Issue Date June 10, 2019 Rev. No.

0
Rev. Date Page No. 1/17
Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

TAPPING OF WATERLINE
TO EXISTING
(METHODOLOGY)

Prepared by: Approved by:

VIRGILIO CRISTOBAL CAROLINE MAY A. SOLLANO

Project In – Charge VP – Mechanical
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

DOC. NO. TITLE PAGE

Title Page 1

Table of Contents 2

Purpose 3

Scope 3

Equipment 3

Materials 3

Site Planning & Preparation 4

Procedures 4

Job Hazard Analysis 12

Quality Control Procedures 16

Responsibilities 16

References 16
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

1. PURPOSE

The purpose of this methodology is to create awareness and ensure compliance with contract
specifications and EHS requirements during tapping of waterline to existing line.

This method statement shall be communicated and be understood by all personnel associated
with the task before commencing the activity.

2. SCOPE

This methodology deals with the of tapping waterline to exsiting at A, D, C & Café area for A & A
RETAIL (Batch 1) Project.

3. EQUIPMENT

Fusion Machine
PPE
Hacksaw Blade
Pipe Cutter

4. MATERIALS

ITEM DESCRIPTION
1 PPR Pipe PN20
2 PPR Fittings
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

5. SITE PLANNING & PREPARATION

Work Coordination
- Daily close supervision
- Daily close coordination with OKADA Facilities

Communication
- Mobile Phones
- E-Mails / Internet

Plans
Only Okada Facilities approved for construction plans shall be used.

6. PROCEDURES

Safety Procedure
 All workers to wear appropriate PPE for the task, i.e. goggles, mask, gloves etc.
 All workers must be understand and physically fit in performing the test.
 Materials and equipment must be inspected before use.
 Ensure safety work permit is approved before proceeding to test.
 Install safety signage around the area.

Pre-Tapping Procedure
 Coordinate with OKADA FM the schedule of adjustment / relocation of PPR pipes.
 Tenants of the affected areas shall be informed that there will be an interruption of
the supply of waterline for about 6 hours.
 Prepare pre-fabricated pipes and fittings.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Draining Procedure
 Prepare a pipe / hose connection from the existing PPR Pipe stub-out and tap to
the nearest drain located at lower ground floor.

 Close the existing main isolation valve.

 Drain the isolated system by opening the existing valve. (to be facilitated by
OKADA FM).

Tapping Procedure

 Locate the pipes to be relocated.

 Carefully cut the pipes using a pipe cutting tool.
 Join the prefabricated pipes & fittings to the existing pipes using fusion machine.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Disinfection & Flushing Procedure

 Open the PPR stub out valve which serves as temporary drain valve and ensure
continuous flow of water to the drain pipe connected at the drain located at LGF.
 Leave the valve open until the water is clear and free from debris.
 Disinfect the pipes using chlorine.

 Install Chlorine injection point at waterline stub-out.

 Prepare manual test pump as chlorine injection pump.
 Chlorine Hypochlorite quantity should be calculated using Chlorine Calculation
Procedure.
 Ensure valves from main isolation valves are closed.
 Install vent valve to highest elevation stub-out.
 Observe air coming out of vent valve until such time that water is already coming
out and then close vent valve.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Testing Procedure

 Pre-testing will be performed prior to shutdown works to get the existing system
pressure. The resulting value will be treated as the working pressure of the
system.
 The pipeline will be charged with water by opening the main isolation valve and air
will be released manually through mounting a temporary air vent to an existing
water stub-out.
 Pressurize the pipework and equipment to the working pressure and close all
isolating valves including the temporary drain valve to isolate the system. Vent the
trapped air through air vents and check for leakage.
 Release the pressure and then record the static pressure.
 Pressurize the pipework to 1.5 times of the working pressure.
 Gauge pressure is checked from the pressure gauge.
 After thorough checking for possible leakage waiting for about 15 to 30 minutes,
the specified test pressure is recorded in witness of the representative(s) from
OKADA FM.
 Maintain the pipework under pressure for 1 hour and record the final pressure.
This record shall be witnessed by OKADA FM.
 If any leaks are found, repair it by shutting the system down again, closing the
main isolation valve and draining the water pipes in coordination with the OKADA
FM.
 Leave the system full after the pressure test as witnessed by OKADA FM.

