FIRST 250MMSCFD

TRAIN OF KM500
GAS TREATMENT
PLANT

METHOD STATEMENT OF HDPE PIPING

HAV-EXT-QC-STA-0245

EXTERRAN - REVIEW STAMP

Proj. No.: 4996 P.O. No.: 89005190

DOCUMENT REVIEW CODES:

1 2

Approved & Accepted as Final. Approved & Accepted as

WORK may proceed. Marked. Revise & Re-Submit.
WORK may proceed.

3 4

Rejected & Returned. Revise and Review NOT required. For

Re-Submit. WORK shall NOT information only. WORK may
proceed. proceed.

Acceptance of this document by Exterran does not relieve the CONTRACTOR or

Supplier/Vendor of any responsibility for compliance with the terms and conditions
of the Contract/PO.

Name:
Signature:
Date:

B 28.09.2021 REISSUED FOR APPROVAL ZU CY BO

A 17.08.2021 ISSUED FOR APPROVAL YS AA BO
REV. DATE REVISION STATUS PREPARED BY CHECKED BY APPROVED BY
 METHOD STATEMENT OF HDPE
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1. SCOPE & INTRODUCTION ................................................................................................................. 3

2. REFERENCES ........................................................................................................................................ 3
3. ABBREVIATIONS ................................................................................................................................. 3
4. RESPONSIBILITIES .............................................................................................................................. 3
5. RESOURCES .......................................................................................................................................... 4
6. GENERAL INFORMATION ABOUT HDPE ....................................................................................... 5
7. STORAGE, HANDLING AND TRANSPORTATION ......................................................................... 5
8. HDPE PIPE INSTALLATION PROCEDURE....................................................................................... 6
8.1 Butt Fusion Method ................................................................................................................................... 7
8.2 Electrofusion Welding............................................................................................................................. 9
8.3 Welder / Personnel Qualification / Training ......................................................................................... 10
9. LEAKAGE TEST ................................................................................................................................. 10
10. DRAINING ........................................................................................................................................... 11
11. REPAIR PROCEDURE ........................................................................................................................ 11
12. RISK ASSESSMENT ........................................................................................................................... 12
 METHOD STATEMENT OF HDPE
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1. SCOPE & INTRODUCTION

This Method of Construction describes the activities to be performed for the installation and
pressure testing of HDPE pipes and installation at Exterran project.
The project specific procedures and specifications will be strictly followed in any part of the
activities described in this document.
Exterran Core Policies for Environment, Health & Safety, and requirements specified in the
Safety Health & Environmental Requirements for Contractors will strictly be followed in all phases of
the erection works. Please refer to the risk assessment section of this document for the activity specific
risk assessment.
The purpose of the method is determining the order of precedence, the installation and site
fabrication method of HDPE Piping, risks that may be developed during the work, precautions to be
taken and the equipment to be used in work.

2. REFERENCES

ASTM 2557 – Thermal Butt Fusion Welding Procedures

DIN 8074 & DIN 8075 – HDPE Pipes for Clean Water
ISO 4427 – 1996: Polyethylene Pipes for Water Supply-Specifications
ISO 11414 – 1996: Plastic Pipes and Fittings-Preparation of PE Pipe Assemblies by Butt Fusion
IFC Drawings
Exterran Site prep, Excavation and Backfill standard
Piping design basis
ITP for HDPE Piping HAV-EXT-QC-ITP-0234
Attachment-1 Risk Assessment for Installation of HDPE Pipe

3. ABBREVIATIONS

HDPE : High Density Polyethylene

CLIENT : Exterran
CUSTOMER : Pearl Petroleum
QCE/QCI : Quality Control Engineer / Quality Control Inspector
QCC : Quality Control Chief
QCM : Quality Control Manager

