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Method Statement For Installation & Hydrotest of GRP & Upvc Pipes
Method Statement For Installation & Hydrotest of GRP & Upvc Pipes
Table Of Contents
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 1 of 19 162-C20
1. TITLE
2. SCOPE OF WORK
2.1. GENERAL DESCRIPTION
2.2. PLANT & EQUIPMENT
2.3. MATERIAL
2.4. SITE PLANNING & PREPERATION
2.5. WORK METHODOLOGY
2.6. ORGANIZATION, RESPONSIBILITY & SUERVISION
3. HEALTH & SAFETY
3.1. GENERAL
3.2. RISK ASSESSMENT
3.3. ES&H CONTRACTOR REQUIREMENTS
3.4. PERSONAL PROTECTIVE EQUIPMENT (PPE)
3.5. CONTRACTUAL REQUIREMENT
3.6. INFORMATON TO PERSONNEL
3.7. PERMIT REQUIREMENTS
3.8. EMERGENCY PROCEDURE
3.9. TRAFFIC MANAGEMENT PLAN
4. ENVIRONMENTAL ISSUES
4.1. ENVIRONMENTAL IMPACT ASSESSMENT
4.2. ES&H CONTRACTUAL REQUIREMENTS
4.3. CONTRACTUAL REQUIREMENT
5. QUALITY ASSURANCE
5.1. CONTRACTUAL REQUIREMENTS
5.2. CRITICAL WORK
5.3. INSPECTION & TESTING
5.4. FOLLOW UP & EVALUATION
6. APPENDICES
6.1. RISK ASSESSMENT
6.2. SUPPLIER CATALOGUE
6.3. JOINT TESTER CATALOGUE & METHODOLOGY
6.4. LIFTING PLAN
6.5. EXCAVATION COMPETENT PERSON
6.6. LIFTING COMPETENT PERSON
1. TITLE.
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 2 of 19 162-C20
Method statement for installation and Hydro test of GRP and uPVC pipe lines for Treated
Sewage Effluent Overall Improvements Line system
2. SCOPE OF WORK
2.1 General Description.
This method statement is intended to outline the ways, procedures and the proper execution of
Installation and Hydro Test of GRP and uPVC pipe line for Treated Sewage Effluent Overall
Improvements Line of Irrigation network system of the above contract.
RC Specification reference:
SECTION 02082 GUIDELINE SPECIFICATIONS FOR MANHOLE COVER AND FRAMES
SECTION 02085 GUIDELINE SPECIFICATIONS FOR UNDERGROUND PIPING
MATERIALS
SECTION 02086 GUIDELINE SPECIFICATIONS FOR FIBERGLASS REINFORCED PIPES
SECTION 02230 GUIDELINE SPECIFICATIONS FOR SITE CLEANING AND GRABBING
SECTION 02310 GUIDELINE SPECIFICATIONS FOR GRADING
SECTION 02315 GUIDELINE SPECIFICATIONS FOR BACK FILL MATERIAL & FILL
SECTION 02340 GUIDELINE SPECIFICATIONS FOR SOIL STABILIZATION
SECTION 02530 GUIDELINE SPECIFICATIONS FOR SANITARY SEWAGE
SECTION 02585 GUIDELINE SPECIFICATIONS FOR UNDERGROUND UTILITY PIPE
SLEEVES
SECTION 03215 GUIDELINE SPECIFICATIONS FOR REINFORCEMENT OF CONCRETE
SECTION 03310 GUIDELINE SPECIFICATIONS FOR STRUCTURAL CONCRETE
SECTION 09910 GUIDELINE SPECIFICATIONS FOR PAINTS
SECTION 09960 GUIDELINE SPECIFICATIONS FOR HIGH PERFORMANCE COATING
SECTION 15110 GUIDELINE SPECIFICATIONS FOR VALVES
SECTION 15150 GUIDELINE SPECIFICATIONS FOR SANITARY WASTE AND VENT
PIPING
To execute the job below listed equipment shall be used but not limited to the following
1) Crane with lifting tools of sling belt, shackle, chain block
2) Bulldozer
3) Backhoe
4) Dump Truck / Dump Trailer
5) Grader
6) Pay loader
7) Generator
8) Pipe Shaver & Cutter
9) Hand Grinder
10) Hydrostat Pump and Pressure Gauges
11) Joint Tester & Accessories.
