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 Rev. 02
OF GRP PIPE LINES
Page 2 / 7 Date: 29/11/2015

TABLE OF CONTENTS

1. SCOPE

2. PURPOSE

3. APPLICABLE CODES, STANDARDS AND SPECIFICATIONS

3.1 Standards, Specification and Procedures

4. 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

 DOHA WEST SEWAGE TREATMENT WORKS EXT#5
Doc No: AT-SUEZ-MS-0022/15
METHOD STATEMENT FOR THE DEFLECTION TEST Rev. 02
OF GRP PIPE LINES
Page 3 / 7 Date: 29/11/2015

1. 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 : DGT-X-LT-000-801
Piping class
HSE Plan : Asiatech HSE Plan
All related ITPs

4. DEFINITIONS AND ABBREVIATIONS

4.1 Definition
Project : Doha West Sewage Treatment Project, Extension: 5
Contractor : Suez Treatment Solutions Qatar
Consultant : Egis
Sub-Contractor : Asiatech Engineering & Contracting WLL

4.2 Abbreviations
SUEZ : SUEZ Treatment Solutions Qatar
HSE : Health & Safety and Environment
ITP : Inspection & Test Plan
GRP : Glass Reinforced Plastic
QA/QC : Quality Assurance / Quality Control
BLDG : Building
PTW : 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 Rev. 02
OF GRP PIPE LINES
Page 4 / 7 Date: 29/11/2015

5. 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 Rev. 02
OF GRP PIPE LINES
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 Rev. 02
OF GRP PIPE LINES
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.

% Deflection = X 100
Actual I.D

Vertical I.D + Horizontal I.D.

Actual I.D. = X 100
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: Manufacturer Recommendation

- Initial Deflection: 1.5% Allowable vertical deflection: 3.5%

- Final 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 Rev. 02
OF GRP PIPE LINES
Page 7 / 7 Date: 29/11/2015

11. 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 Area Risk Assessment DOC NO: RA-AT-SUEZ-020

Occupational Health &safety S Contract No. DW5-001-2015

&safety Safety
Environment E DEFLECTION TEST Date: 21/12/2015
Quality Q

Sl Description of Hazard Potential and P C Risk Precautionary Measures and Safeguards P C Risk
No Activity Consequences L/M/H to control the risk L/M/H

1. Site Personal Injury/ Serious 3 2 Med  Before Star the work conduct the Tool box Talk 3 1 Low
Preparation Injury / Property Damage Meeting
and Heat Stress the  Ensure First Aid kit should be available always
personals 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

2. Enter 3 4 High  Ensure a valid permit to work 3 1 Low

inside the Pipe  Check the gas level to ensure no toxic gas
(Confined presence in the pipe.
Space entry)  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
it’s to be recorded.
3. Climate Property Damage / Personal 3 2 Med  Ensure Weather condition poor we should plan 3 1 Low
(Weather Injury before starting the job
Condition)
 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.
4. Bolt Nut Fixing Falling Hazards/ Personal 3 2 Med  Ensure bolt nuts tighten only Calibrated Torque 3 1 Low
Injury/ ranch
 Ensure correct size nut bolts can use.
 Ensure worn appropriate PPEs

5. Use of PPE Personal Injury 3 3 Med  Ensure that all persons using proper PPE such 3 1 Low
as Safety helmet, goggles, hand gloves, safety
shoes,

 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