4. RESPONSIBILITIES

Project Manager:
Responsible for accomplishing the stated project objectives which include creating clear and attainable
project objectives, building the project requirements, and managing the constraints of the project
management triangle, which is cost, time, scope, and quality. The Project Manager shall be responsible
for ensuring that the Project Quality Plan and the Inspection and Testing procedures, HDPE
Pipe Installation Method Statement, HSE safety, and all contractual documentation are maintained up
to date and accessible to all parties.
Construction Manager:
Responsible for overall construction activities ensuring that all HDPE Pipe Installation Method
Statement, quality, and safety procedures shall be implemented and required approval permits shall be
obtained.
 METHOD STATEMENT OF HDPE
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Site Engineer:
Supervise operations in accordance as per approved method statement of hdpe pipe installation,
approved shop drawing, specifications, material submittals, and schedules to achieve the acceptance of
the project deliverables.

HSE Manager:
Health, safety, and environmental (HSE) managers generally plan, coordinate and implement issues
and directives within the organization. Ensures safe environmental working conditions for all
employees.

HSE Engineer:
Ensure enforcement of safety procedures in accordance as per approved HSE Plan.
Will be closely monitoring the site engineer’s strict implementation of the Installation Method
Statement of HDPE (High Density Polyethylene) Pipe and Risk Assessment, the use of proper tools
and equipment to maintain safety, certifications of equipment and their adherence to safety regulations,
reporting of any unsafe work or stopping work that does not comply with HSE procedures.

5. RESOURCES

Plant and Equipment:

Drilling machine
HDPE (High Density Polyethylene) butt fusion welding machine
Survey equipment
Clamps, jointing tackles, trimmers & heater plate
Slings & ropes
Cutting machine
Rollers
Spanners
Torque wrench
Ladder
Pipefitter tools
Testing instruments & equipment such as pumps, gauges, stop ends, etc.
Barricade/plastic barriers
Mobile crane as required for the lifting of materials
Hand tools as per site requirement for construction
Power tools as per site requirement for construction

Workforce:

Site Engineer
HSE Engineer
Helper
Equipment Operators
Rigger
Banksman
Welders
Pipefitters
 METHOD STATEMENT OF HDPE
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6. GENERAL INFORMATION ABOUT HDPE

High Density Polyethylene is a versatile material having outstanding mechanical and chemical
properties, and is obtained by the polymerisation of ethylene gas in varying densities ranging
between 0.910 to 0.965 gr/cm³. It has been a practice to use the following terms in describing
polyethylene plastics:

Low Density (LDPE)

Type I (0.910 to 0.925) =
Medium Density
Type II (0.926 to 0.940) =
(MDPE)
Type III (0.941 to 0.965) =
High Density (HDPE)
HDPE pipes are widely used in water main schemes,
irrigation systems, drainage systems,
building water pipe systems, industrial process lines,
agricultural piping and many other public utilities.
HDPE is able to withstand continuous operating
–18°C to +71°C.
temperatures ranging from

A black high-density polyethylene, HDPE contains a carbon black additive to help resist the
effects of ultraviolet radiation.

HDPE resists most organic and inorganic chemicals. While polyethylene also resist many strong
and weak acids, alkalis, organic solvents and some aggressive gasses, it should not be used with
strong oxidizing acids, aromatics, or chlorinated hydrocarbons. However, it is one of the few
thermoplastics having excellent resistances to strong bases. HDPE is finding widespread use in the
petrochemical industry because it is well suited for handling sulphur-based compounds, crude oil,
and gases under low pressures. Due to its resistance to chemicals and UV, HDPE is used
extensively for environmental remediation and landfill projects.

All plastic pipe is designed to have a designated pressure rating at a temperature of 23°C for
water. HDPE pipe and fittings are all designed according to a Standard Dimension Ratio
(SDR), which expresses the relationship between the outside diameter and the wall thickness of
the pipe. A consistent SDR will result in a consistent pipe pressure rating through different size
ranges.

7. STORAGE, HANDLING AND TRANSPORTATION

Handling and transportation of piping materials shall be done with utmost care to avoid any
damage. The quality level of the materials should be maintained from delivery to the finished project.
Damages of the surfaces (scratches, marks, etc.) have to be avoided. The storage has to be free from
waste such as stones, screws, nails, etc.

