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Danet Abu Dhabi

Infrastructure & Roadworks
Contract - 100

2012/MS – 04 Rev 4 16
th
March 2008 Page 1 of 14






Method Statement
MS – 04
Proposed Pipeline Works
(Pressure Lines)


4 16/03/08
Engr. Ehab Hassan
Pr.Engr.
KN
N.S.Vijayakumar
QC Engr.
KN
Engr. Mohamed
Ashraf Ahmed
Sr. P.M.
KN
3 08/03/08
Engr. Ehab Hassan
Pr.Engr.
KN
N.S.Vijayakumar
QC Engr.
KN
Engr. Mohamed
Ashraf Ahmed
Sr. P.M.
KN
2 16/03/07
Engr. Sanjaykumar
Sr. QC Engr.
KN
Engr. Amr Fikry
C.M.
KN
Engr. Mohamed
Ashraf Ahmed
Sr. P.M.
KN
1 05/03/07
Engr. Ricky Khosla
(OE)
ADMAC
Engr. Khalid
Assaf (PM)
ADMAC
Mohamed Al
Shabasy (SM)
KN
0 30/09/06 Najjar (QS) ADMAC
Engr. Khalid
Assaf (PM)
ADMAC
Mohamed Al
Shabasy (SM)
KN
Revision Submitted Date Prepared by Checked by Issued by

Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 2 of 14



REVISIONS








4 16-03-08 Consultant, PMT comments incorporated and resubmitted for approval


3 08-03-08 Red sand Bedding and Wrapping Tape Systems Included


2 16.10.07 Consultant, PMT comments incorporated and resubmitted for approval
1 05.03.07

Comments incorporated and resubmitted for approval
0 30.09.06 Issued for Approval
Revision Date Description of Modifications

















Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 3 of 14




1.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 RESPONSIBILITIES

6.0 GENERAL

7.0 INSPECTION & TESTING

8.0 HEALTH & SAFETY

9.0 ATTACHMENTS


Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 4 of 14

1.SCOPE

This Method statement covers Pressure Pipeline works for
Water and Irrigation Pipeline network for Danet Abu Dhabi
Infrastructure Works project. which include dewatering,
excavation/formation, bedding of granular material, pipe
laying, pipe surround with gravel/red sand and Wrapping
tape for Water pipe line Network.
2. REFERENCES - Material Approval Requests :
Ms-29/Danet-100/KN/RS/06
MS-07/Danet100/KN/RS/06 Rev2
Ms-28/Danet-100/KN/RS/06 Rev 3
- Drawings :
Water Pipeline -Danet/KN/W/2000
Danet/KN/W/PR/2001, 2002, 2003
Irrigation Pipeline Danet/KN/IM/5000, 5001, 5002,
5003, 5004, 5005, 5006 & 5007
- Specifications : Volume 2A, Section 3, 4.21 & 6
- ADWEA Specifications for water works
- RFI/CIVIL/044 Rev. A dated 24 Feb. 2007 for
Working and Test Pressure
3. TOOLS & EQUIPMENT Typical Equipment

Dewatering Equipment
Excavator
Wheel Loader
Dump Trucks
Crane
Trailers
Plate Compactors
Hand Rollers
Warning Tape
Nylon Lifting Slings
Surveying Instruments

Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 5 of 14
4. RESPONSIBILITIES






contractor surveyor has to issue and record data such as
levels, alignment, coordinates, existing utilities value for
clearing, grading, excavation, formation, pipe bedding,
pipe laying, surround backfilling and other activities and to
ensure that the work is carried out according to site
engineer instructions.
Contractor Foreman has to supervise/organize the
clearing, grading, excavation, formation, pipe bedding,
pipe laying, wrapping, surround, backfilling and other
activities and to ensure that the work is carried out
according to site engineer instructions.
Contractor Site Engineer for raising/requesting
inspections, monitoring the works, Coordinate with the
Laboratory and site team for conducting all the tests at
various stages and to coordinate with consultant inspector
for inspection.
Contractor’s QA/QC, receives request from site engineer
and issues to consultant further on agreeing about the
time, Date and to ensure that the quality of the work is as
per specification.
contractor’s site Laboratory Technician, to provide the
laboratory all samples required at various stages
according to instructions from laboratory manager and
consultant.
contractor’s Laboratory Engineer/Manager, to ensure that
all samples provided at various stages are tested
according to specification and certified prior to forwarding
it to the consultant (Engineer/QA-QC) for approvals.


Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
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March 2008 Page 6 of 14

5. Procedure
The work will be carried out accordingly in the following phases:

- Dewatering (If required) (Method Statement – MS 02)

- Excavation/Formation (Method Statement – MS 03)

- Bedding – Red sand (Water Pipeline) (Method Statement – MS 03)

- Bedding – Red Sand (Mar/Ms/104/Danet/100/KN/Mas/08/0)

- Pipe Laying

- Pipe Wrapping

- Hydrostatic Pressure Test (in accordance with Contract specifications Clause 4.21 and RFI /
044 Rev. A)

- Pipe Surround – Red sand (Water Pipeline) (Method Statement – MS 03)

- Pipe Surround – Red Sand (Irrigation Pipeline, Ms-044/Danet-100/KN/RS/07)

- Backfilling (Method Statement MS 03)

- Embankment (Method Statement MS 03)

5.1 Surveying will be conducted according to MS-01.
5.2 De-watering (if required) will be conducted according to MS-02.
5.3 Excavation (including trial holes) will be conducted to the proper formation level
according to MS-03.
5.4 The soil at the formation level will be compacted as per MS 03.
5.6 After formation compaction is confirmed, compliant bedding will be prepared using
approved material (i.e. Red sand for Water pipeline – Ms-05/Danet-100/KN/RS/06 Rev1
& Redsand for Irrigation pipeline – Ms-044/Danet-100/KN/RS/07) according to the
specifications and as indicated in the approved shop drawings.

Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 7 of 14
5.7 Pipe Laying
a. Pipe shall be laid after the Wrapping tape System according to clause 6.0 by lowering it
manually (for light weight pipes) or by crane (using nylon slings to hold, for heavy weight
pipes) on the Red sand bedding.
b. The socket of the previously placed pipe will be cleaned, lubricated by putting the rubber
ring in the socket and applying liquid soap on the rubber rings, spigot and socket as per
specifications.
c. The spigot side will be pulled into the socket with the come-along jack until it is impeded
to the end of the socket.
d. After the pipe has been released to rest on the bedding, the joint gap, line and level are
checked.

6.0 Procedure for Anticorrosive pipe Wrapping Tape Systems
a. Ensure the outside of pipe and fitting is clean and dry.
b. Nylon brushes to be used for any cleaning.
c. Ensure the primer is thoroughly mixed and stored in clean containers.
d. Using the clean dry brush. Pre measured quantity of primer will be used for each pipe
length and applied evenly to achieve the coverage specified by the manufacturer.
e. When the primer is nearly dry (tack to touch) wrap the pipe using approved self adhesive
wrapping tape securing the required overlap securing sufficient tension.
f. Wrapping tapes shall be applied with 55% overlap and ensure the least 150mm overlap
when splicing the roll ends. Spigot ends of pipes will be free from wrapping for the length
required for connection purposes. No air pockets or separation underneath the wrapping
tape is allowed.
g. During the pipeline installation, the pipeline is covered with polyethylene sleeving as per
the specification. Joints and all uneven surface shall be covered with approved non shrink
non-drying mounding mastic filler compound compatible with tape to form a smooth
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Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 8 of 14
surface. For tape application the maximum slope of profile is 45 degree. Application of
filler will be on dry and clean surface and manufacturer’s recommendation will be applied.
6.1 Protection of flanged Joints in Buried Conditions
a. Lines area to be wrapped is extended 400mm on both side joint i.e.(800mm total length
irrespective of the diameter of the piping)
b. Clean and dry the outside surface.
c. Use clean dry brush apply the primer evenly on the prepared clean area.
d. Uneven surface of all joints and fitting shall be filled with approved non-shrink, non
drying mounding mastic filler.
e. Wrap the prepared joint with self adhesive tape of 55% overlap. The pipeline is covered
with polyethylene sleeve as per specification.

