MS & RA Combined

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Pu b l i c W o r k s A u t h o r i t yD R A I N A G E A F F A I R S

DOHA WEST SEWAGE TREATMENT WORKSEXTENSION # 05

egis

CONTRACTOR

Suez Environment- Marubeni JV


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DOHA WEST SEWAGE TREATMENT WORKS EXT#5

METHOD STATEMENT FOR THE INSTALLATION OFGRP PIPELINES FOR PARTIAL UG NETWORK

Doc No: AT-SUEZ-MS-0017/15

Rev. 03

Page 3 / 23 Date: 31/12/2015

1. PURPOSE The purpose of this procedure/method statement is to provide the minimum requirements for the

handling&Installationof following GRP pipelinesof partial UG Network (Drawing shown below) at Doha West

Sewage Treatment Plant Extension 5 works as per project standard and specification:

a. 482B_ECA101A - Clarified water connection.

b. 482B_ECA101B - Clarified water connection.

c. 539_ESA008_ - Equalization tank - Waste water pump common header underground.

d. 488C_BAC011_ - SAS to Balancing Tank 610B.

g. 582_1ECA008_ - Line from PSF pumps to PSF header.

h. 582_2ECA008_ - Line from PSF pumps to PSF header.

i. 929_EID001_ - Industrial water supply to industrial water network.

j. 929_EID002_ - Industrial water supply to industrial water network.


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2. SCOPE The scope of this procedure describes the general requirements and procedure for the Transportation,

Offloading & Installation of following GRP pipelines:

a.482B_ECA101A

b. 482B_ECA101B

c. 539_ESA008_

d. 488C_BAC011_

g. 582_1ECA008_

h. 582_2ECA008_

i. 929_EID001_

j. 929_EID002_

as per the requirement of client for “Doha West Sewage Treatment Plant Extension 5 works”.

3. APPLICABLE CODES, STANDARDS AND REFERENCES

QCS 2010

General arrangement drawings:

DGT-M-DA-482-801

DGT-M-DA-581-801

DGT-M-DA-581-802

DGT M DA 581 803


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4. DEFINITIONS AND ABBREVIATIONS 1. Definition

Pipes : Circular tubes through which fluid can flow

Installation : Material transport and handling, pipe laying including the complete operationof laying, jointing and testing pipes in trenches.

Pipeline : long, continuous line of pipes and fittings including valves and ancillary structures

Plant : Doha West STP

Client : Suez Environment Marubeni JV

Consultant : Egis.

Contractor : Asiatech Engineering & Contracting WLL

2. Abbreviation

SUEZ : Suez Environment

HSE : Health, Safety & Environment

BLDG. : Building

GRP : Glass Reinforced Plastic

UG : Under Ground

PTW : Permit To work

QA/QC : Quality Assurance / Quality Control

5. RESPONSIBILITY


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Project Manager:Shallberesponsible for the execution of the projectactivities as per this procedure and to

ensure that works are taken in safe manner, to the requisite quality and to agreed time scale.

Site Engineer:Shallreview the work and liaises with QA/QC to jointly ensure that all the QC documents are

properly maintained.

Supervisor:Shall be responsible along with the safety officer to ensure the required compliance to safe

working practices. He shall arrange all necessary equipment, tools and tackles with the other related team

and direct /guide the work force.

QA/QC Engineer/Inspector : In conjunction with the Engineer, is responsible and dedicated for inspection

and quality control in accordance with the specification. Any non-compliance must be reported to the

concerned manager and be guided by him to resolve the same.

Safety Off icer:Shall be responsible for the implementation of safety procedures on site. And he will ensure

that the work will be proceeded in accordance with the safety procedure/policy and are undertaken in asafe and proper manner.

6. MATERIALSHANDLING AND STORAGE

1. Collect the required permanent materials from the client for the installation work.

2. Before receiving the material check for the permanent identification like nominal diameter, name of

manufacturer, iso number or any other references.

3. Transport, handling and storage of pipes and fittings shall be carried out as follows:

a) In accordance with the manufacturer’s recommendation.

b) Effective precaution shall be taken to prevent damage to the pipe and fitting.