 HDPE (High Density Polyethylene) pipes and accessories shall be protected at storage against
humidity and UV (Ultraviolent) radiations (especially polypropylene)
 HDPE Pipes a maximum of three rows may be stored on top of one another.
 METHOD STATEMENT OF HDPE
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All materials intended for installation shall be stored on suitable supports (timber, sandbags,
pallets, etc.). No material shall be stored directly on the bare ground. HDPE pipes have to be stored flat
and without bending stress, if possible in a wooden frame. All open ends of the HDPE pipes & pipe
fittings shall be protected by end caps or covered to avoid dust and dirt collection inside the pipes.

Lifting tools (belts, shackles, chain blocks, etc.) for HDPE pipes shall be used in accordance
with good engineering practice to lift with safety and great care and shall be inspected prior to work
commencement.

The HDPE (High Density Polyethylene) pipes fittings must be securely tied to both sides and
end with belts or ropes. While traveling the HDPE pipes should not vibrate and or slide on the trailer
bed causing damages to the external surfaces.

All spooled parts shall be lifted and transported in a similar manner. Special care shall be taken
to avoid any significant deformation or stress during lifting or transportation.

The target of the unloading operation shall be the minimum lifting and moving activities for the
material. In this way, the damage of the parts/material will be reduced practically to none.

Prior to the installation of the HDPE pipes and accessories, the face of the pipes and hdpe pipes
fittings shall be cleaned.

All HDPE pipes shall be protected against damage during handling from supplier to fabrication
yard and further to the final installation site. Special care shall be taken to seal surfaces of hdpe pipes
fitting ends, and avoid contact with other materials (e.g.: oil, grease, etc.) to avoid surface
contamination.

This also includes protection during the erection phase in order to avoid contamination from
other activities on the site.

Transportation of any material shall be arranged taking the following points into consideration:

HDPE pipes fittings and accessories, item shape, dimensions, and weight
Transportation route
Workspace around the installation area
HDPE pipes and fittings installation sequence
Certified lifting equipment and tools.
Safety precautions.
 Qualified personnel (Crane operators, riggers, etc.)
8. HDPE PIPE INSTALLATION PROCEDURE

Polyethylene pipe or fittings are joined to each other by either Butt Fusion Method or Electrofusion
Method
 METHOD STATEMENT OF HDPE
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8.1 Butt Fusion Method

The most widely used method for joining individual lengths of large diameter polyethylene pipe is by
heat fusion of the pipe butt ends as shown in figure 1. This technique, which precludes the need for
specially modified pipe ends or couplings, produces a permanent, economical and flow-efficient
connection. Field-site butt fusion may be made readily by trained operators using specially developed
butt fusion machines that secure and precisely align the pipe ends for the fusion process.

The integrity of butt fusion joining procedure is such that, when it is performed properly, the strength
of the resulting joint equals or exceeds the structural stability of the pipe itself.
The six steps involved in making a butt fusion joint are:

1- Securely fasten the components to be joined,

2- Face the pipe ends,
3- Align the pipe profile,
4- Melt the pipe interfaces,
5- Join the two profiles together,
6- Hold under pressure

8.1.1 Secure
Each component that is to be fused must be held in position so that it will not move unless it is moved
by the clamping device.
Clean the inside and outside of the pipe to be joined by wiping with a clean lint free cloth. Clamp the
components in the machine. Check alignment of the ends and adjust as needed.

8.1.2 Face
The pipe ends must be faced to establish clean, parallel mating surfaces. Most, if not all, equipment
manufacturers have incorporated the rotating planer block design in their facers to accomplish this
goal. Facing is continued until a minimal distance exists between the fixed and movable jaws of the
machine and the facer is locked firmly and squarely between jaws. This operation provides for a
perfectly square face, perpendicular to the pipe centreline on each end and with no detectable gap.