12) Water Pump
13) Level Instrument
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 3 of 19 162-C20
14) Aluminum Ladder
15) Mortar Pans
16) Mamoties
17) Shovels
18) Buckets
19) Pick Axes
20) Hand Axes
21) Crow Bars
22) Water Truck
23) Roller and Plate Compactor
24) Chainsaws and axes
25) Traffic Control equipment
26) Complete Dewatering pump unit set
27) Forms materials
2.3 Material
Material such as GRP pipe (ASTM D3517), uPVC pipe Class 5, Air Release Valves, Butterfly
Valves, Gate Valve, Flange, Raiser Pipe, Tee, Bolts & Nuts, coupling, Rubber Wrap, vent pipe, wire
mesh, SS strips, FRP cage ladder, J bolts, Flexible Coupling, Manhole, FRP Platform, Dismantling Piece,
Flange , conduit, Tee, Mitered Elbow, Reducer, Reinforcement bar, marker Post, Timber post,
Anticorrosive paint, Adhesive, Concrete, Hessian sack, bolts, nuts, gaskets etc.
Before starting, survey, coordinates and elevation of the center line of the trench, verify the depth
and exact location of all existing underground facilities by manual excavation of trial pits and/or by cable
detector wherever necessary prior to commencement of the work and shall take all necessary precautions
to protect the existing facilities without any disturbance of the existing pipes / structures or underground
cables, provide necessary supports where required and all the procedures shall be shown on the workshop
drawings subject to RC approval, valve chamber, pipe sleeve, etc are to be established as per the latest
revision of IFC drawing. Surveyor shall write down the number and revision of the drawing in the survey
report. Copy of the IFC drawing and approved shop drawing if any shall be attached along with the
survey report. Develop a geotechnical report to determine the characteristic and properties of the soil
materials that will be encountered during excavations for the design control measures. Lay a temporary
access road leading to specific work area and install the directional sign boards. Obtain the encroachment
permit and work permit from RC prior to start the job. A competent person shall inspect the work
condition for excavation including the location and detection of all utilities & services. No employees
shall be within the swing radius of the excavator and erect the warning signs for safety.
2.5Work Methodology
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 4 of 19 162-C20
Access and egress shall be installed at the edge of excavation and the perimeter to be
barricaded.
Identify the location to keep the required equipment’s of cranes, trucks and other
equipment’s within the adjacent marking area.
Before starting any excavation RC approved Excavation Competent person shall be
consulted.
If an unexpected item of archaeological interest is encountered, work must be stopped
and inform to RC for their instruction.
Inspect and ensure the required pipes and its connecting accessories are in conformance
with the specifications.
Trench size and shape depends on soil parameters such as type, density, moisture content
and stable/unstable condition. Develop a geotechnical report for the characteristic and
properties of soil, propose the design control measures of trench construction and obtain
RC approval prior to start the work.
The width of execution shall be made minimum in such a way that worker can stand in
the space on either side of pipe to work comfortably.
Edge of excavation shall be properly slope and excavated material shall be stored away
from excavation
If excavated material is suitable for backfilling shall be used, otherwise shall be hauled
away and dumped in disposal area as approved by RC.
TRENCH DETAILS:
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 5 of 19 162-C20
Remove the underground water to prevent softening of foundation bottoms, under cutting
footings and soil changes, detrimental stability of subgrades and foundations, convey the
removed water from excavation and rain water to collecting or run-off area as per RC’s
direction
Establish and maintain temporary drainage ditches and other diversions limits for each
structure and shall not use trench excavations as temporary drainage ditches.
