Method Statement For Hydro Test (Hdpe Pipes, Fire Fighting Pipeline, Manholes & Domestic Water and Drainage Network)

NEOM-11 Regional Infrastructure
RAPCO FOR CONTRACTING AND INDUSTRIAL SERVICE CO
Contract No. 4800000642
Contract Title RAPCO - NEOM ROAD PROJECTS TEAM OFFICES (NRPTO)
Work/Service Order No. 000
Work Order Title N/A
4800000642-000 - METHOD STATEMENT AND RAMS FOR FIRE FIGHTING

SYSTEM PIPES (INTERNAL & EXTERNAL)
Document No. 11-600000-4800000642-RCI-FPR-MST-000002
Document Revision History:
Status Prepared by Checked by Approved by
Rev. Revision Description Date
(Reason for Issue) (Name/Position) (Name/Position) (Name/Position)
04A – Mobilization Ubaidullah / Rana Faheem / Samson David/

01 For Approval 21.06.2023
& Construction MEP Inspector QC Manager Project Manager
04A – Mobilization M. Rasheed / Velavan A / Samson David/

02 For Approval 25.11.2023
& Construction MEC QC Inspector QC Manager Project Manager
Signatures:
Document Review Status Date: Name/Signature:
1 - Work May Proceed

2 - Incorporate Comments - Proceed
3 - Revise & Re-submit. Do NOT proceed
4 - Review Not Required - Proceed
Electronic documents once printed, are uncontrolled and may become out-dated. Refer to Aconex for current revision
11-600000-4800000642-RCI-FPR-MST-000002_02 REV_02 Page 1 of 32

METHOD STATEMENT
4800000642-RAPCO- NEOM ROAD PROJECTS TEAM OFFICES (NRPTO)
METHOD STATEMENT AND RAMS FOR FIRE FIGHTING

SYSTEM PIPES (INTERNAL & EXTERNAL)
Document No:11-600000-4800000642-RCI-FPR-MST-000002
©NEOM [2023]. All rights reserved.

Document history
Revision code Description of changes Purpose of issue Date
01 FIRST ISSUE FOR APPROVAL 20.06.2023
02 SECOND ISSUE FOR APPROVAL 25.11.2023
Document approval
Prepared by Reviewed by Approved by
Name MD. Rasheed Velavan A Samson David
Job Title MEC QC Inspector QC Manager Project Manager

RAPCO Contracting & Industrial Services Co.
METHOD STATEMENT AND RAMS

FOR FIRE FIGHTING SYSTEM
PIPES (INTERNAL & EXTERNAL)
Prepared by: Reviewed by QA/QC Approved by: Project

Approvals
Mech QA/QC Manager Manager
Engineer
Name: M. Rasheed Velavan A Samson David
Signature:
Date: 25.11.2023 25.11.2023 25.11.2023

Contract No: 4800000642 Date: 20-June-2023
Project Name / No.: NEOM ROADS PROJECTS TEAM OFFICES Revision: 01
METHOD STATEMENT – Fire Fighting System Pipe Works
(External & Internal)
TABLE OF CONTENTS
1. Purpose 06
2. Scope of Works 06
3. Reference Documents & Code 06
4. Definitions 07
5. Responsibility 08
6. Equipment’s, Tools & Materials 09
7. Health, Safety & Environment 09
8. Materials Storage & Handling 12
9. Detailed Construction Sequence (Methodology) 13
10. Preparation 16
11. Installation Procedure 17
12. Testing 25
13. Warning Tape 27
14. Flushing, Tagging & Identification 27
15. Commissioning 28
16. Attachments 28