8.1.3 Align
Remove any pipe chips from the facing operation and any foreign matter with a clean, untreated, lint-
free cotton cloth. The pipe profiles must be rounded and aligned with each other to minimize mismatch
of the pipe walls. This can be accomplished by adjusting the clamping jaws until the outside diameters
of the pipe ends match. The jaws must not be loosened or the pipe may slip during fusion. The
minimal distance requirement between fixed-end movable-jaws mentioned above allows the pipe to be
rounded as possible to the joint area. The closer to the joint area that the pipe can be clamped, the
better control the operator has in properly aligning the pipe.
 METHOD STATEMENT OF HDPE
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8.1.4 Melt
Heat the ends of the pipe to the pipe manufacturer’s recommended temperature, interface pressure, and
time duration. By doing so, the heat will penetrate into the pipe ends and a molten “bead” of material
will form at the pipe ends. Heating tools which simultaneously heat both pipe ends are used to
accomplish this operation. These heating tools are normally furnished with thermometers to measure
internal heater temperature so the operator can monitor the temperature before each joint is made.
However, they can be used only as a general indicator because there is some heat loss from internal to
external surfaces, depending on factors such as ambient temperatures and wind conditions.
Other surface temperature measuring device should be used periodically to insure proper temperature
of the heating tool. Additionally, heating tools are usually equipped with suspension and alignment
guides which centre them on the pipe ends.
The heater faces which come into contact with the pipe should be coated by manufacturer to prevent
molten plastic from sticking to the heater faces. Remaining molten plastic can interfere with fusion
quality and must be removed according to the manufacturer’s instructions. Parameters affecting melt
quality are heating temperature, heating time, fusion pressure, polymer melt flow behaviour, ambient
temperature, and wind conditions. The melt flow
behaviour of polyethylene may differ significantly from one material to another according to polymer
structure characteristics such as the degree of branching, molecular weight and molecular weight
distribution.

8.1.5 Join
After the pipe ends have been heated proper time, the heater tool is removed and the molten pipe ends
are brought together with sufficient force to form a double rollback bead against the pipe wall. For
manually operated fusion machines, a torque wrench can be used to accurately apply the proper force.
For hydraulically operated fusion machines, the fusion force can be divided by the total effective
piston area of the carriage cylinders to give a hydraulic gauge reading psi. The gauge reading is
theoretical; the internal and external drag needs to be added to this figure to obtain the actual fusion
pressure required by the machine.

8.1.6 Hold
After the pipe ends have been heated proper time, the heater tool is removed and the molten pipe ends
are brought together with sufficient force to form a double rollback bead against the pipe wall. For
manually operated fusion machines, a torque wrench can be used to accurately apply the proper force.
For hydraulically operated fusion machines, the fusion force can be divided by the total effective
piston area of the carriage cylinders to give a hydraulic gauge reading psi. The gauge reading is
theoretical; the internal and external drag needs to be added to this figure to
obtain the actual fusion pressure required by the machine
 METHOD STATEMENT OF HDPE
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8.2 Electrofusion Welding