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7. MANPOWER, TOOLS AND EQUIPMENT

1. Direct Manpower

- Supervisor - 01

- Safety Supervisor - 01

- QA/QC Inspector - 01

- Surveyor - 01

- Fitter - 04

- Helper - 06

- Rigger - 02

2. Tool s & Equipment

- Trailer - 01

- Crane 25T - 01

- Total Station - 01

- Fitter Tool Box - 04 set

- Chain puller - As per requirement

- Fabric slings- As per requirement

8. PROCEDURE


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Join ing of GRP pipes:

Joining of pipes shall be made as per the procedure and directions of pipe supplier. Thefollowing steps to be followed during installation of GRP pipes. There are different types methodof joining and the following joining method and procedure shall be applied;

All the pipes as per the required length shall be joined with coupling, which is called as double

bell coupling joint. The following steps shall be followed;

- Foundation & Bedding: The bed must be over excavated at each joint location to ensure

that the pipe will have continuous support and does not rest on the coupling. The

coupling area must be properly bedded and backfilled after the joint assembly completed.

- Cleaning of Coupling: All the coupling grooves and other parts shall be thoroughly

cleaned to ensure no dirt, presence of oil and any other unwanted particles inside thecoupling and its groove. (see below cleaning method)


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- Clean and Lubricate Spigots: Clean thoroughly the pipe spigots to remove any dirt, grit, grease and

other unwanted/foreign materials (see below picture). Inspect the spigot sealing surface for possible

damage and apply a thin layer of lubricant to the spigots from the end to the black alignment stripe.

Keep clean both the coupling and spigot until completion of insertion.

- Coupling shall be mounted on one pipe, prior join two pipes together, by using clamp or sling

around the pipe at a distance of 1 to 2 meter from the spigot on to which the coupling will be

mounted.

- Make sure that the coupling as well as the pipe should have enough gaps from the ground or at

least 100 mm above the ground level to keep away from dirt. Other techniques may also be used


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The final spool or the closure spool to be installed will be DSP spools, in some cases it will be the

rocker pipes with DSP.

Select two couplings to be installed and place one coupling square onto the end of closure pipe (with


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- Flanged Joints : GRP flanges shall be joined according to the following procedure;

1. Clean the flange face thoroughly and the O-ring groove as well

2. Ensure the sealing gasket / O-ring is clean and undamaged.

3. Position the sealing gasket/ O-ring in the cleaned groove and be secured with small strips of

tape or adhesive.

4. Align flanges to be joined and tightened with required bolts, nuts and washers.

5. Tighten all the bolts by using proper spanners/torque wrench and check the torque value with

Manufacturer.

6. Check all the bolts once again after one hour to ensure the bolts are properly tightened or to

adjust to get the required torque value if necessary.


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It is important that to control the bolting torque of the flexible steel coupling. Do not over

tight/torque these coupling bolts and follow only manufactures recommended assembly

instructions, but with the pipe supplier’s recommended bolt torque limits.

Mechanical Steel Couplings: Mechanical couplings have been successfully to join pipes ofdifferent materials and diameters, and to adapt to flange outlets. If a mechanical coupling is used

to join GRP to another pipe material then only mechanical coupling with dual independent bolting

system shall be used (see below picture). This allows for the independent tightening of the GRP

pipe side, which typically requires less torque than recommended by the coupling supplier.


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9. INSTALLATION SEQUENCE FOR PARTIAL UG NETWORK

Partial UG Network is divided into two zones as per the drawing shown.


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General Layout


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Zone 1 installation sequence:

Station A-A:

C O P

+ 3 9 3 5 0

C O P

+ 4 0 5 0 0

B O P

+ 4 0 4 5 5

C O

P + 3 9 5 0 0

B O P + 3 9 0 9 0

B O P + 3 8

6 3 4

B O P + 4 0 2 8 7

SECTION : A-A

Ø 1 4 0 0

Ø 1 4 0 0

Ø 8 0 0

Ø 4 0 0

Ø 8 0

Ø 8 0

488C_BAC011

539_ESA 008 929_EID001 929_EID002

482B_ECA101B

2150

482B_ECA101A

2500

1500

1450

1510

Station A-A location:

53,600 mm from 482 B (puddle included).

North coordinate: 505000.


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Station B-B:

C O P + 3 9 3 5 0

B O P

+ 3 8 6 3 4

SECTION : B-B

Ø 1 4 0 0

Ø 1 4 0 0

482B_ECA101B 482B_ECA101A

3000

Station B-B:

49.515 mm from 581(puddle pipe included)..

E t di t 631550


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1. 482B_ECA101A/B: the installation of both the lines will be carried out in parallel

a. General Installation Procedure will be followed to install both the pipelines

b. The sequence of installation of pipes will be based on the attached drawing AQAP-0501-15-JC& AQAP-0502-15-JC

c. After completing the installation of the both pipeline carry out visual inspection and proceed to installnext line in the sequence.

