary wastewater Mohammed Raoofuddin Yazid Nofal
piping Arshad Mohammed

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 Document Type

Royal Commission for Jubail and Yanbu

Method Statement

TABLE OF CONTENTS

1. TITLE.

2. SCOPE OF WORK

General description.
Plant and equipment.
Materials.
Site planning & preparation
Work methodology.
Organization, Responsibilities & Supervision.
Work Force.

3. HEALTH & SAFETY

Risk assessments
Jubail ES & H Contractor Requirements
Protective & Safety Equipment.
Contractual Requirements.
Information to personnel.
Emergency Procedures.
Permit Requirements.

4. ENVIRONMENTAL ISSUES

Environmental Impact assessment.

Jubail ES & H Contractor Requirements
Contractual Requirements.
Emergency Procedures.

5. QUALITY ASSURANCE

Contractual Requirements.
Critical works.
Inspection & Testing.
Follow up & Evaluation.

6. APPENDICES

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Royal Commission for Jubail and Yanbu

Method Statement

1.0 TITLE

Installation of Under Ground Piping for sanitary wastewater system.

2.0 SCOPE OF WORK

General description

This method statement is intended to outline the ways, procedures and the
proper execution in the installation of UPVC pipe installation for the above
mention contract.

Plant and equipment

To execute the job below listed plant & equipment shall be used but not limited to
the following:

Crane/Boom Truck
Generator
Hand Tools
Sling/Belt
Shackle
Chain Block or Come along

Material

The material used shall be in accordance with the specification and contract
drawings such as UPVC pipe, Lubricant and gasket.
Pipe UPVC CL-3 and CL-4
Dia.-160,
225
Pipe UPVC CL-5
Dia.- 110

Transportation and handling

Pipes shall be stored on a plain ground in the wooden timbers or on sand

mounds with adequate chokes to prevent from movements.
From the lay- down area to the trench site, it shall be transported by trailers.
Prior to unloading of pipes from trailers, all items shall be inspected for any
visual / transportation damages.
Care shall be taken to prevent pipes from rolling or falling from flat bed trailer and
this shall be attained by using proper supports, chocks.
The rubber gaskets received along the pipes and fittings shall be stored in shelter
with original packing until it is used at site.
The supplied lubricant is special vegetable soap (free from grease / petroleum
products). Only the supplied lubricant shall be used. The lubricant paste shall be
mixed with equal ratio of water (1:1) while using it.
During handling, measures shall be taken to avoid touching or contaminating the
pipes ends.
Site Planning

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Royal Commission for Jubail and Yanbu

Method Statement

Before starting the installation, coordinates and elevation of the center line of the
bedding are established as per the latest revised IFC drawing inside the trench
construction area as a reference points.The surveyor writes down the drawing
number and revision of the drawing into the survey report. IFC drawing shall be
attached to the survey report. Excavation permit shall be obtained from RC before
commencement of any excavation.

Work Methodology:

Trench Excavation:

The width of excavation shall be made minimum to comfortably contain the space of
worker standing on either side or sufficient to work.
The side slope of trenches shall be at the angle of repose of the excavated material.
Shall be ensuring that all the excavation is safe to work around throughout
construction activities until backfilled.
Excavated material to be placed at safe distance from the edge of the excavation.
Ladders access to trench must be secured at their highest point.
The necessary service access with slope shall be provided as required.
The trench width shall be extending to minimum half of the pipe diameter at each side.
If the excavation area is deeper than 1.2 meter it shall be step by steps, two or more
steps.
The width of steps shall be 1.2 meters or greater.
Instable soil condition, the trench shall be made by manufacturer recommendation
and or manufacturer procedure.

Trench De-Watering (If Required):

In case of high ground water table, adequate dewatering shall be requiring through
suction pumps or well-point system depending on the ground water condition.
Dewatering equipment shall be provided and maintained to remove and
dispose of all
surface or ground water entering excavations and other parts of the work. Each
excavation shall be kept dry during subgrade preparation and continually
thereafter
until the construction to be provided therein is completed to the extent that no
damage from hydrostatic pressure, flotation, or other cause will result. Ground
water

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Royal Commission for Jubail and Yanbu

Method Statement

level shall be maintained at least 500 mm below the bottom of each

excavation.