Electrofusion welding works shall be carried out according to the Polyethylene Pipes & Fittings
Technical Catalogue. This technique permits joining, of pre-assembled pipes and fittings, to be carried
out with minimum equipment. The electrofusion welding process involves the use of a fitting.
This is basically an outer sleeve which the two pipe ends slide into. An internal stop prevents the pipe
ends from meeting. Fusion barcode are commonly designed for the fitting. Controlled parameters are
given on the fitting code, such that when barcode reader is used, it will automatically adjust the fusion
time by small amounts to compensate for variations in ambient temperature. Alternatively, welding
parameters written on the fittings can be manually keyed in the electrofusion machine.
Sufficient melt pressure will be generated which will lead to safe and reliable joints. If the
electrofusion welding fails, then the welded fitting should be cut out from the pipeline, and a new
fitting should be welded in place. In order to establish a consistent and structurally sound joint, the
preparation procedure shall be strictly followed. This will minimize the contamination and disturbance
effects that might inhibit the fusion mechanism.
Electrofusion Welding Sequences
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For successful joining of the pipes, the important pipe preparation stages must be followed.
The joining process during electrofusion welding can be divided into the following stages:
a) Pipes to be joined shall be marked, cut and finished with square ends. This ensures that
the central cold zones function to contain the melt.
b) The pipes to be joined shall be cleaned properly with the end surface scraped to expose
the uncontaminated surface. With the electrofusion joining process, there is little or no
relative movement between the pipe and the coupler. Therefore, any contamination on the
pipe surface is retained at the joint interface, which can significantly reduce the strength
of the joint.
c) Fittings to be used in welding with the pipes shall only be unpacked during the welding
stage. The Joint interface shall be cleaned only with industrial solvent recommended by
the product manufacturer. Ambient temperature during the welding process shall be
between 5C to 50 C.
d) The pipe and fitting should be clamped during welding to eliminate relative movement.
This ensures that the molten polymer is contained at the fusion interface, allowing the
development of a strong joint. Contact surfaces of the welding plug must be clean.
e) The fitting-code label stuck on the contacted fitting is exclusively to be used. Should the
fitting code label of the fitting to be welded is not readable due to damage, then an
identical fitting with a readable fitting code label from the same manufacture and of the
same series is to be used. No barcode label of fitting of different series shall be used as
substitute. Reading of fitting code label shall be in accordance with the manufacturer’s
instruction. Manually input of welding parameters shall strictly follow the recommended
parameters of the fitting.
f) The welding process will only begin when a signal to start appears in the display of the
machine and no error is indicated.
g) The welding process is duly finished when a display of end appears on the machine and
indicating the welding time and given voltage on the monitor.
h) Cooling time recommended by the manufacturer shall be strictly followed. The joint
shall not be subjected to any internal or external force during the cooling period.

8.3 Welder / Personnel Qualification / Training

Manufacturer’s recommendation and training shall be followed / conducted for qualification of

personnel who work on HDPE pipe and joints.

9. LEAKAGE TEST

Preparation
- Examine system installation for compliance with drawings and specifications.
- Examine system for leaks at valves, flanges, welds, connections, and joints.
- Examine piping system for defective, broken, or cracked piping and fittings.
- Maintain joints, including welds and bonds, uninsulated and exposed for examination
during testing. Joints previously tested may be insulated or covered.
- Clear test area of personnel not involved with pneumatic testing.

Execution
- Gradually pressurize piping system to specified test pressure.
- Maintain test pressure for about 10 min.
 METHOD STATEMENT OF HDPE
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- Visually examine valves, flanges, welds, joints, and connections for major leaks.
- Gradually pressurize piping system to test pressure.
- Maintain test pressure for about 10 min.
- Soap test welds, joints, and connections while system is at test pressure.
- Depressurize system.

Defects And Repairs

- Any leakage or defect seen as a result of test has to be repaired and tested again.

Records
- Test parameters and results shall be recorded.

10. DRAINING
After the hydrostatic test, the pressure shall be released in a mainner and at a rate so as to
endanger personnel or damage equipment.

- All vents shall be opened before the system will be drained and shall remain open during
draining to prevent pulling a vacuum on the system.
- All lines and equipment shall be drained.

11. REPAIR PROCEDURE

Repair situations may arise if a polyethylene pipe has been damaged. Damage may occur
during shipping and handling, during installation, or after installation. Damage may include
scrapes or abrasions, breaks, punctures, or emergency squeeze-off. Permanent repair usually
involves removing and replacing the damaged pipe or fitting. In some cases, temporary repairs
may restore sufficient serviceability and allow time to schedule permanent repairs in the near
future.
Damaged pipe or fittings should be inspected and evaluated. Pipe, fittings, fabrications or
structures with excessive damage should not be installed. Damage that occurs after installation
may require that the damaged pipe or component be removed and replaced.
- Scrapes or gouges in pressure pipe cannot be repaired by filling–in with extrusion or hot air
welding. The damaged section should be removed and replaced.

- Improperly made fusion joints cannot be repaired.

Improper butt fusions must be cut-out and re-done from the beginning. Poorly joined
electrofusion fittings must be removed and replaced.