2. 539_ESA008 (Approx. 162 mtr)

a. General Installation Procedure will be followed to install the pipelines

b. The sequence of installation of pipes will be based on the attached drawing AQAP-0504-15-JC

c. After completing the installation of the pipeline carry out visual inspection and proceed to install


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c. After completing the installation of the both pipeline carry out visual inspection and for carrying outthe various test based on line list DGT-X-LT-000-801-B and inspection based on approved ITP.

Line will be partially backfilled keeping coupling area clear for the hydro-test.Hydro-test and deflection test procedures are submitted separately.

Backfilling sequence will be part of civil works method statement

Zone 2 installation sequence:

Station C-C:

Ø 1 4 0 0

Ø 1 4 0 0

Ø 8 0 0

Ø 8 0

Ø 8 0

B O P

+ 3 6 7 7 9

C O P

+ 3 7 1 8 9

C O P

+ 3

7 5 0 0

B O P

+ 3 6 7 8 4

C O P + 3 9 5 0 0

B O P

+ 3 9 3 6 4

929_EID001

929_EID002

539_ESA 008

582_2ECA 008

582_1ECA 008

3000 2500 1000

500


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1. 582_1ECA008 / 582_2ECA008 :The installation of both the lines will be carried out in parallel

a. General Installation Procedure will be followed to install both the pipelines

b. The sequence of installation of pipes will be based on the attached drawing AQAP-0507-15-JC& AQAP-0508-15-JC

b. After completing the installation of the both pipeline carry out visual inspection and proceed toinstall next line in the sequence.

2. 539_ESA008 (Continuation from Zone 1 to Trench li mit

a. General Installation Procedure will be followed to install the pipelines

c. The sequence of installation of pipes will be based on the attached drawing AQAP-0504-15-JC

d. After completing the installation of the pipeline carry out visual inspection and proceed to installnext line in the sequence.


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& AQAP-0522-15-JC

c. After completing the installation of the both pipeline carry out visual inspection and for carrying outthe various test based on line list DGT-X-LT-000-801-B and inspection based on approved ITP.

Lines will be partially backfilled keeping coupling area clear for the hydro-test.Hydro-test and deflection testprocedures are submitted separately.Hydro-test and deflection test procedures are submitted separately.

Backfilling sequence will be part of civil works method statement.

10. SAFETY PRECAUTIONS

a) Isolate the area with proper barrier and warning tape in order to control unauthorized entry to the

working area.

b) Provide common safety equipment at site (fire extinguisher, bucket with sand, fire watch etc.) in

accordance with fire and safety regulations.

c) Prior to start the activity; ensure that all work permit have been obtained from concerned authorities as

per the general site requirements.

d) Ensure that all lifting equipment shall be certified and the lift/drop zone shall be barricaded with warning

tape and sign boards.

e) Daily tool box talk shall be conducted by the supervisor prior to commencement of each day activity.


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LIFTING ARRANGEMENT


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C C


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Typical Sections.

ASIATECH

9500

SECTION : X-X

Ø 1 4 0 0 Ø 1 4 0 0

Ø 8 0 0

Ø 4 0 0 Ø 8 0

Ø 8 0

8500 8500

639929_EID002

482B_ECA101A 482B_ECA101B

488C_BAC011

539_ESA 008

929_EID001


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METHOD STATEMENT FOR THE INSTALLATION OF

GRP PIPELINES FOR PARTIAL UG NETWORK


Rev. 02

Date: 13/12/2015

SEQUENCE OF INSTALLATION


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Rev. 02

Date: 13/12/2015

INSPECTION & TEST PLAN


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Doc. No.:

Rev. No.:

Date:

PIPING

DGT-ME-0-IT-0028

0

26/11/2014

Inspection Test Plan

Doha West Sewage Treatment Works Ext 4

UNDERGROUND GRP PIPING INSTALLATION

Activity:

Location / WorkLot

TypeName /

SignatureType

Name /

SignatureType

Name /

Signature

0

0.1 100%Lamination procdure

No

Manufacturer

recommendation, project

specification

Approved lamination

procedureH A R

0.2 100%Lamination procdure

Manufacturer

recommendation, projectLaminator Qualification

H A R

Fit up training

certifciate to be

RFI is not resquested

RFI is resquested

Equipment / Tag N° or Line Ref.:

Subcontractor/ N°:

SUEZ

Inspection

SUBCONTRACTOR

InspectionInspection / Test Activity

EGIS

InspectionITP Item No. Frequency ITR N° applied Acceptance criteria Documentation Comments

