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Public Works Authority

DRAINAGE AFFAIRS
DOHA WEST SEWAGE TREATMENT WORKS
EXTENSION # 05
CONSULTANT

egis
CONTRACTOR

Suez Environment- Marubeni JV

SUB CONTRACTOR

ASIA TECH ENGINEERING &


CONTRACTING W.L.L
Method Statement for the Deflection Test
of GRP Pipe Lines

02

29.11.2015

05

JERIN JOY

NIDHIN

SABU

R.M.RAO

01

25.11.2015

07

JERIN JOY

NIDHIN

SABU

R.M.RAO

00

14.11.2015

05

JERIN JOY

NIDHIN

SABU

R.M.RAO

REV.

DATE

PAGES

PREPARED

CHECKED

REVIEWD

APPROVED

CLIENT APPRD

DOHA WEST SEWAGE TREATMENT WORKS EXT#5


Doc No: AT-SUEZ-MS-0022/15
METHOD STATEMENT FOR THE DEFLECTION TEST
OF GRP PIPE LINES

TABLE OF CONTENTS
1.

SCOPE

2.

PURPOSE

3.

APPLICABLE CODES, STANDARDS AND SPECIFICATIONS


3.1

4.

Standards, Specification and Procedures

DEFINITIONS AND ABBREVIATIONS


4.1

Definitions

4.2

Abbreviations

5. EQUIPMENT TO BE USED
5.1

Simple Mold

5.2

Manual Micrometer

6. CALIBRATION AND DEFLECTION LIMITATIONS


7. RESPONSIBILITY
8. DEFLECTION TEST PROCEDURE
8.1

General Requirements/Steps to be followed

9. METHOD FOR DEFLECTION CALCULATION


10. DEFLECTION LIMITATIONS
11. SAFETY PRECAUTIONS
12. ATTACHMENTS

Asiatech Copyright - No reproduction without permission

Rev. 02
Page 2 / 7

Date: 29/11/2015

DOHA WEST SEWAGE TREATMENT WORKS EXT#5


Doc No: AT-SUEZ-MS-0022/15
METHOD STATEMENT FOR THE DEFLECTION TEST
OF GRP PIPE LINES

1.

Rev. 02
Page 3 / 7

Date: 29/11/2015

SCOPE
This procedure describes the general requirements and procedure for vertical Deflection Testing to the
requirements of Flowtite GRP pipes and QCS 2010 standards. This procedure covers the requirement of
deflection test above DN 700 pipe lines after assembled and installed.

2.

PURPOSE
The purpose of this procedure is to familiarize all relevant personnel with the requirements for deflection testing
of piping systems by Asiatech and its subcontractors if any.

3.

APPLICABLE CODES, STANDARDS AND SPECIFICATION


3.1

Standards, Specification & Procedures


The latest issue of each of the following codes and standards shall be applied. The revisions to be used
shall be those in effect at the time of the purchase order is issued:
QCS2010
Qatar construction Standards 2010
ASME B 31.3
Process Piping
Fabrication and Installation Procedure (Method Statement) for GRP Piping

3.2

References
Line List
Piping class
HSE Plan
All related ITPs

4.

: DGT-X-LT-000-801
: Asiatech HSE Plan

DEFINITIONS AND ABBREVIATIONS


4.1

Definition
Project
Contractor
Consultant
Sub-Contractor

4.2

:
:
:
:

Doha West Sewage Treatment Project, Extension: 5


Suez Treatment Solutions Qatar
Egis
Asiatech Engineering & Contracting WLL

Abbreviations
SUEZ
HSE
ITP
GRP
QA/QC
BLDG
PTW

:
:
:
:
:
:
:

SUEZ Treatment Solutions Qatar


Health & Safety and Environment
Inspection & Test Plan
Glass Reinforced Plastic
Quality Assurance / Quality Control
Building
Permit to Work

Asiatech Copyright - No reproduction without permission

DOHA WEST SEWAGE TREATMENT WORKS EXT#5


Doc No: AT-SUEZ-MS-0022/15
METHOD STATEMENT FOR THE DEFLECTION TEST
OF GRP PIPE LINES

5.

