Professional Documents
Culture Documents
Rev No: 00
Date:
Prepared by Reviewed by Approved by
Kumar Abhishek
REVISION HISTORY
Date of
Rev. No. Description of Change Author Reviewer
Revision
Page |1
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 2 of 19
Republic of Maldives.
Content
2.0 Scope
3.0 References
4.0 Responsibilities
5.0 Resources
6.0 Procedure
10.0 Attachments
Page |2
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 3 of 19
Republic of Maldives.
Page |4
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 5 of 19
Republic of Maldives.
Pipe laying line shall be marked with respect to datum reference line given by the
authority/customer. Marking shall be re-checked by the respective site Engineer
along with surveyor.
Page |5
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 6 of 19
Republic of Maldives.
fig- 4
6.6 Storage of Rubber Gaskets
Rubber gaskets are usually supplied in bags and should be stored in them itself
in a cool dark place.
Rubber Gaskets should be stored away from direct sources of heat and direct
sunlight.
Material should be issued from the stores in strict rotation of first come first out
basis.
Page |6
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 7 of 19
Republic of Maldives.
Make shoring and shuttering of timber planks or steel frame for excavation in
sandy soil or water bearing strata.
If the excavated soil is found sandy the same shall be used for backfilling
otherwise any other approved soil shall be used for backfilling. So dump the
excavated material away from the excavated pit, at least half the depth of
excavation.
Keep excavation pits free from water, use-dewatering pumps if required.
Page |7
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 8 of 19
Republic of Maldives.
Page |9
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 10 of 19
Republic of Maldives.
6.13 Jointing of Pipes:Two main types of joints are used with ductile iron pipes and
fittings:
I. Socket and spigot flexible joints:
1. Push on joints;
2. Mechanical joints;
II. Rigid flanged joint.
I. Flexible Joint
It incorporates gasket of elastomeric materials and the joints may be of the simple
push-on-type or the type where the seal is affected by the compression of a rubber
gasket between a seating on the inside of the socket and the external surface of
spigot. Joints of the latter type are referred to as mechanical joints. Both push-in
(See fig. 5A) and mechanical joints are flexible joints.
Flexible joints require to be externally anchored at all changes in direction such as
at bends, etc., and at blank end to resist the thrust created by internal pressure and
to prevent the withdrawal of spigots.
The DI pipes shall be push-on joined using socket and spigot type ends by placing
EPDM rubber gaskets between them.
fig - 5 A
Thoroughly clean the spigot and the interior of the socket. Clean gasket and insert
into socket with the square section gasket heel in the retaining groove and the
gasket fish tail towards the back of the socket.
Gasket should be kept in dark place (avoid sunlight), before using, it should be
ensured that there is no deformation and damage in gasket.
The insertion of gaskets is facilitated by folding the gasket as shown in (fig:5 A) by
looping it into a heart shape with the gasket fish tail towards the back of the socket
Apply radial pressure to the gasket at the heart shaped loop (or cross loops) to force
it into place. Check that the gasket is located correctly around its entire
circumference with the retaining heel firmly embedded in its seating. Apply a thin
film of lubricant (vegetable Grease) to the inside surface of the gasket and to the
outside surface of the spigot. Lubricant shall be a vegetable / food grade. Document
P a g e | 10
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 11 of 19
Republic of Maldives.
evidence is required. Support the pipe or fittings just clear of the trench bottom and
enter spigot into socket until contact is made. Push fit joints have the capability of
permitting both angular deflection and longitudinal movement within defined limits.
Joint Assembly:
Crowbar DN80 and DN 150: - Push against the end of the pipe socket face with
a crowbar or lever to complete the joint (see fig. a) below.
Chain Pulley DN80 to DN 500: - Where suitable equipment is available on site
joints can be made using the Chain Pulley. This method minimizes the human
effort required to make a joint and is widely used. Using this method, higher
Diameter Pipes can be joined properly. The pipes are locked using Chain pulley
(see fig-b). And by to-and-fro motion of the lever, pipes are slowly and steadily
joint each other and made to the correct insertion depth.