Emergency Arrangements
 The Health & Safety officer will be responsible for coordinating the emergency
procedure. If there is an emergency the Health & Safety officer will be notified
immediately.
 The Health & Safety officer will then notify the relevant emergency services if
required
 The Health & Safety officer will notify the Safety Advisor of the emergency, if the
site nurse is required he will be notified, the Safety Advisor will attend the
emergency and take control of the emergency.
 The required notification, investigation and reporting of the incident will be
conducted in accordance with the site HSE Plan.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Shutdown Schedule

TIME ACTIVITY RESPONSIBLE

12:00 MN Close the waterline main OKADA FM (Assisted by

isolation valve. WEL)

12:15 PM Drain the system by WEL

opening the waterline
valve which serves as a
temporary drain valve.

1:15 AM Cut the PPR pipes using WEL

a pipe cutting tool.

1:45 AM Join the pipes using WEL

fusion machine.

2:45 AM Perform Disinfection & WEL

Hydrostatic Test by
closing the temporary
drain valve and observe
the pipe if there’s any
leak upon reaching the
maintaining pressure.
Record the pressure
reading as initial reading.

5:45 AM Energize the system by WEL

opening the main
waterline isolation valve.
If leaks are found, repair
the system by shutting
down again the system.
Draining of the system
and repair of fusion of
joints will take about 1
hour.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

JOB HAZARD ANALYSIS (JHA)

JOB DESCRIPTION: SCAFFOLD ERECTION JHA Ref. No.

Facility: Work Area / Equipment: Permit No.

Date:

PERSONAL PROTECTIVE EQUIPMENT: Hard Hat, Safety Shoes, Hand Gloves, Safety Harness.

ABATEMENT ACCTIONS
TASK/ POTENTIAL HAZARDS/ Yes
PROCEDURE RISK / No Engineering Controls, Administrative Controls, PPE

Damage to onsite
detectors / switches /  Take extreme care during erection and override
transmitters etc. it if needed.

 Provide guardrail & toe board to prevent falling

of tools / objects.
 Don’t keep the unnecessary materials on the
Fall of objects / Tools. scaffold platform.
 Hand tools to be tied with permanent structure
or person.
 If required barricade the area during erection
work.
Accidental Fall of Person  The Scaffolder must use Safety Harness to
prevent accidental fall .
Erection & Use
of Scaffolding  The scaffold must be inspected, certified &
Unstable Scaffold
tagged by the competent person confirming its
suitability.
Weak Scaffold  The scaffold tag must indicate the maximum
load that it can bear.
 The scaffolding is to be inspected at least
Damaged Scaffold weekly for any damage due to weather
condition (rain, high wind etc) or other unsafe
conditions.
Modified Scaffold  In case of any modification, addition in the
scaffold, it has to be re-inspected & certified.
Improperly Supported  Ensure Scaffold is securely supported on a
Scaffold rigid ground and not on process piping / vessel
or equipment.
Incomplete Scaffold  Do not use if green Tag is missing.
 Do not use if red tag is available.
Name: Designation:
Line Officer Company: Date:
Signature Controlling Team:
Signature:

JOB HAZARD ANALYSIS
JOB DESCRIPTION: PRE- FABRICATION / INSTALATION OF PIPES / PRE
TAPPING
Facility: Work Area / Equipment:
PERSONAL PROTECTIVE EQUIPMENT: Hard Hat, Safety Shoes, Hand Gloves, Dusk Mask, Face Shield
TASK/
POTENTIAL HAZARDS/ RISK
PROCEDURE
Falling object
Fall of personnel.
Stability of the side wall.
Electrocution due to
FABRICATION OF
PIPES substandard electrical cables
and connections
Improper use of speed cutter,
grinders.
Head injury due to non-
wearing of proper PPE.
Caught in between pipes
INSTALLATION
Falling of workers while
OF PIPES
installing pipes. Inadequate
lifelines for full body harness.
Material Handling Improper use of equipment’s
Issue Date June 10, 2019 Rev. No. 0
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010
JHA Ref. No.
Permit No.
Date:
ABATEMENT ACCTIONS
Yes /
No Engineering Controls, Administrative Controls, PPE
 No one will be allowed under suspended load.
 Ladder / Flat forms to be used & supported with
Scaffolding Proper width to be maintained for
movement of personals
 Regular inspection to be done to find out signs of
cracks.
 Regular inspection of electrical cables. Use of
standard and proper specifications of electrical
cables and wires at site. Use of proper
connections. Only qualified electrician to conduct
electrical works.
 Only qualified and competent workers shall
operate cutting machines. Orientation and training
of workers on proper operation of cutting
machines.
 Provision of required PPE, posting of signage,
orientation of all site workers.
 Competent workers shall perform the activity.
Follow work methodology.
 Proper installation of scaffolding and platforms.
Wearing of full body harness and continuous
awareness on fall protection.
 Use of PPE in handling materials, Follow properly
the work methodology, No shortcuts, Critical
inspection of the tools, materials and equipment’s
to be used at worksite.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Hot work
Heat Emission./ Heat
activities,
exposure Proper ventilation, use of PPE.
Fabrication

 Strict enforcement of EHS Rules and Regulations,

Slip and trip (same level) Regular housekeeping, Provision for clear access,
Use of PPE appropriate at the area such as but
not limited to head/foot protection and skull guard
Pipe fit up and
welding fusion
Hot work  Strict enforcement of EHS Rules and Regulations,
activities Process owner training on proper loading and
Caught in between (Pinch unloading of materials / materials handling,
Points) Periodic preventive maintenance of the
equipment. Use of PPE appropriate at the area
such as but not limited to head/foot protection and
skull guard and gloves
.

Name: Designation:
Line Officer Company: Date
Signature Controlling Team:
Signature:
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

JOB HAZARD ANALYSIS

JOB DESCRIPTION :PIPE FLUSH CLEANING JHA Ref. No.

Facility: Work Area / Equipment: Permit No.

Date:

PERSONAL PROTECTIVE EQUIPMENT: Hard Hat, Safety Shoes, Hand Gloves, Safety Harness.

ABATEMENT ACCTIONS
TASK/ Yes /
POTENTIAL HAZARDS/ RISK
PROCEDURE No Engineering Controls, Administrative Controls, PPE

Hazardous waste  Use appropriate PPE properly

Uncontrolled load.
 Work area clean of dirt and working tools
Fall and slip  Standing in the right position
Cleaning and
Pipe Leak  Ensure that wastes generated are placed in
flushing pipe shelters
Hose may break loose due to
 Completely remove weld slag, flux, debris, grease,
load overweight
oil and any foreign matter on the surfaces of field

 The person using the tool shall ensure the line of

fire path is clear prior to applying force to the tool

Name: Designation:
Line Officer Company: Date
Signature Controlling Team:
Signature:
 Issue Date June 10, 2019 Rev. No. 0
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

JOB HAZARD ANALYSIS

JOB DESCRIPTION: DISMANTLING OF SCAFFOLD JHA Ref. No.

Facility: Work Area / Equipment: Permit No.

Date:

PERSONAL PROTECTIVE EQUIPMENT: Hard Hat, Safety Shoes, Hand Gloves, Safety Harness.

ABATEMENT ACCTIONS
TASK/ Yes /
POTENTIAL HAZARDS/ RISK
PROCEDURE No Engineering Controls, Administrative Controls, PPE

Damage to onsite detectors or

 Take extreme care during removal and override it if
switches
needed.

 Take proper care while dismantling the scaffold to

prevent fall of scaffold parts.
Fall of objects / Tools.  Hand tools to be tied with permanent structure or
person.
 Use proper PPE during removal of scaffold.
Dismantling of  If required barricade the area during dismantle work.
Scaffold Accidental Fall of Person  The Scaffolder must use Safety Harness to prevent
accidental fall .
Unstable Scaffold  Inspect the scaffold for its stability & support before
removing in sequence. .
Loaded Scaffolding  Remove safely the load / equipment / plant from the
scaffold before dismantling the scaffold.
 The scaffolding is to be inspected for any damage
Damaged Scaffold before dismantling.
 Take extreme care while removing a loose part /
attachment from the scaffold.
 Arrange the dismantled parts of the scaffold and stack
Scattered Materials properly.
Housekeeping  Segregate different parts of scaffold and store it
separately.
Defective Part  Remove and discard the defective parts / attachment
from the scaffold storage.
Name: Designation:
Line Officer Company: Date
Signature Controlling Team:
Signature:
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Rev. Date Page No. 14/17
Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