Rev. 02
Page 4 / 7

Date: 29/11/2015

EQUIPMENT TO BE USED

5.1 Simple Mold


The equipment could be a simple cylinder shape mold having the calibrated OD with two hooks at both sides for
pulling and holding inside the pipeline.
Another option could be by using two steel bars (vertical and horizontal) with wheels fixed on a small truly shape
equipped also with two hooks for pulling and holding inside the pipeline (Refer below sketch).

5.2 Manual Micrometer


A tubular inside micrometer could be used to check the pipe deflected diameter for every location (refer below
sketch)

6.

CALIBRATION AND DEFLECTION LIMITATION


The equipment OD shall be calibrated to be the same as required max deflected ID of the GRP pipe with a
tolerance of +0.5 mm.
Example: Pipe ID = 590
The deflection test level = 1.5%

Asiatech Copyright - No reproduction without permission

DOHA WEST SEWAGE TREATMENT WORKS EXT#5


Doc No: AT-SUEZ-MS-0022/15
METHOD STATEMENT FOR THE DEFLECTION TEST
OF GRP PIPE LINES

Rev. 02
Page 5 / 7

Date: 29/11/2015

The calibrated OD of the equipment = 590-1.5*590/100 = 590-8.85 = 581.15 + 0.5 mm.

7.

RESPONSBILITIES
Piping Engineer shall be responsible for the preparation and performance of the test described in this
procedure.
Q/C Engineer shall review the system completion package to ensure that all the pre-test requirements have
been met as per this procedure.
Q/C Engineer shall submit an inspection notification to the client for review and approval of deflection test and
for approval.

8.

DEFLECTION TEST PROCEDURES


8.1General Requirements /steps to be followed
Deflection test generally applicable only for the underground backfilled pipes and pipe lines (Refer line
list DGT-X-LT-000-801)
Proper back filling and compaction is required to do the deflection test. And this test will be useful
means of checking that the installation requirement have been met and should be completed as soon
as possible after the installation is finished.
Check the pipes internally prior to start the deflection test in order to avoid any unwanted/foreign
material inside the pipes.
Each part of the installed pipeline shall be having a ROPE throughout the pipe line for pulling the
equipment 5.1 is used.
The pipe line shall be divided in to segments and each segment shall be tested independently by one
of the equipment mentioned in section 5.0.
The segments have been divided into 4 types;
1. Type1: The pipeline is straight and without any bend and different length. Pipe DN=<1400 mm.
2. Type2: The pipeline is having one bend only and different length from each side. Pipe DN=<1400
mm.
3. Type3: The pipeline is either straight or having bends and pipe diameter is DN>= 1400mm
4. Type4: This pipe line is having more than one bend and pipe diameter is < 1400mm
The deflection test shall be performed in two stages, initial and final.
The initial deflection test shall be performed after backfilling the surround material only around
300mm above the pipe crown.
The final deflection test shall be performed after complete backfilling to the final ground level.
The equipment 5.1 will be tied with two ropes, the one inside the pipeline which is already laid along
with pipes and the other from the back side.
Pull the equipment from one end to the other carefully to avoid any damage for the pipe.

Asiatech Copyright - No reproduction without permission

DOHA WEST SEWAGE TREATMENT WORKS EXT#5


Doc No: AT-SUEZ-MS-0022/15
METHOD STATEMENT FOR THE DEFLECTION TEST
OF GRP PIPE LINES

Rev. 02
Page 6 / 7

Date: 29/11/2015

One operator will pull the rope from other end of the pipeline continuously until it reaches to that end.
If there is more bends on the pipeline, deflection can be checked by using item# 5.2 micrometer, where
one technician can enter inside the pipe and check the ID at different locations and record the
readings.(Confined space trained person only can enter inside the pipe.)
Segment 4 is not possible to be checked by any methods it requires to split the pipeline in to two or
more segments to be one of the 5 segment types, since the chance for access an operator is
impossible.

9.

METHOD FOR DEFLECTION CALCULATION:

Actual Vertical I.D Installed Vertical I.D.


X 100

% Deflection =
Actual I.D

Vertical I.D + Horizontal I.D.


X 100

Actual I.D. =
2

Actual I.D. will be determinedbefore the line to be bacfilled, free from external constraint. Only socket coupling
installation is allowed.