6.2 Cable / Pipe Connections
Welded stud and soldered cable / pipe connections shall be coated to the same standard as
the pipe to which it is attached. After completion of cable connection, the cable tail shall
be secured to the pipe with a lap of tape. The cable connection shall be cleaned, primed
and profiled with mastic before tape wrapping. Cleaning and priming shall be as detailed
above. The tape wrap shall have a minimum of three and a half circumferential overlap.
6.3 Bonding / Overlap of Backing
Where required the tape shall be capable of being cigarette wrapped around the pipe and
with the adhesive removed, the PVC backing shall be bonded over its full overlap to PVC
layer beneath with suitable PVC adhesive.

6.4 Inspection
a. Inspection of coated pipe joints, fittings etc. shall be visual for satisfactory adhesion and
100% holiday inspection by a holiday detector set at the working voltage. Third party is
the responsible for carrying out the holiday detection test for the pipe wrapping.
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Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 9 of 14
a. The applied tape shall be inspected to confirm that effective bond is formed between the
pipe surface and the tape. This inspection shall be carried out not less than 24 hours after
application. The working voltage shall be set at least twice per working day.
b. Specific inspection upon completion of works may be required by certain project
specifications.

6.5 Points To Note
a. Wrapping must be done in shaded area and wrapping should not be done under direct
sunlight. Whilst this may not affect the product’s performance properties, this makes the
SBS modified bituminous compound extremely sticky and cumbersome to handle.
Workers may also find difficulty in peeling off the release film in high ambient
temperatures.
b. Wrapping by hand or machine must be undertaken by experience personnel under proper
supervision. Unsatisfactory workmanship shall be rejected especially where overlaps are
not consistent and where rucking is evident.
c. Rucking, especially at in-situ joints is to be avoided. Awkward and abrupt changes in
shape shall be the subject of special attention and care during wrapping, ensuring
elimination of entry paths for ground water and ground salts. Angle and speed of
automated machines should be agreed upon (for necessary overlap as per specification)
and locked to ensure continuity and uniformity of wrapping.
d. Handling after wrapping, Cotton belts shall be used for lifting purpose.
e. Wrapped joints shall not be subject to pressure from lifting devices. All skis used to
support pipes shall be thoroughly padded.
f. Wrapped pipes must be supported on unwrapped ends of pipe and not laid on the ground
except as necessary in the trench for final positioning and laying.
g. Wrapped pipes shall be protected from direct sunlight at all times and laid in the trenches
as far as possible immediately after wrapping procedure is completed, and necessary
inspection / checks done.

Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 10 of 14
h. All Polybit Bitutape Pipe Wrapping Tape and its ancillary products (Bitutape Primer,
Bitutape Moulding Paste, Bitutape Outer Wrap) should be stored in cool, dry / conditioned
stores, covered, away from sunlight, at less than 30 deg. C temperature. Stocks should be
rotated on a first in / first out basis.
i. Tapes should be taken out from the conditioned stores just prior to application. Storing of
tapes at project site / wrapping yard without proper storage facility is not acceptable and
may affect application performance of the tape.

6.6 Backfilling
a. Once several pipes have been laid and checked for alignment and level, pipe surround
(Red Sand surround for Water pipeline & sand dune surround for Irrigation pipeline) shall
follow in layers of 150 mm thickness (compacted with hand rammers) until the required
level is reached as per the approved shop drawings.
b. Testing of laid pipe shall be carried out prior to the placement of pipe surround in
accordance with Contract specifications Clause 4.21 and RFI/44 Rev. A for pressure test
for water line and according to Contract specifications Clause 6.60.8.1 for Irrigation line.
c. Subsequent to pipe surround, backfilling will be done in accordance with MS – 03.
d. Followed by the backfilling, embankment construction will be carried out as per MS – 03.
7.0 INSPECTION & TESTING:

7.1 Hydrostatic Pressure Test
 Testing of laid pipe shall be carried out prior to the placement of pipe surround in
accordance with Contract specifications Clause 4.21 and RFI/44 Rev. A for Water line
and according to Contract specifications Clause 6.60.8.1 for Irrigation line.
Pressure and Leakage Test of Water Supply Network & Irrigation Pipeline
Preparation before commencing the Test
a) Each section of pipe under test will be properly sealed off and stop ends temporarily
anchored.
b) The pipeline to be partially backfilled with all joints and sockets to be exposed.

Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 11 of 14
c) Any valve included in the section shall be set in the open position.
d) Blank flanges shall be installed.
e) All concrete anchors or thrust blocks included in the section must have reached their
required 7 days strength.
Testing Procedure
a. The section of the pipeline shall be filled with normal drinking water or chlorinated water
at the lower end.
b. Pressure Gauge shall be fixed at the lowest point.
c. During the filling operation care will be taken to ensure that there is no entrapped air in
the section of the pipeline. It will be ensured that water cross section is fully flowing
through the air valve / nearest fire hydrant units before closing the system and applying
pressure. All peak points of the pipeline shall be adequately vented during the filling
operation to expel as much air as possible.
d. The pressure shall be raised to a test pressure of 13.5 bars and a graph of actual pressure
against volume of water used at intervals of 0.5 bars will be prepared. The pressure at the
lowest point of the section under test shall not exceed the above test pressure.
e. The test pressure shall be maintained for a period of 1 hour (by pumping if necessary).
f) The pump will then be disconnected and no further water be permitted to enter the
pipeline for a further period of three (3) hours.
g) At the end of this period the pressure shall be recorded and if the pressure is less than 12
bars, then pump shall be used and required quantity of water to be filled to restore the test
pressure shall be measured in litres.
h) The maximum acceptable leakages shall not exceed the following,
- For Water Network Supply - 0.02 litres per millimetre of nominal pipe diameter per
kilometre of pipeline per 24 hours for each bar head of test pressure applied.
- For Irrigation line – 3 litres per 1000m length per 25 mm nominal bore per 24 hours.
- The test procedure will be carried out in full coordination with ADDC and will be
according to ADWEA Specifications.

Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 12 of 14
Leakage Repair
a. Initially, locations of leakage (whether from the fittings used for testing or from the
pipeline joints) will be confirmed.
b. Once location of the leaks’ is/are confirmed, suitable measures will be taken to solve /
repair the same.
c. After repair works are completed pipeline will be re-tested according to the above
mentioned testing procedure (Point No. 2 of section 6).
Note:
See attached (Sketch 1 & 2) as attached detailing the Testing Equipments for Water Supply
Network & Irrigation line respectively.
7.2 Disinfection and Flushing (Only for Water Network Supply line)
Introduction
a. The quantity of water for flushing has to be calculated as 3 (three) times of volume of the
pipeline, the quantity available chlorine for disinfection has to be calculated as 20 mg/l.
b. Granular hypochlorite will be used with 62% available chlorine according to the required
quantity of the available chlorine of 20 mg/l.
Procedure
a. The pipeline is disinfected at the same time as the hydrostatic tests performed.
b. One end of the new installed pipeline has to be connected to the source of water (existing
pipeline, all water used for testing shall be of drinking quality).
c. The second end of the pipeline will be plugged with adequate flange, stop valve &
discharge hose.
d. Required quantity of granular hypochlorite is mixed with sufficient quantity of water.
e. Water is started to fill from the source and at the same time hypochlorite mixture is
injected from adjacent point to the source.
f. When the chlorine reaches at the second end of the line, stop valve is closed and to stop
further filling.


Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 13 of 14

g. Leave the chlorine inside the pipeline for 24 hours after which the line is flushed and
values for free chlorine and PH checked.
h. Samples will then be taken to the laboratory for testing.
i. The flushed water will then be discharged in to the Municipal Storm Water manhole
through a flexible hose pipe after obtaining necessary approval from the competent local
authority.
Note:
Acceptable value for free chlorine is 0.2 to 0.5 mg/l and for PH, it is 6.5 to 9.2 mg/l.


8.0 Prevention of fire Hazard
a. Bituminous wrapping tape, primer, solvents etc are fire hazardous materials these shall be
stored separately under closed store.
b. Fire extinguishers shall be kept in vicinity of wrapping stores.
c. No smoking sign/Fire hazard sign boards shall be visibly installed.

8.1 Confined Space

a. Continuous communication with the external outdoor personnel must be established.