Other Methods: -Rack and lever, side-link tackle and hydraulic tackle can also
be used to joint integral pipes.
After successfully inserted the spigot, the joint should be thoroughly checked
whether it is correctly seated. This is done by inserting the metal rule into the socket
gap. If the depth of penetration is same circumferentially, then joint is ok. Any
difference in depth of penetration if found, the gasket may be displaced which prone
for leaking during hydro testing.
II. Flanged Joint
Flanged joints are made on pipes having a machined flange at each end of the pipe.
The seal is usually effected by means of a flat rubber gasket compressed between
two flanges by means of bolts which also serve to connect the pipe rigidly (see fig
5B). Gaskets of other materials, both metallic and non-metallic, are used for special
applications.
P a g e | 11
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 12 of 19
Republic of Maldives.
P a g e | 12
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 13 of 19
Republic of Maldives.
ii. Clean gasket and insert into socket with the square section gasket heel in the
retaining grove (fig 2)
iii. Coat with lubricating paste on the spigot end of the pipe and the exposed surface
of gasket. The gasket recess must not be coated with lubricating paste, except
for small diameter pipes or fitting when problems arise on fitting the gasket(fig 3)
Joint Assembly:
Prepare & lubricate the joint area & place pipe / fitting in position, ready for jointing.
P a g e | 13
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 14 of 19
Republic of Maldives.
Hold the socket end of the fitting with crowbars slightly dug into the ground and
anchored at the ears provided in the socket. Push the crowbar in a jerk
simultaneously. (See fig 1 & 2). Pipe socket face must be protected with a piece of
hard wood.
6.15 Valve Installation
All valves, gates, operators and appurtenances shall be installed with proper flow
direction in accordance with the approved drawings as per the specifications laid for
pipe laying to the locations indicated on the drawings. The installation shall be true
to alignment and rigidly supported. The nominal size and thickness of the flanges
shall be as defined for pressure rating conforming to IS 14486 /14845 PN 1.6.The
pressure rating of the flanges shall be equivalent to the valve with which they are
being installed. The selection of the flange out of these three ratings shall be based
on the design pressure at the place of installation
Valves shall be flanged and the flange face at right angles to the valve centerline.
Backside of valve flanges shall be machined or spot faced for proper seating of the
head and nut. Nuts and bolts shall be of the best quality bright steel, machined on
the shank and under the head and nut. Studs, bolts and nuts shall be galvanized.
Bolts shall be of accurate length so that only one thread shall show through the nut
in the fully tightened conditions. Grade of nuts and bolts shall be conforming to IS
1363:2002.
Throughout erection, the valves shall be supported properly on wooden sleepers,
etc. and shall be concreted immediately thereafter, as directed. Before the valves
are actually fixed, they shall be cleaned and greased and it should be seen that all
parts are in perfect working condition.
The hand wheels shall be provided with extension for easy grip. All operators when
fitted to the valve shaft must ensure clockwise closing and this must be indicated on
the housing.
6.16 Hydrostatic Testing:
After a new pipe line has been laid, jointed and back filled, it shall be subjected to
pressure test to ensure that pipes and joints are sound enough to withstand the
maximum pressure likely to be developed under working condition.
The test pressure should not be less than the following:
The maximum sustained operating pressure
The maximum static pressure + 0.5 N/mm2
The maximum sustained operating pressure (or the maximum static pressure) +
Maximum calculated surge pressure.
P a g e | 14
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 15 of 19
Republic of Maldives.
At the lower end the Calibrated pressure gauge and the connection to the pump
shall be established for testing the test pressure at the higher end with a valve for
air outlet.
If the pressure gauge cannot be installed at the lowest point of the pipeline, an
allowance in the test pressure to be read at the position of the gauge has to be made
accordingly
6.17 Pressure testing equipment: The test equipment’s shall be used
A suitable main pump for attaining the required pressure.