- Broken or damaged fittings cannot be repaired and, as such, should be removed and replaced
- Water may not be released to environment unless is in compliance with the EIA
requirement.

11.1 Permanent Repair

For large diameter polyethylene pipe that has been poorly backfilled, excessive deflection may
be correctable using point excavation to remove backfill, then reinstalling embedment
materials in accordance with recommended procedures.
Where replacement is required, any joining method appropriate to the product and service
requirements is generally acceptable.
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Butt fusion joining procedures require that one of the components move longitudinally. Permenant
repair of constrained pipe typically employs techniques that do not require longitudinal movement of
one or both pipe ends.
The use of butt fusion as the repair procedure requires a large excavation due to the requirement that
the pipe be able to move approximately 2-3 cm to perform the weld.

11.2 Temporary Repair

Until permanent repairs can be affected, temporary repairs may be needed to seal leaks or
punctures, to restore pressure capacity, or to reinforce damaged areas. Temporary repair
methods include but are not limited to mechanical repair couplings and welded patches.

12. RISK ASSESSMENT

Attachment-1 Risk Assessment for Installation of HDPE Pipe

 RISK ASSESSMENT FORM

NOTE: THIS DOCUMENT SHOULD BE ATTACHED TO THE METHOD STATEMENT. WHEN APPROVED IT
MUST BE KEPT AT THE WORKING PLACE FOR REFERENCE PURPOSES

PROJECT

TASK DESCRIPTION Installation of HDPE Pipes

SUBCONTRACTOR HAVATEK
LOCATION Project wise
RISK ASSESSMENT 001 REVISION NO 0 DATE 28/09/2021
NO

SEVERITY FREQUENCY OF LIKELIHOOD

1 1 2 3 4 5 1 Very Low (once in a year)
LIKELIHOO

2 2 4 6 8 10 2 Low (once in three months)

3 3 6 9 12 15 3 Medium (once in a month)

4 4 8 12 16 20 4 High (once in a week)

D

5 5 10 15 20 25 5 Very High (Every day)

1 2 3 4 5 X
SEVERITY Serious (S) (Hospital
OF THE Very Low (VL) (first aid is Medium (M) (Hospital
Low (L) (First aid is given, 1 treatment is needed, more Very serious (VS) (death, loss
given. Work may be treatment is needed, 3 days
HAZARD carried on)
or 2 days of leave is given)
leave is given)
than three days of leave is of limb, occupational diseases)
given)
Risk Class = Severity of the Hazard X Frequency of Likelihood
L Low Risk; No need to take emergency action, on-site training

M Medium Risk; Measure shall be taken, on-site training, warning signs, document

H High Risk; Stops the work, emergency measure shall be taken, strict measures, change in work schedule, training

VH Very High Risk: stops the work immediately, emergency measure shall be taken, inspection of site risks and decreasing the risk class with the new measures to be taken, drafting new work schedule
 RISK ASSESSMENT FORM

Risk Analysis Control Measures Residual Risk Additional control

Description of the Measures
No Activity Hazards (Hierarchy of Measures; Elimination, Substitution,
Risk S L Score S L Score
Engineering Controls, Administrative Controls, PPE)
 Tidy site; clear defined walkways,
 Suitable and sufficient steps into huts and kept in
good condition,
 Aware of first aid station, site emergency
assembly point, drinking water station, toilet rest
shelter and temporary facilities. Construction
 Drinking water station or water cooler to be Manager /Site
provided. Engineer must ensure
Genaral activity in Slip/Trip and falls, Serious injury,  Periodically breaks in hot weather. the necessary
1 workplace and extreme unconciusness/ 4 3 12 3 1 3 welfare arrangment.
 Awareness to workers to use plenty of cooled
welfare facilities temprature fainting drinking water and ORS – if required.
Effective fulltime
 Work perform by buddy system (two or more
supervision
workers crew).
 All necessary PPE worn as per project
requirement.
 Adequate illumination (access & task) if any
work to be carried out after sunset.
 Mobilization/demobilization form to be used.
 Designated route to be determined by Contractor
Collision  Adequate traffic management plan
Conflict between  Back up alarm while reversing heavy equipment
various users.  Trained flagmen
Being hit by  Follow Client’s guidelines
Plant movement moving machinery Serious Injury  Excavation to be protected to prevent falls.
and vehicles. Risk Property Damage Toolbox Talk
2  Proper signage to be installed,
of crushing when 5 3 15 3 1 3 Training
 Proper lighting will be installed
heavy equipment is
reversing.
 RISK ASSESSMENT FORM

 Obtain lifting permit.