Pipe Laying Procedure:

Position the crane (If it is needed) near the trench in a safe distance
Unload the pipe and lower into the trench.
Make sure that the bedding is mechanically compacted prior to pipe laying as per
the required specification.
After placing the first pipe, bring the second pipe near the pipe earlier placed
and install it with clamps, chain blocks/pullers.
Once the pipe is fixed in the coupling, check the alignment and move to other
joint. Keep continue this way for the entire line.
Release pipe from the crane, remove the slings and the clamps.
Make sure that pipe is firmly supported.
Pipe haunch is the most important part of the initial back filling, except joints.
Haunch the bottom of the pipe with the correct material to be used.
Carry on the same procedure for the rest of pipes.
No pipe shall be laid on trench with the presence of water.

Pipe haunching
UPVC Pipe
Clean the bell end thoroughly from inside, specially the internal groove, from dirt,
grease or any material deposition.
Fix the rubber gasket in the bell groove.
Mark the pipe around the circumference at the spigot end as per manufacture
recommendation.
The beveled end of the spigot and the gasket in the bell grove are first cleaned
and cleared of any foreign particle.
Apply thin film of lubricant on spigot and bell end pipe.
By using the lubricant (use the same lubricant which is recommended by the PVC
pipe manufacture) applied to the spigot end.
The lubricated spigot is then pushed past the gasket into the bell until the guide
mark on the spigot is flush with the lip of the bell, with the rubber joint; It is usually
possible to manually insert the spigot into the bell for pipes of nominal diameter
100mm and smaller; for larger diameter mechanical assistance may be needed
for insertion.
Using the bar and block method is recommended as field technician is able to feel
the amount of force being used and whether the joint goes together smoothly.

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Method Statement

Cutting of pipes:

Measure the desired length and scribe the pipe using a pipe fitter's wrap- around.
When holding the pipe in a vise, use a 6 mm thick rubber pad to protect the pipe
from damage. Use a hacksaw or power saw with abrasive wheel to cut the pipe.
Check the squareness of cut. Pipe up to 100mm should be square to within
1.5mm, larger pipe to within 3mm.Use a disc grinder to file to correct squareness.

Thrust Block/Concrete Pouring

All the dimensions are as per contract drawings.

The area where the concrete is to be cast bottom shall be well compacted and
the polyethylene sheet shall be laid over the compacted area
The thrust blocks shall be cast in place concreting method.
The dimension, size, Fabrication, bending details and placement details of epoxy
coated reinforcement steel bars are as per contract drawing.
Prior to pour concrete the forms all preparatory works shall be inspected as per
RC approve and concrete pour record shall be filled.
The concrete shall be used within 90 minutes from the time of mixed and
delivered from patch plant.
1
Concrete pouring is very sensitive matter to prevent the uplift of the fittings.
Extra care shall be taken during this process.
Thrust block shall be casted only after line inspected and tested.

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Method Statement

Polyethylene sheet shall be installed between the pipe and concrete.

Preparation prior to Testing:
Prior to hydro testing, underground piping shall be partially back filled to the
required height with all joints exposed during the hydro test to detect any possible
leakage.
Flushing should be done to remove all debris and dust inside the pipe before
starting test.
All pipes end must be sealed off with test plug or blind flange.
Vents shall be provided at all high points of the piping system in the position in which the
test is to be conducted to purge air pockets while the component or system is filling .
Drains shall be provided on manifold as well on pipe being tested to drain water after test.
Provide Pressure relief valve with gate valves rated 5% above the test pressure at
the highest portion of the pipe to be hydro tested.
In addition to the pressure relieving device, a bleed valve shall be provided to
Protect the piping and equipment from overpressure. The bleed valve shall be readily
accessible in case immediate depressurization is required.
Test pump shall be placed on a firm ground away from the piping system to be
hydro tested.
Before the hydrostatic test is carried out, permanent and temporary Supports
shall be installed.
All pressure gauges to be used for hydro testing must be calibrated.
An isolation valve shall be provided between the pressure testing manifold and
the system being tested. The isolation valve shall be rated for the manifold test pressure
when in the closed position.
Before employing the pressure testing manifold in the actual system pressure
test, it shall be separately pressure tested to at least 1.2 times the system test
pressure but not less than the discharge pressure of the pump used for the pressure
testing.

Water Leak Test Procedure for (Gravity line):

Shall take all necessary precautions for the safety of personnel during testing
operation.
Testing shall be carried out on each section of sewer between Successive
manhole. .
Cracked or defective pipes, fittings, and valves shall be removed and replaced with
sound material until satisfactory
Plug all openings below the highest vent stack.
Repair leaks encountered.
Maintaining and fill the line 3 m above top of the pipe at upper end of the pipeline.
Filled water shall be allowed to stand in piping not less than 24hours.
The amount of water needed to maintain this water level shall be measured during a
24-hour test period.
Leakage shall not exceed 0.06 L/h/100 m/mm of 300mm nominal diameter or less.
Leakage shall not exceed 0.12 L/h/100/m/mm of 300 mm nominal diameter or greater.
Joints showing any visible leakage shall be replaced or remade as necessary.