Calibrated pressure gauge with a range of 1.5 to 2 Times of testing pressure
(Calibration interval of pressure gauge shall be 6 months) If the range is not
available then it shall be 1.5 to 4 times
Flow regulating valve or Scour Valve for depressurizing of pipe line.
Stopwatch
Suitable stub ends, slip-on flanges, blank flanges fitted with drain valve, non-
return valve, necessary hoses of adequate pressure rating and couplers etc.
6.18 Sequence of Testing
The testing scheme shall be submitted to client prior to test.
For testing of pipe section, clean construction water shall be used.
Flushing shall be done before the start of hydro test through line scour valve.
During filling of water proper venting shall be done at highest point to remove all
the entrapped air Calibrated pressure gauge, one at pressurizing point and one
in end point shall be installed during testing.
First the test pressure in the pipe line section is raised from zero pressure to the
Nominal pressure or working pressure and hold for one hour.
The test pressure shall be measured at the lowest point of section under test or
suitable allowance on static head shall be made to ensure the test pressure does
not exceed the required test pressure.
The test pressure shall be applied and maintained for one hour. The minimum
test period shall not be less than 10 minutes.
If the visual inspection satisfies and there is no leakage in the pipes and joints
the test can be considered as passed.
If there is pressure drop during the test, water shall be pumped in to sufficiently
equalize the drop in pressure. The amount of water pumped in shall be carefully
measured in order to measure the leakage.
The area of defect shall be identified and repaired suitably, and the test shall be
repeated for the satisfaction of Engineer In-charge.
Readings at the location of the Pressure gauge to be noted during the testing
and the reading are tabulated
P a g e | 15
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 16 of 19
Republic of Maldives.
After completing the test, the ends shall be covered with dummies to ensure no
foreign particles shall be entered to the pipeline.
6.19 Back filling of Trenches
The excavated earth can be used to fill trench in layers with proper tamping. Taking
due care so that no damage is caused to the pipes.
7.0 Quality assurance
QA/QC personal shall check the materials at the receipt, storage and before use to
ensure Specifications Compliance.
DI Pipe size Dimension, Thickness shall be checked as per drawing and as per
inspection report.
DI Pipe Excavation, laying and jointing shall be checked as per code and
specification.
Both side gap of DI pipe should be 150 to 200 mm.
DI Pipe alignment shall be checked as per code and specification.
Hydro Test shall be checked as per approved drawing, specification and code.
Trench cover should be ensured 900-1100 mm.
8.0 Health and Safety
The health safety and environment Management plan institutes the overall
mechanism for the risk management process with regard to the project. As an
integral part of the planning process prior to commencement of any operational
activity a suitable and sufficient specific assessment of risk associated with the
works should be done.
8.1 Training
Quality orientation training, Pep talk and HSE Induction training based on site
requirement shall be provided to all personnel to work in the site.
Job specific training shall be provided to the working personnel:
JCB operators
Pipe Laying team
Hydro Test team
All work force related to the Activity
First aiders
P a g e | 16
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 17 of 19
Republic of Maldives.
Medical facility for the crew when in need, shall be utilizing the clinic / hospital
identified for the purpose.
List of First Aider/Fire Fighting Team shall be displayed.
An exclusive Emergency Vehicle shall be provided, for any eventuality.
P a g e | 18
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00
Quality Management System Job Code:
Project Quality Plan, Issue: Rev: 00
JMC PROJECTS (INDIA) LIMITED
Document No. Date :24.11.2020
JMC-MWSP-W-DI-MST-R-00
Client: Ministry of National Planning, Housing and Infrastructure, Govt. of the Page 19 of 19
Republic of Maldives.
10.0 Attachments
Procured Material MTC from Vendor/Supplier
Inspection Request (RFI)
Pipe Laying Recorded with chain age in register.
Hydro Test Report
P a g e | 19
Project Name: MWSP, Maldives.
DOC No: JMC-MWSP-W-DI-MST-R 00