Review of Procedures & Qualifications

Lamination procedure

GRP Laminators Qualificationo

,

specificationecor

included as well

1

1.1 100% DGT-ME -0-TR-001

Approved drawing &

applicable material

specification, relevant

project specification

Material Delivery Note H M -

1.2 100% DGT-ME -0-TR-003

Relevant project

specification,

manufacturer standards

Material Delivery Note H R -

2

2.1 100% DGT-ME -0-TR-004

Manufacturer


specification

H W W** For puddle pipe only

other wise blank

Lamination kits and consumables inspection

Trench readiness inspection and Puddle Survey

Free issue material inspection

Material Control

Pipe and Spool Erection

2.2 100% DGT-ME -0-TR-005Project specification,

scope of workIsometric Drawing H W R

First spool to be

installed to be inspected

2.3 100%DGT-ME-0-TR-002

DGT-ME-0-TR-007

Manufacturer


specification

Approved lamination

procedureH W R

Inspection during

jointing, edge

preparation, bevels,

cleaning, root gap,

composition and layers,

lamination length,

thickness, Barcol test

2.4 100%DGT-ME-0-TR-006

DGT-ME-0-TR-012

Check Coordonates,

Spool N° Location as per

Isometrics.

Isometric Drawing H H WRelease for Pipe partial

bacfilling

Line Setting out and Survey for first spool locations and

identification.

Line installation completness check (including valves,

instruments….)

Field Butt-Wrap & Coupling joins (when cuttings are done at

site).


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Doc. No.:

Rev. No.:

Date:

PIPING

DGT-ME-0-IT-0028

0

26/11/2014

Inspection Test Plan

Doha West Sewage Treatment Works Ext 4

UNDERGROUND GRP PIPING INSTALLATION

Activity:

Location / WorkLot

TypeName /

SignatureType

Name /

SignatureType

Name /

Signature

RFI is not resquested

RFI is resquested

Equipment / Tag N° or Line Ref.:

Subcontractor/ N°:

SUEZ

Inspection

SUBCONTRACTOR

InspectionInspection / Test Activity

EGIS

InspectionITP Item No. Frequency ITR N° applied Acceptance criteria Documentation Comments

3

3.1 100% DGT-ME -0-TR-008Proper Isolation and

Safe condition provided

Isometric Drawing and

P&IDH W -

Not apply for Visual

inspection

3.2 100%DGT-ME-0-TR-009

DGT-X-LT-000-801, Pipe

Testin rocedures, H H W

Release for Pipe testing

Pipe Testing: Pressure Test, Visual Inspection, Deflection

Flushing & Pipe Testing

.DGT-ME-0-TR-013

,

Project Specification

3.3 100% DGT-ME -0-TR-010 H W -

3.4 100% DGT-ME -0-TR-011 P&IDIsometric Drawing and

Red Mark up drawingsH H W

4

4.1 100%

As per Hand Over

Procedure

DGT-Z-IA-000-001

ITP Signed off with all

ITR uploaded to PWWorkpack procedure H R R

Once to worklot is

completed

4.2 100%Red Mark up

DrawingsRed Mark up Drawings H R R

Flushing of process line (or cleaning when flushing is not

appicable).

TYPE OF INSPECTIPONComment:

Test, Air test.

QA/QC documentation

Documentation

Final Installation after reinstatement

Red Mark up Drawings

M: Monitor

R: Review of document

A: Approval

H: Hold point

W: Witness



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Rev. 02

Date: 13/12/2015

RISK ASSESSMENT


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RISK ASSESSMENT

Risk Assessment Area Risk Assess ment DOC NO: RA-AT-SUEZ-019

Occupational Health &safety S

GRP PARTIAL UG PIPE INSTALLATION

Contract No. DW5-001-2015

Environment E Date : 31/12/2015Quality Q

SlNo

Description of Act ivi ty

Hazard Potential andConsequences

P C RiskL/M/H

Precautionary Measures and Safeguardsto control the risk

P C RiskL/M/H

1. SitePreparation

Personal Injury/ SeriousInjury / Property Damageand Heat Stress thepersonals / Personal Injuryduring Manual handling /Slips, trips and falls due to

Uneven ground surface orslippery surface / SharpObject in leveled area couldcause Foot injuries.

3 2 Med Obtain PTW and prepare JSA prior to start thework.

Before Start of the work conduct the Tool boxTalk Meeting

Ensure First Aid kit should be available alwaysduring the work period.

Ensure emergency contact numbers should bedisplayed

Ensure all personals to be instructed as to thesymptoms of Heat Stress and how to deal withsuspected cases.