 Conduct pre-task briefing
 Only trained workers to be engaged.
 Radius to be cleared from any movement.
 Activity to be carried out according to MS and
Work should be stopped it there is any deviation
in work methodology.
 Only trained operative to be engaged.
 Original 3rd party certificates to be verified prior
to engage any lifting equipment’s (boom truck,
etc.), operator, riggers and all lifting gears.
Topple of boom
 Daily inspection to be done by operator.
truck
 Certified Rigger to be assigned.
Collapse onto  Tag lines to be used to control the load.
buildings & over  Lifting activities are not allowed when wind
sailing existing Serious injury speed is more than 10 meter/ second. Toolbox Talk
structures/public Property damage  Exclusion zone with caution signs. Training and close
Loading/un-loading/ areas  Area shall be barricaded and personnel entry monitoring by
lifting by boom truck shall be controlled where pipe or other material supervisor
3 and Storage of pipes Load droppings 4 4 16 being lifted. 4 1 4
 To be make sure that fire extinguisher is
Struck by object mounted on the boom truck and fork lifter.
 Pad to be used for boom truck outriggers.
 Wooden shipping braces and side stopper must
be used as runners between layers of pipe while
storage.
 Pipes shall be stored maximum in three tiers or
as received with strap belt.

 If trench depth is 1.5 m or more then

Work in  Confined space permit to be obtained & gas
excavation may Unconciouseness testing to be conducted. Training,team
4 cause/ include Physical Injury, 4 4 16  Control un-authorized entry. 4 1 4 briefing and
Pipe Installation Fall hazard property damage  Only trained operatives to be engaged. moniroting
Excavation  Proper access to be provided into the trench.
collapse  Correct tools to be used.
 RISK ASSESSMENT FORM

Poor access to the  Work to be done as per approved MS.

trench, oxygen  Excavation wall/edge protection to be checked.
deficiency  Proper PPE to be worn by workers
 Don’t stand near excavation edge.
 Don’t stay between pipe and excavation walls
when pipe is lifted.

 Hot work permit to be obtained.

 Only trained operator to be engaged/ assigned.
 All power tools to be inspected and color coded.
 Area shall be inspected prior to start of work.
Power tools  All flammable and combustible material shall be
(Grinder, drill removed from work area.
machine trimmer  Suitable fire extinguisher to be placed.
machine)  Site portable electrical tools shall be 110V.
operation may  All cables kept off the ground or underground to
cause electric avoid tripping hazard.
Shock Serious Injuries (eye  Work at height safety measures shall be taken.
Slip trip and fall and body), 4 3 12  All tools to be disconnected from power source 4 1 4 Toolbox Talk
Sharp Edge electrocution when not in service/ use. Training
Pipe Installation
Flying objects, hearing impairment,  Don’t put hands between trimming tools and
noise, damaged property damage pipe, place the pipes in the clamps with the ends
grinding disk, Soil contamination, against the trimming tool and with the pipe
markings aligned.
Oil leakage, noise  Care while taking the trimming tools out of
and electricity service and not touch the trimmed end.
hazard by  Use dip tray for generator.
generator  Combustible material to be removed and proper
housekeeping to be maintained.
 Suitable PPEs including ear muffs/ plugs shall be
worn by the operatives.
HDPE Pipe  All electrical equipment shall go under
Welding (Butt inspection.
welding/ Fusion Serious Injury and  Competent supervision and control.
Welding) and property Damage,
 Engage trained & authorized personnel only.
Cleaning may skin/ eye irritation,
 Ensure the cables & plugs used in good condition Toolbox Talks
cause Contact with Propanol Vapours 4 4 16 2 2 4
and any joints is made by proper lugs.
hot surface may cause
Electrocution drowsiness and  Ensure proper earthing done in the job (material)
Trip Hazard dizziness to close the loop.
Fire, eye or skin  The main source of electric supply must be
contact and provided with GFCI/ Breaker.
 RISK ASSESSMENT FORM