8.2 Avoidance of eye and skin irritation

a. Wear eyes of face protection shield and hand gloves, Contact with the eye shall be
immediately attend by medic as per manufacturer safety data sheet.



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Danet Abu Dhabi


Infrastructure & Roadworks
Contract - 100



Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16
th
March 2008 Page 14 of 14



9. ATTACHMENTS
a. Inspection & Testing Plan (ITP/Pipeline/P/04 Rev. 1)
b. Complete safety shall be maintained during the execution of works as per reference
"Safe/01" (as attached).
c. Drawing No. DANET/KN/MISC/SK/302 - Water pipeline test method
d. Drawing No. DANET/KN/MISC/SK/303 - Irrigation pipeline test method

e. Water Network Pressure Test Certificate
f. Irrigation Line Pressure Test Certificate
g. Material Acceptance Certificate Form No : Mar 05
h. Material Receipt Inspection Report Form No : MRIR/01
i. Certified Applicators, Letter Ref No:2012/A1-2/MAA/419-07
j. Wrapping Tape Check List Form No:19
k. Survey and Setting out Check List No.24
l. Bedding and Pipe Laying Report Check List No.01

ITP Reference Number:
ITP/Pipeline/P/04
Rev. 3
Date: 16-03-2008
1
Establishing method
statement
Submit to Engineer Before work Approved document 1.37.2 (Volume 2A) H A R
2
Material submittal /
approvals
Submit to Engineer Before work Approved document 1.3 (Volume 2A) H H A S
3 Shop drawings Submit to Engineer Before work Approved document 1.5 (Volume 2A) H A R S
4 Material received on site
verifying the compliance of
received material
For each Item Approved MAR & MRIR Form 1.3 (Volume 2A) H H S
Att Form No.MIRIR/01 & MAR
05
5 Surveying ITP/Survey/01 Rev. 2 1.4 (Volume 2A) Att Form No.24
6 Excavation/Formation ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S Att Form No.24
7 Red Sand Bedding ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S S Att Form No.24
8
Anticorrosive pipe
Wrapping
Holiday Test ADWEA Spec w-p-ss-010
ADWEA Spec w-p-ss-
010
H W S S Att Form No.19
9 Pipe Laying
Checking levels &
Alignment
For every length
of Inspection
raised
Will be carried out according
approved shop drawings
Section 3 & 6 H H S S Att Form No.19, 24
10
Pipe surround and Pipe top
Level
ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S S
11 Hydro test of Pipe Hydrostatic Pressure Test
For every length
of Inspection
raised
Will be carried out according to
specification & RFI/44 Rev A
Section 4.21 &
RFI/44 Rev A
H H S S
Test Certificates (E-07.56.017,
Rev 0, MAR, Dated 05.01.2003 &
Form: Danet/IRR/PT/01, Rev 0)
12 Backfilling ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S S
12.1
Placing of selected Backfill
in Layers
ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S
12.2 Field Compaction ITP/Earthworks/03 Rev 5
Section 1.28.3.2
(Volume 2A)
H H H S
13
Disinfecation / Flushing for
water Pipes
Laboratory Test for chlorine
and PH value
Acceptable value for free chlorine is
0.2 to 0.5 mg/l and for PH, it is 6.5 to
9.2 mg/l
Section 7.2 H H S S
14 Embankment ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S Att Form No.19
Consultant
SIGN: SIGN:
NAME: NAME:
DATE: DATE:
Contractor
Contractor:
Inspection and Test Plan for:
Inspection Points: H= Hold Point, W= Witness Point, R= Review Point,
S= Surveillance, A=Approval, WAT=Water Net Works Consultant
Item No. Activity Description
Project Managers: Engineer / Engineer Representative:
Contract No: 100
KN Project No: 2012
Project Title: Danet Abu Dhabi
Infrastructure Works
ITP SIGN OFF – POST COMPLETION OF WORKS
Verifying Document / Report
Contractor Consultant WAT Testing Laboratory
Inspection Points
Legend: ITL= Independent Testing Laboratory, ITP= Inspection and Test Plan, CI= Comments
Incorporated
Proposed Pipeline works ( Pressure lines )
Inspection and Test
Activity
Acceptance Criteria Frequency
Specification
Reference
Location (for Post Completion signoff):
PMT