Employees to wear mandatory PPE all timeduring work and has to wear task oriented PPEif it is required.

All the Personnel involved must be trained andcompetent

Access should check before enter inside thechamber

Access and egress must be clear all timeduring work and suitable lights need to beprovided in access and egress area for thenight shift.

Work area must be clean from all obstructions Area should be barricade Select proper suitable certified Cranes Check the work permit Supervision is mandatory during the activity Entry for Un-authorized personnel must be

prohibited in the working area

3 1 Low


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Appropriate signage must be placed.

2. Critical Lifting Boom truck failure/Riggergear failure, lift due to strongwind/stand storm poorvisibility, /Serious Death,Serious injury, PropertyDamage.

3 4 High Use proper Use PPE ‘s at all times Ensure all riggers should be certified by

approved third party rigging and slingingtraining.

Crane operator must be trained, competentand certified by third party.

Adequate access at lifting vicinity should bemaintained

Safety Officer should closed monitoring ofErection of Structure erection activity closely incase any problems he can stop the work

Certified cranes shall be used. PTW must be implemented. Critical or common lifting must be carried out

under the supervision of trained and competentlifting supervisor and supervisor must bepresent all time during the activity.

Critical lifting must be carried out as per the

lifting plan and lifting procedure. Over sized slings and shackles are used to

minimize rigging gear failure. All personnel involved in lifting must be

properly instructed and familiarized with alllifting plan details.

Crane boom swing movement should notobstruct other facilities.

Site pro-lift meeting will be held for finalinstructions and personnel conditionverification.

Only personnel involved in the lifting will be

present at site. Under no circumstances lifting will be started if

wind speed is higher than 30km/h All lifting activities will be carried out during day

time to ensure best visibility. Don’t allow people to work directly below load

being lifted or under suspended load Tag line should tied at both end of lifting

objects Tool box talk should be conducted before

proceeding to work.

3 1 Low


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Lifting area must be segregated andbarricaded with appropriate signage.

3. Climate(WeatherCondition)

Property Damage / PersonalInjury

3 2 Med Ensure Weather condition is good beforestarting the job

In case rain / sand storm will comes we shouldproperly cover any electrical, Electronic

equipment and stop the all cranes for the windspeed above 30 km/h.

Ensure while raining time to stop any liftingactivity.

3 1 Low

4. ElectricalCables

Personal Injury / SeriousInjury / Property Damage

3 4 High Electrical Cables should be free of any wear ordamages.

MCB & RCCB is required. Every week Electrical Supervisor or Electrician

Should check/inspect visibly and it should berecorded.

3 1 Low

5. Lifting

Operation indark time

Personal Injury / Serious

Injury / Property Damage

3 4 High Any lifting activity in evening (Dark time) time

should provide proper lighting. Lifting of materials in vertical position or

horizontal position by crane only Ensure trained rigging crew required All lifting Equipments should Certified by third

party.

3 1 Low

6. Cutting &Grinding

Personal injury / Burninginjury/ Property damage

3 4 High Ensure check the Hot work permit with validdate

Provide proper Fire Extinguisher (ABC) Ensure cutter should use face shield, apron,

etc... & proper PPE’s. Arrangement for sufficient passage of air Ensure work area always keep clean tied. Ensure any combustible materials area fire

watch person required Ensure Electrical cables are in good condition Check the Grinding machine in good condition Ensure grinding m/c have safety guard , handle Any electrical problems inform to maintenance

Electrician or Electrical Supervisor Maintain good house keeping

3 1 Low


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Ensure any flammable liquid in cutting areashould be removed and then start the job

7. Bolt Nut Fixing Falling Hazards/ PersonalInjury

3 2 Med Ensure bolt nuts tighten only using CalibratedTorque wrench

Ensure use of correct size nut bolts. Ensure use of appropriate PPEs

3 1 Low

8. Use of PPE Personal Injury 3 3 Med Ensure that all persons using proper PPE suchas Safety helmet, goggles, hand gloves, safetyshoes,

Personnel should wear necessary safetyprotective Equipment during work and it shouldbe related to that particular activity.

3 1 Low

Prepared By : EMMANUEL-HSE SUPERVISOR

Checked By : BIJU PONNAN-WORK SUPERVISOR

Approved By : NIDHIN THAMPY-SITE MANAGER

Signature :

Signature :

Signature :

Date : 31/12/2015

Date : 31/12/2015

Date : 31/12/2015

LOW = GREEN P = Probability

MED = ORANGE C = Consequence

HIGH = RED R = Risk Level

Documents

MS & RA Combined