7. GENERAL JOB HAZARD ANALYSIS

REGISTRY OF OCCUPATIONAL HEALTH / SAFETY HAZARDS

Additio Residual Risk

Current Risk Level nal
Hazard Health & Regulatory Current Control Measures Level
Sources Risk Measur
Code Hazards Provision and/or Programs P
PROXIMIT es
P I R R
Y Needed P D S R S/NS
T

DO 13 -
Caught in Competent workers shall
Installation of Rule 1410 Minor
1 between Injury perform the activity. Follow work 3 3 9 3
Pipes Construction damage
pipes methodology.
Safety
Falling of
workers while
installing DO 13 - Proper installation of scaffolding
pipes. Installation of Injury / Rule 1410 and platforms. Wearing of full Moderate
2 3 4 12 3
Inadequate Pipes Fatality Construction body harness and continuous Damage
lifelines for Safety awareness on fall protection.
full body
harness.
Fabrication
Regular inspection of electrical
Electrocution and Cutting
cables. Use of standard and
due to of pipe, DO13 - Rule
proper specifications of
substandard temporary Injury / 1210 - Minor
3 electrical cables and wires at 3 3 9 3
electrical lighting Fatality Electrical damage
site. Use of proper connections.
cables and fixtures. Use Safety
Only qualified electrician to
connections. of Power
conduct electrical works.
tools.
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Rev. Date Page No. 15/17
Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Add’l
Hazard Health & Regulatory Current Control Measures Residual Risk
Sources Risk Current Risk Level Measures
Code Hazards Provision and/or Programs Level
Needed
Only qualified and competent
Improper
DO 13 - workers shall operate cutting
use of Laceration /
Fabrication Rule 1410 - machines. Orientation and Minor
4 speed Amputations 3 3 9 3
areas. Construction training of workers on proper damage
cutter, / Fatality
Safety operation of cutting
grinders.
machines.

Head injury DO 13 -Rule

Delivery,
due to non- 1080 Provision of required PPE,
unloading Injury / Moderate
6 wearing of Personal posting of signage, 3 4 12 3
and lifting of Fatality Damage
proper Protective orientation of all site workers.
materials.
PPE. Equipment.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Add’l
Hazard Health & Regulatory Current Control Measures Residual Risk
Sources Risk Current Risk Level Measures
Code Hazards Provision and/or Programs Level
Needed

Hotwork
DO 13 - Gas
activities,
Illness, & Electric
Heat Fabrication Minor
8 Heat Welding and Proper ventilation, use of PPE. 3 3 9 3
emission and damage
stroke Cutting
Installation
Operation.
of pipes.

Hotwork DO 13 - Rule
activities, 1100 - Gas &
Illness,
Burn Fabrication Electric Minor
9 Heat Proper ventilation, use of PPE. 3 3 9 3
Hazards and Welding and damage
stroke
Installation Cutting
of pipes. Operation.

Use of PPE in handling

Material
DO 13 - Rule materials, Follow properly the
Handling
Installation Injury 1410 - work methodology, No shortcuts, Minor
10 (preparation 3 3 9 3
of pipes (hands) Construction Critical inspection of the tools, damage
transport
Safety materials and equipments to be
materials)
used at worksite.

Awareness on proper lifting

Injury technique during toolbox
Manual Pipe fit up DO 13 - Rule
(back meetings, Buddy system / group
lifting of and 1410 - Minor
11 injury – lifting during heavy load lifting, 3 3 9 3
construction welding Construction damage
ergono Use of mechanical lifting
materials fusion Safety
mics) equipment (crane, pulleys, etc)
when necessary
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Add’l
Hazard Health & Regulatory Current Control Measures Residual Risk
Sources Risk Current Risk Level Measures
Code Hazards Provision and/or Programs Level
Needed