1.0 PURPOSE
The purpose of this method statement is to define the procedures to be adopted, to assure that
the laying of the pipe line and associated works are carried out strictly in accordance with the
requirement specified in the relevant specification, procedures, manufacturer’s recommendation
and relevant drawings.
This procedure describes the methods to be used for the installation of HDPE Pipes, Seamless
Corban Steel Pipe, Galvanized Steel Pipes, fittings and associated works on this project.
2.0 SCOPE OF WORKS
This Scope of Works shall be read in conjunction with the Drawings, Standard Specifications and
Particular Specifications if mentioned. The scope of this method statement & Quality plan shall
cover the following activity.
• Survey and setting out work
• Excavation to required formation level
• Installation of HDPE pipe, CS Pipe, Galvanized Pipes & fittings
• Pipe bedding and surround
• Backfilling
• Testing
• Laying of detectable warning tape
• Locating & protecting existing services
• Preparation of Existing ground level
• Filling of the area with approved material
• Other applicable works as per approved shop drawings
• HSE, Traffic and Environmental Management Plans for Segment Construction
• Recording of all filling detail.
3.0 REFERENCE DOCUMENTS & CODE

❖ The legislation and code of practice to be followed as per approved HSE plan of the Project.
❖ ASTM & ISO standards for pipe
❖ Neom/ Pioneer Camp Project Specification – Section 014000 Quality Requirements.

❖ Neom/ Pioneer Camp Project Specification - Section 013520 Health & Safety requirements.
❖ Neom/ Pioneer Camp Project Specification - Section 014500 Quality Control.
❖ Neom/ Pioneer Camp Project Specification - Section 017300 Execution.
❖ Neom/ Pioneer Camp Project Specification - Section 210500 Common Work Result for Fire Fighting
❖ Neom/ Pioneer Camp Project Specification - Section 221113 Facility Water Distribution Piping

Contract No: 4800000642 Date: 18 Sep-2022
❖ Neom/ Pioneer Camp Project Specification – Section 220523 General duties valves.
❖ Neom/ Pioneer Camp Project Specification – Section 220529 Hangers and Supports for Plumbing
Piping and Equipment
❖ Neom/ Pioneer Camp Project Specification - Section 211313 Wet Pipe Sprinkler Systems
❖ Approved ITP.
❖ Pressure Test Report
❖ Approved Material Submittal.
❖ Approved Shop Drawing.
❖ Manufacturer’s recommendation.
❖ UPC-Uniform Plumbing Code
4.0 DEFINITIONS
❖ Client- NEOM Saudi Arabia

❖ Engineer/Client Representative - BECHTEL
❖ ASTM- American Society of Testing Materials
❖ ANSI- American National Standard Institute
❖ ASME- American Society of Mechanical Engineers
❖ AWWA- American Water Works Association
❖ PDI- Plumbing & Drainage Institute
❖ NSF- National Sanitation Foundation
❖ HDPE- High Density Polyethylene.
❖ GI- Galvanized Iron
❖ ABS- Acrylonitrile-butadiene-styrene plastic.
❖ WIR- Work Inspection Request to Engineer
❖ ITP- Inspection Test Plan
❖ IR- Inspection Request to Engineer
❖ ICL- Inspection Checklist
❖ SCH- Schedule
HDPE Piping: Piping (ASTM D3261, PE16, SDR 11 as indicated in project specification
Galvanized Steel Piping: Building Inside, for Sprinkler.
Carbon Steel Piping: Pump Room Area
(ISO 4427, EN12201, AS/NZS4130, ASTM 3035, DIN8074, GOST18599, DIPS, ASTM F714)