As per RC direction and opinion - construct, operate, and maintain all temporary dams,
watercourses and other work of all kinds including pumping plant, well point dewatering
sets and relief of well systems to remove and pump the groundwater from the work and to
ensure the stability of excavations, while construction is in progress. Well point systems
and relief systems pumping units shall be designed specifically for the type of service
required.
Methods of disposal of all water from the work and waste products shall be subject to RC
approval.
Standby suction pump shall be kept aside and be used as and when the existing
dewatering pump operation gets a breakdown
Dewatering system is removed after backfilling the pipe trench layer by layer till 1 meter
above the ground water level.
i) GRP Pipe.
RC representative shall inspect the pipes and approve prior to install
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 6 of 19 162-C20
By using crane, lay the standard length of the pipe to the trench
During the pipe handling or installation of the pipe, if any damage such as cracks,
delamination, fracture occurs, the pipe shall be repaired/replaced
The joint shall be carried out by an experienced and trained pipe technicians
Select and use the proper lubricant and its quantity requirement per joint as recommended
by pipe manufacturer
The rubber gaskets received along with the pipes and fittings shall be stored in shelter
with the original packing and must be protected from the exposure to grease, oils and
solvents
Mark the home line on the pipe around the circumference, measure back from the edge of
the spigot the required insert depth plus 50 mm and scribe a line or as per manufacturer
recommendation
Fix one coupling at each pipe end prior to lower into the trench
Clean the inside coupling and internal groove from dirt, grease or any other foreign
material deposited in it
Insert the gasket into the coupling groove by applying a uniform pressure and push it into
the gasket grove in position and do not put any lubricant in the coupling groove or on the
gasket at this stage
When installed, pull carefully the gasket in radial direction around the whole
circumference to check for well distributed compression of the gasket
Use by spatula or adhesive scrapper to apply the lubricant on gasket to facilitate easily
fixing the coupling to the pipe
Apply a thin film of lubricant on the pipe spigot and align the coupling with the pipe
Any excessive lubricant shall be quickly removed from the pipe or fittings, as this may
affect the integrity of the system
Fix a cross bar on the coupling face, use two nylon rings and fix the puller (come along
with jacks) at each side of the pipe spring line.
Ensure that the coupling and pipe are in aligned position, then start tighten the puller
from both ends in same time, the pipe will gradually insert into the coupling, till the joint
is firmly fixed together
After assembly by putting the joint together, the scribe line on the pipe shall be 50 mm
from the coupling.
Remove pullers and follow the same procedure for other pipe joints
In case of Plain Coupling Joint: Pipes are usually delivered with a coupling attached,
clean the pipe end with a fine brush, lubricate the pipe end by means of a dry clean piece
of cloth and sponge, inspect the pipe ends for delamination, use come along type puller to
push the pipe in the coupling of the already installed pipe, the pipe is pushed until it
touches the middle center of the rubber sleeve in the coupling, Backhoe may be used for
pipe joining.
Immediate backfilling after joining is recommended to prevent hazards like floating of
pipe due to heavy rain and thermal movements due to large difference between day and
night temperatures. Floating of pipe can damage the pipe and create unnecessary
reinstallation costs. Thermal expansion and contraction can cause loss of seal due to
movement of several pipe lengths.
If the section of pipe are placed into trench and backfilling is delayed, the center portion
of the pipe has to be backfilled till the pipe crown portion to help minimize the
movements.
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 7 of 19 162-C20
A copy of MSDS for adhesive shall be submitted to RC later, since, supplier will deliver
it along with the ordered our pipe material at our end.