Strict enforcement of EHS Rules

and Regulations, Regular
Pipe fit up Accident DO 13 - Rule
housekeeping, Provision for
Slip and trip and / 1410 - Minor
12 clear access, Use of PPE 3 3 9 3
(same level) welding Incident, Construction damage
appropriate at the area such as
fusion Injury Safety
but not limited to head/foot
protection and skull guard

Strict enforcement of EHS Rules

Installatio and Regulations, Process owner
n and training on proper loading and
Caught in removal of Accident Dole 13 - unloading of materials / materials
between piping / Rule 1410 - handling, Periodic preventive Minor
13 3 3 9 3
(Pinch tools, Incident, Construction maintenance of the equipment. damage
Points) equipment Injury Safety Use of PPE appropriate at the
and area such as but not limited to
materials head/foot protection and skull
guard and gloves

Orientation/induction of newly
Supervisors, Disregard
hired workers / supervisors,
foremen and EHS
OSHS D.O. Daily toolbox meeting, Constant
lead men not concerns / Accident
13 Section communication with supervisors
practicing Unaware / Minor
14 12: Safety during EHS Committee meeting, 3 3 9 3
safety while of EHS Incident, damage
and Health Strict enforcement of EHS Rules
leading / standards Injury
Information and Regulations, Constant
supervising and
monitoring of activities during
their workers practices
operation.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Add’l
Hazard Health & Regulatory Current Control Measures Residual Risk
Sources Risk Current Risk Level Measures
Code Hazards Provision and/or Programs Level
Needed

Ensure the pressure relieving

Exceeding Accident
Unaware device is set at maximum
Maximum / Minor
15 of testing allowable pressure for weakest 3 3 9 3
Allowable Incident, damage
method. portion of the segment to be
Pressure Injury
hydro-tested.

Keep away from the pressurized

segment of the system being
hydrotested.

Bursting Accident Monitor the pressure gauge from

Injury to of / a safe distance away from the Minor
16 3 3 9 3
Workers pressurize Incident, potential source of high pressure damage
d piping Injury jetting. (Such as Flange joint
etc.)

Ensure the workers are wearing

required PPE.

Never increase the hydrotest

Accident pressure more than the
Damage to Defective
/ maximum allowable pressure for Minor
17 equipment / gauge 3 3 9 3
Incident, the weakest portion in the damage
System manifold
Injury segment or pressure rating of
the hose and coupling.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

Add’l
Hazard Health & Regulatory Current Control Measures Residual Risk
Sources Risk Current Risk Level Measures
Code Hazards Provision and/or Programs Level
Needed
Disregard
Do not leave the pressurized
EHS
hose or pump unattended when
Un-attended concerns / Accident
the hydro-test is going on.
Pressurized Unaware / Minor
18 3 3 9 3
Tool / of EHS Incident, damage
Isolate the equipment from all
Equipment standards Injury
source of energy when not in
and
use.
practices

Accident Do not change (exceed /

Changing the Unaware
/ decrease) the duration of Minor
19 duration of of testing 3 3 9 3
Incident, hydrotest without permission damage
hydrotest. method.
Injury from OKADA FM.

Unsafe
Accident
depressurizat Unaware
/ Ensure the safe depressurization Minor
20 ion of of testing 3 3 9 3
Incident, of water in the system. damage
hydrotest method.
Injury
fluid.
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Prepared by: CMAS-QMR Approved by: President - WRS
Document No WP-OD-M-010

8. QUALITY CONTROL PROCEDURE

PREVENTIVE MEASURE /
ITEM POTENTIAL QUALITY DEFICIENCY
CHECKING METHOD
Check machine if its working
Fusion weld imperfection properly and ensure that the
1 operator is knowledgeable with the
proper use of the fusion machine.

9. RESPONSIBILITIES

The following key persons are responsible to implement the established QA / QC activities.

Project In-charge is responsible to organize and manage site planning, coordination to all
trades, control and supervise workforce to achieve the proper and safe execution of work.

Safety Officer is responsible for implementing the site for safe working procedure and to
ensure all the health & safety precautions in place during execution of the job.

General Foreman is responsible for site daily implementation and execution of this procedure.
He shall organize and manage all activities for the implementation of this procedure. Protective
measures and day-to-day activities.

Workers – execution of daily assigned task.

10. REFERENCES

10.1 WEL Safety Program