10.

DEFLECTION LIMITATIONS

QCS 2010 requirement according:

Initial Deflection: 1.5%

Final deflection: 3.5%

Manufacturer Recommendation

Allowable vertical deflection: 3.5%

Nevertheless GRP pipe Manufacturer, could in a case by case basis, agreed with a deflection limitation up to the
QCS requirement (3.5%).

Asiatech Copyright - No reproduction without permission

DOHA WEST SEWAGE TREATMENT WORKS EXT#5


Doc No: AT-SUEZ-MS-0022/15
METHOD STATEMENT FOR THE DEFLECTION TEST
OF GRP PIPE LINES

11.

Rev. 02
Page 7 / 7

Date: 29/11/2015

SAFETY PRECAUTIONS

11.1 Warning signs shall be posted at appropriates locations for the duration of the tests.

11.2 Only authorized personnel shall be permitted to enter inside the pipe line to be deflection tested.

11.3 All necessary measures shall be taken to that all personnel are adequately protected during the course of
the test and no work shall be on the sections of the line for the duration of the tests. Care must be taken
when the persons enter inside the pipe due to the likely risk of contaminants, and gas etc...
This must be carefully selected and agreed with site HSE so as not to affect the personal and the other
work areas.

12.

ATTACHMENTS

Asiatech Copyright - No reproduction without permission

RISK ASSESSMENT
Risk Assessment

Risk Assessment Area


Occupational Health &safety
&safety Safety
Environment
Quality

Sl
No

Description of
Activity

1.

Site
Preparation

2.

Enter
inside the Pipe
(Confined
Space entry)

S
E
Q

Hazard Potential and


Consequences

DEFLECTION TEST

Risk
L/M/H

Personal Injury/ Serious 3


Injury / Property Damage
and
Heat
Stress
the
personals

DOC NO:

RA-AT-SUEZ-020

Contract No.
DW5-001-2015
Date: 21/12/2015

Precautionary Measures and Safeguards


to control the risk

Risk
L/M/H

Med

Before Star the work conduct the Tool box Talk 3


Meeting
Ensure First Aid kit should be available always
during the work period.
Ensure emergency contact numbers should be
displayed
Ensure all personals to be instructed as to the
symptoms of Heat Stress and how to deal with
suspected cases.
Access should check before enter inside the
chamber
Work area must be clean from all obstructions
Area should be barricade
Check the work permit

Low

High

Ensure a valid permit to work


3
Check the gas level to ensure no toxic gas
presence in the pipe.
Provide duct type exhaust fan.
Ensure, no personnel should enter the pipe the
oxygen level is low.
Proper access to be provided
Only trained (Confined space entry) personnel
shall enter inside the pipe.
Attendant shall be present all the time at the
entrance
Ensure continuous monitoring of gas level and
its to be recorded.

Low

3.

Climate
(Weather
Condition)

Property Damage / Personal 3


Injury

4.

Bolt Nut Fixing

Falling
Injury/

Hazards/

5.

Use of PPE

Personal Injury

Med

Personal 3

Med

Med

Ensure Weather condition poor we should plan 3


before starting the job
In case rain / sand storm will comes we should
proper cover the any electrical, Electronic
equipment and stop the all cranes the wind
pressure above 30 km/h.
Ensure while raining time work will stop.
Ensure bolt nuts tighten only Calibrated Torque 3
ranch
Ensure correct size nut bolts can use.
Ensure worn appropriate PPEs

Ensure that all persons using proper PPE such 3


as Safety helmet, goggles, hand gloves, safety
shoes,

Low

Low

Low

Personnel should wear necessary safety


protective Equipment during work and it should
be related that particular activity.

Prepared By : EMMANUEL-HSE SUPERVISOR

Signature :

Date : _____21/12/2015______________

Checked By : BIJU PONNAN-WORK SUPERVISOR

Signature :

Date : ____ 21/12/2015_______________

Approved By : NIDHIN THAMPY-SITE MANAGER

Signature :

Date : ____21/12/2015_____________

LOW = GREEN

P = Probability

MED = ORANGE

C = Consequence

HIGH = RED

R = Risk Level