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 8 of 19 162-C20
centerline of pipe. Reinforcement shall be provided at every faces of concrete thrust
block
Spread the polyethylene sheet on the compacted sand surface, where the concrete to be
casted
Forms to be made with adequate support to get the required size of thrust block size,
dimension, shape, reinforcement by steel bars shall be as per the contractual drawings
Prior to pour concrete, the form works and all preparatory works shall be inspected by
RC
Concrete class C25b shall be used within 90 minutes from the time of mixed and
transported to site from the batching plant as per RC specification 03310
Thrust block shall be casted by cast in site concrete at bends, elbows, tee, valves, caps,
plugs, etc. as per contractual drawings and site requirements
Vibrator shall not be used to move concrete horizontally
If the concrete temperature is greater than 30 degree or wind blow as in sand condition,
concrete pouring shall not be performed
Concrete pouring is very sensitive matter is to prevent the uplift of the fittings, extra care
shall be taken during the process
Concrete pouring of thrust blocks shall be constructed as per IFC drawing and site
requirements and as per manufacturer’s recommendation
Curing of the concrete shall be made as per RC specification
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 9 of 19 162-C20
Level and compact the surface, lay the polythene sheet and pour the blinding concrete to
50 mm thick as per drawing
Construct the reinforced concrete base
Construct the valve / washout chamber with puddle flange and water stopper, removable
precast concrete slabs, provide the concrete support with J bolt, sump pit, FRP platform,
install valve support assembly, protected coat by polymide epoxy, .. etc as per the
contractual drawing
Inside the chamber, mount the gate / butterfly valve on the concrete support, connect the
pipe with valve, flange, dismantling piece, flexible coupling, flange adaptor, tee, elbow,
reducer, FRP hand rail, pressure indicator, flow meter, analyzer, coupling, extension rod,
pedestal base mounting, GRP puddle pipe, mechanical coupling, carrier pipe, fix
neoprene warp around rubber, sealant, bolts & nuts, gaskets, water proof membrane,... etc
as per drawing
RC representative will conduct a field inspection and witness the hydro test, follow the
hydro test procedure as mentioned below, Prepare the inspection records and obtain RC
approval
Paint the chamber by epoxy, and other mechanical parts., etc shall be painted by anti-
corrosive paint as per specification
Close the chamber at top cover by constructing the reinforced bar of precast concrete slab
with the provision of manhole provision, vent pipe, extension spindle, wire mesh,, etc as
per drawing
Use suitable material to back fill and to be compacted to at least 95% of the maximum
density.
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 10 of 19 162-C20
in such a way that deflection of unsupported span lengths are maintained within
acceptable limits as per drawing.
Construct the concrete platform, install the valve support for fixing the valve as per
drawing, before installation, RC representative shall inspect the valve and its connected
fittings of its installation to this.
By using the crane and a support lay and install the valve, its connected fittings of HOR
elbow, reducer, Tee, irrigation line pipe, Air release valve, FRP hand rail, access
platform to operate the Air valve, gasket, bolts & nuts., etc., ensure its connection are
assembled and aligned in line and grade as per drawing.
2.5.11 Hydro Test Procedure (for pipe Dia 1200mm and below)
Inspect the completed installation to assure that all requirements have been met
Installed pipe lines shall be hydro tested to 1.5 times of working pressure in presence of
RC representative for approval
Fill the line with potable water at the lowest point with open valves and vent at highest
point so that air will be expelled from the line to avoid pressure surge during the
pressure build up
Once water comes out on the highest point of the vent, close the valve
Pressurized the line slowly
Wait until pressure is stabilized
If no sign of pressure drop disconnect the pump from manifold.
Check all joints for possible leak
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 11 of 19 162-C20
If no leak is found, continue the test to the required period of at least 30 minutes to
complete the test
After completion of the test and accepted by RC, open slowly the valve to release the
pressure inside the pipe.
Upon completion the test, written records of every test indicating the tested section of
the pipe, date, time, name of the tested engineer and RC approved authority.