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Royal Commission for Jubail and Yanbu

Method Statement

Hydrostatic Test Procedure for (Force Main pressure line)

Inspect the completed installation to assure that all requirements have been met.
Fill the line with potable water, well water or sea water at the lowest point with open
valves and vent so that air will be expelled from the line to avoid pressure surges
during the pressure build up.
Once the water comes out on the highest point of the vent close the valve.
Test pressure shall be 1.5 times of working pressure.
Pressurized the line slowly.
Wait until the pressure is stabilized.
If no sign of pressure drop disconnect the pump from manifold.
Check all joints for possible leak.
If no leak found, continue the test to the required time to complete the test.
Open slowly the valve to release the pressure inside the pipe located near the vent.
Drain the line to approved location to complete the testing.
All necessary safety shall be carried during testing operation.
The initial hydrostatic test shall be made with partial backfilling keeping all joints
exposed.
The gauge calibration interval shall not exceed one month. Calibration certificate
shall be made available to inspection personnel prior to commencement of the
pressure test.
A minimum of two (2) pressure gauges are required for the test system, one
pressure gauge shall be on the test manifold and the other on the test system.
Pressure at each test gauge shall be checked and recorded on inspection sheet.
Walk through along with the lines to observe any trance of wet soil. Check the joints.
Repair leaks encountered.(if any)
The length of the piping being tested shall not be more than 1 km.
Pressurized the line slowly as required the test pressure at 1.30 Mpa.
The test pressure shall be maintained for a minimum period of 4 hours.
Fill up the inspection sheets accordingly.
The test shall be considered as pass if no sign of leakage is observe at the
permanent joints and there is no pressure drop.
The inspection sheet(s) shall be signed by the RC representative.
Upon satisfactory completion of the test and acceptance the system shall be
depressurized gradually.
After completion the test, the water shall be transfer to the other line to use for testing
or to tanker.

AFTER PRESSURE TEST REQUIREMENTS

Release of pressure and draining shall be done on the downstream side of check valves. All
vents shall be opened before draining to facilitate drainage and to prevent formation of a
vacuum. No test fluid shall remain in low spots
The test fluid shall be disposed as directed by the Royal Commission .
Vents and drains used only for the pressure test shall be plugged, seal welded and penetrant
tested.

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Method Statement

All temporary items installed for testing purposes (e.g. manifolds, valves,blinds, spacers and
supports) shall be removed.
Items that were removed from testing shall be re-installed.
Items, such as instrument air tubing, check valve discs which were disconnected before
testing shall be reconnected.
Isolation valves closed for the test purposes and that are required to be in the open position
for process reason shall be opened. If the valve cavity has a drain, the cavity shall be
drained.

Pipe Backfilling up to Grade

After the pipe joint hydrotest, the pipes can be backfilled and compacted in lifts
of 150mm up to warning tape and thereafter in lifts of 300mm up to FGL.
The backfilling should be compacted to 90% max dry density as per RC contract
drawing. No. 692-320-20TR-CE-211 and RC Specification-02315.
Sand used for backfilling shall be free of any contamination.

Responsibility
The Project Manager and Construction Manager are responsible for the proper
implementation of this Procedure.
QA/QC Manager is responsible for the implementation of all required Quality
Control Activities such as Test and Inspection.

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Royal Commission for Jubail and Yanbu

Method Statement

QA/QC Engineer is responsible for the proper carrying out of the inspection and
Testing details as per Specification and Procedure.
Field Engineer and Piping Superintendent and supervisor responsibilities are to
manage all the everyday activities as per plan and schedule. They Coordinate with
the HSE Department to ensure that Proper Safety Implementation respective to
Personnel, Equipments and Environment are strictly adhered. Piping Supervisor
responsibility is to monitor everyday field activities, assuring that implementation is
as per this Method statement.