inhallation of  The supply taken from the DB must be marked

chemical with “ Only for Welding Machine ” and shall not
(isopropanol, be used for other purposes.
alcohol) fumes use  Provide leather/ welding gloves to the
for cleaning of operator to avoid from accidental contact
heater plates and with hot surface.
pipes  Ensure a firewatcher always present while
welding activity is carried out and he should
ensure that no smoldering shall occur after
welding is completed and remained at site for 1
hour after welding work completed.
 Don’t touch hot surface of heater plates untill
cooled/ temprature has come down.
 Don’t touch heater plates when it is connected to
power supply.
 Fire extinguisher shall be readily available within
10 feet of welding activities.
 Propanol and alcohol is Highly flammable, Use
and store only in well-ventilated areas.
 Keep away from sources of ignition - No smoking
nearby storage of propanol and alcohol.
 Avoid contact with eyes and skin.
 MSDS to be explained, followed and kept with
chemical.
 In case of contact with eyes, rinse immediately
with plenty of water and seek medical advice – if
required.

Improper  Inspection and ensure proper connections before

connection of hose starting the work.
and accessories,  Approved hydro testing procedure to be
Hose rupture, Hose followed.
leaks.  Secure the hoses with whip checks and safety
Un calibrated pins
Hydrotesting pressure gages/test Seious Injury
 Use only rated capacity hoses for the job. Toolbox talk and
5 (Pressurizing and manifold. Water Logging (Soil 4 3 12 4 1 4
depressurizing) Contamination)  Ensure that only trained and competent close moniroting
Defective pressure personnel to arrange/fix the pipeline pressure test
gage. equipment and instruments.
Over pressurizing.  Ensure fittings and joints are appropriate for the
pressurization of unit.
Spillage and slip
 Follow the approved hydro testing procedures/
method statements.
 RISK ASSESSMENT FORM

 Ensure the pressure monitoring device is

installed at weakest portion of the segment to be
hydro-tested.
 Use calibrated pressure gauges.
 Use pressure gauges on its intended purpose
only.
 Monitor the pressure gauge from a safe distance
away from the potential source of high pressure
jetting (Such as Flange Joint, Spade, and
Coupling etc.)
 Do not leave the pressurized hose or pump
unattended when the hydro-test is on-going.
 Isolate the equipment from all source of energy
when not in use.
 Pressurized the line maximum up to desired
pressure limit and sustain it for maximum 2
hours.
 Depressurized system before disconnecting
hoses and removal of any fittings.
 Use rated manifolds with test pressure
certificates
 Keep warning signs and testing area to be
Barricaded.
 Pressurizing to be done slowly and steadily
 Engage competent personnel on the job.
 Pressure fluid shall be drained according to
method statement.

Proper supervision
Slipping and
Wind-up and Injury, property and implementation
6 Tripping, poor 3 3 9  All loose material to be secured and dispose on 3 1 3
housekeeping damage, air polution of housekeeping
housekeeping regular basin in approved bins.
policy
 RISK ASSESSMENT FORM

RISK ASSESSMENT COMMUNICATIONS FORM

I, THE UNDERSIGNED HEREBY ACKNOWLEDGE THAT THIS RISK ASSESSMENT HAS BEEN DISCUSSED WITH ME AND THAT I UNDERSTAND THE CONTENTS
AND THE RISKS INVOLVED IN THE TASK TO BE PERFORMED. I HAVE ALSO BEEN INSTRUCTED ON THE SAFE METHODS TO PERFORM THIS TASK.

NAME COMPANY POSITION SIGNATURE