Drain the line to approved location until the pipe is empty
All necessary precaution shall be carried out during testing operation
Initial hydrostatic test shall be made with partial backfilling keeping all joints exposed
The gauge calibration interval shall not exceed three (3) month, calibration certificate
shall be made available upon request by RC
Minimum two (2) pressure gauges are required for the test system, one pressure gauge
shall be checked and recorded on inspection sheet
Walk through along with the lines to observe any trace of wet soil, check the joints
When the pressure required is reached and applied for 24 hours, allowable 5% pressure
drop shall be calculated. Upon approval from Royal Commission, the leakage
calculation in L/Km per 24 hours can be performed in lieu of pressure drop method
Leakage method is directed by RC, no section of the pipe will be accepted until the
leakage calculation in L/KM (pro-rated for lesser distance) per 24 hours at test pressure
is less than that as shown in the below table
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 12 of 19 162-C20
Wait until the pressure is stabilized
Ensure the gauge location will read the highest line pressure
Fill up the inspection sheets accordingly
Test shall be considered as pass, if no sign of leakage is observed at the permanent joints
and there is no pressure drop
Inspection sheets shall be signed by the RC representative
Upon satisfactory completion of the test and acceptance the system shall be
depressurized gradually
After completion the test, water shall be transferred to other line to use for testing, same
procedure of test shall be followed
Remove all temporary support items installed for testing purposes.
After approval of hydro test, warning tape shall be installed at a distance of 300 mm
height from top of the pipe.
Trench shall be backfilled with sand above the pipe and compacted in accordance with
specification.
2.5.14 Curing.
Curing of concrete slabs, chamber, pipe joints and thrust block shall be made as per RC
specification.
Wet burlap curing shall comprise of at least 2 layers of constantly damped burlap laid
light against the pre-soaked concrete surface and uniformly damped by hose supplied
water
Hot weathering concreting, the concrete surface shall be covered by plastic sheet for
curing
2.5.15 Backfilling
Use suitable backfill material to fill the pipe trench, washout chamber, closeout
chamber, pipe sleeve, Air release valve shall be placed in layers.
Each layer of backfill shall be compacted to at least 95% of the maximum density as per
RC specification.
Compaction test to be done as per guideline of RC specification.
Warring tape shall be installed as per drawing.
2.5.16 Clean Up
After completion of the work, all equipment’s and construction materials shall be
removed
Debris, trash, rubbish. Etc. shall be cleared and disposed to the designated disposal area.
Nurse:
o Responsible to carry out of health and first aid programs at site,
o Carryout the first aid and medical services to personnel employed at site
o Ensure the adherence to government health regulations and requirements
o Report the findings to Project Manager
o Arrange to stock the adequate number of first aid medicine and other dressing
materials to meet the requirements o In charge to establish the operation of
medical clinic at site
o Consult and assist the hospital doctor, where circumstances dictate
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 16 of 19 162-C20
3.7 Permit Requirements
All necessary permit shall be secured prior to any activity at site per required by RC.
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 17 of 19 162-C20
RC EMERGENCY CONTACT NUMBER
7 ROYAL COMMISSION SECURITY DEPT 013-3417777
8 FIRE BRIGADE 998
9 POLICE 999
10 AMBULANCE 997
4. ENVIRONMENTAL ISSUE
5. QUALITY ASSURANCE.
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 18 of 19 162-C20
Inspection and testing to be carried out in accordance with the approved ITP and RC
specification - under preparation, will be submitted after RC approval.
6. APPENDICES
6.1 Hazard Identification and Risk Assessment
6.2 Supplier’s catalogue copy - recommendation / Guidance on the method of various pipe joint,
installation of pipe system, Pipe bedding, Back filling, Thrust block, Field Hydro test, Repair
work, Safety, .. etc
6.3 Joint Testing Catalogue & Methodology.
6.4 Lifting Plan
6.5 Excavation competent person
6.6 Lifting competent person
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Method Statement for
Installation & Hydrotest of
GRP & uPVC pipes Page 19 of 19 162-C20