Work Force.
Field Engineers
QC Inspectors
Surveyor
Safety Officer
Equipment Operators
Foremen
Pipefitters
Helpers

3.0 HEALTH & SAFETY

Risk assessments

Basic job steps Risk Safe job procedure

Check work permit Excavating without Accomplish safe work, plan, excavation trenching
system approved excavation permit. Safety officer assigned in the area to check
safe work plan/excavation prior to actual excavation,
sign board display at work site.
Equipment Failure of equipment Designated equipment spotter defined access for
operation operation heavy equipment backup/reversing alarm. Must be
always in good condition.
Task Assignment Use of defective Competent/ certified operators for the equipment
equipment & tools inspected to use, hand tools of carpenters, mason &
others crafts must be inspected.
Access barricading No proper access or Provide adequate and appropriate access for
barricading personnel, barricades and install safety signs.
Sloping Collapsed excavation Sloping / stepping of excavation Installation of sheet
piles, and maintain de-watering system.(as required)

Transportation of Accumulation of To designate stock pile area, spoil one meter away
soil excavated soil /spoil near from edge of excavation.
the edge of excavation
would result on failure of
the vacation

Environmental Safety& Health Contractor

All Environmental and Health shall be taken care

Adjacent properties free of accumulations of waste materials, debris, rubbish, and
windblown debris resulting from construction operations.

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Method Statement

All The disinfection procedure shall follow the RC method(s) and standard(s) as
required.
Store volatile wastes in covered metal container remove from premises daily.
Prevent accumulation of waste which creates hazardous condition.
Provide adequate ventilation during use of volatile or toxious substances.
Collect and remove waste materials, debris, and rubbish from site periodically until
execution of final cleaning and dispose off site in lawful manner.
Conduct cleaning and disposal operations to comply with local environmental laws.

Protective and Safety Equipment

All person at all time when on the site have to wear a protective helmet. It is
essential to be properly adjusted to the wearers head. Metal hard hats are
prohibited. No holes in the helmet & not to be painted.
Safety shoes/boots shall be issued to all personnel on the site. Safety shoes
complies with ANSI standards which should be oil, abrasion, and heat resistant
fully useful for the construction sites.
Appropriate glasses and eye protection to be issued to workman as required.
Factors to be considered in selecting eye protection include the degree required
and the comfort provided as required by ANSI.
In places where high slopes workers shall be equipped with a safety full body
harness with retrieval line securely anchored to the structure.
Rubber boots to be provided during concrete woks. These boots should be in
good condition in order to prevent any contact of concrete with workers foot.
All workers as a requirement will use protective hand gloves to protect against
sharp or rough edges, chemicals, and hot or cold surface accordingly.
Self contained breathing apparatus to be available in need to use.
Contractual Requirements
All safety and health which are required to fulfill by the contractor will be taken
care in accordance with the International EH & S Standards in junctions with
clients Specification, Standards, and Instructions.
Information to Personnel
Safety and Environmental education and information to be disseminated to all the
employees, in shape of seminars, safety tool box meetings and safety refresher
courses.
Emergency Procedure
First aid clinic is available at site in the hour of need. Emergency Telephone
numbers are posted and displayed on site on appropriate locations.
Rescue aids will be in place such as retrieval lines, safety harness, etc.
In the event of heat stress and strokes a fully equipped ambulance is available to
transport the victim to the nearest hospital for treatment.
During lifting no one under the lifting materials.

4.0 ENVIRONMENTAL ISSUES

Environmental Impact Assessment

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Method Statement

None
Environmental Safety & Health Contractor Requirements
Same as addressed in above section
Contractual Requirements
Please see the Section above
Emergency Procedure
Please see the Section above
5.0 QUALITY ASSURANCE
Contractual Requirements
Contractor is bound to meet the requirement of Quality Assurance issues.
Critical Works
All critical activities will be performed in accordance with the clients Specification,
instruction as well as International standards.
Inspection & Testing
Inspection and testing to be carried out in accordance with the approved ITP and
RC Specification (Attached ITP).
Follow-up & Evaluation
Work executed shall be evaluated and followed up in accordance with RC
Specifications and International Standards.

Acknowledgement Signatures
The personnel listed below confirm receipt of the method statement and have had the contents explained to them, understand
it and are aware of the site ES&H requirements.
Name Employer Date Signature

Note to FE, CS & FCS Any significant change from this method statement requires it to be revised and resubmitted to RC
before work can commence.

TEST INSPECTION
PIPELINE: Pipelines/Sewers

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Method Statement

LOCATION PLAN

WATER TEST AIR TEST

1. Line No. SEWERLINE (a) Weather N/A

2. Pipe Material (b) Excavation Inspected N/A

3. Dia. of Pipe (c) Bedding Inspected N/A

4. Pipe/Sewer Length (d) Section N/A

TESTING PROCEDURE:
(Briefly Describe)
Pipe line is plugged at all ends and filled with water up to the required length of head. Check exposed
joints for leakage.

Result:

Pass Fail

COMMENTS:

QUALITY CONTROL ENGINEER /DATE

Q.C. INSPECTOR /DATE R.C. ENGINEER /DATE

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