5.0 RESPONSIBILITY
5.1 Project Manager is responsible to monitoring all the construction Quality and safety teams
throughout the activity and keep on tracking base line schedule to meet the project
Milestones.
5.2 Construction Manager is responsible for the overall Works, keeps the Drainage piping
construction activities as per the base line schedule and deploys responsible for the
assignment of field engineers
5.3 Field engineers shall control all the Drainage piping system and complete the work on site
as per the schedule in line with the standard application methods and follow QC Inspectors
for the internal inspection prior to raise an IR to the client engineer in the stipulated time.
Field engineer shall coordinate with the QC inspector and raise IR to the client.
5.4 QA/QC Manager is responsible for all the quality of the work to be implemented as per the
standards & specifications.
5.5 QA/QC Engineer/ Inspector of contractor shall inspect the work & ensure that work is
executed according to the approved method statement & Project requirements like is
shown in the terms of the contract, MTR, drawings, specifications, standards and all
documents to be followed to reach the standard required in the project.
5.6 Safety Manager is fully responsible of implementing the project safety requirements and
deploys the Safety Officer at work site. He is responsible for carry out training, monitoring
the work activities and carry out accident and incident investigations.
5.7 Safety officer is responsible for the safety measures on each activity location, carry out the
inspections and reporting the HSE safety department, implement the risk assessment and
assure that all necessaries safety/health precautions are effectively completed prior to start
the activity.
5.8 Store Controller is responsible to review the documents with approved Material Approval
and verify the items with the packing list for any shortage or description from approved. He
shall verify all documents are forwarded with the item as per requirement of purchase
order. He is responsible for proper storage as per site requirement and check that any
unapproved material is received and stored in store.
5.9 Installer & Workmen shall be well educated & skilled for the installation work. They are
responsible to maintain safe & healthy working environment. They must follow the
instruction given by field engineer.

6.0 EQUIPMENT TOOLS AND MATERIAL
6.1 EQUIPMENT AND TOOLS
• Fusion welding equipment

• Electrical generators, fusion coupler
• Clamps, Jointing Tackles, trimmers & heater plate
• Spanners, Torque wrench
• Cutting machine
• Rollers
• Survey Equipment
• Ladder
• Slings/Ropes
• Pipe fitter Tools
• Fittings Slings
• Barricade/Plastic barriers
• Hydraulic Excavators,
• Rock Breaker (when required),
• Jointing Tackles,
• Water Tankers,
• Dewatering Systems,
• Testing instruments & Equipment’s such as pumps, gauges, stop ends etc.
6.2 MATERIALS
❖ HDPE pipe & Fitting (PE100, PN16, SDR 11 as per project specification & Approved
drawings).
❖ Carbon Steel Pipe & Fittings (SCH 40 or as per project specification & Approved
drawings).
❖ Valves & other accessories, as specif ied in the approved drawings, where specif ic valve
types are not indicated, the f ollowing requirements apply:
1. Shutof f Duty: Use gate valves.
2. Throttling Duty: Use globe valves. (As per project spec#221316, Sec-3.3A)
❖ Pipe Supports.
❖ Galvanized Steel pipes & fitting as per project specification.
7.0 HEALTH, SAFETY & ENVIRONMENT

❖ Risk assessment for all activities has been carried out and attached as annexure, all necessary
control measures should be taken as mentioned in the risk assessment.
❖ Prior to the commencement of work, arrangements will be made for medical facilities and
medical personnel to be available from prompt attention to the injured person. The
contractor’s vehicle assigned to the job site will be used for transporting the injured person to
the first aid station and to the nearest hospital when required.

❖ Site Supervisor/Foreman shall conduct daily Tool Box Talk (TBT) meetings for workers on
the site prior to commencement of works with the participation of Safety Officer. The method
statement briefing should be given to all the staff before the commencement of the work and
a record shall be kept.
❖ All equipment (Light & Heavy) shall have the valid calibration certification and Stickers.
❖ Workmen shall wear all appropriate safety personnel protective equipment (PPE) such as
helmet, coverall clothing, safety shoes, goggles and gloves etc.
❖ Specialist labour that is familiar with this specific works shall put all drainage UPVC piping
system on the site in line with the health and safety guidelines and special precautions shall be
taken care for all the site staff and workers.
❖ If work is at high level, only approved scaffolding with tag and safety harness should be used.
❖ The supervisor has the responsibility to ensure the site is kept clean and free from any debris.
Any material leftover shall be collected and put into designated disposal box. Unused materials
shall be returned to proper storage in every end of each day work.
❖ Any waste generated to above work shall be segregated and disposed according to the site
and Authority Norms. Any chemical/cleaner used for the job will be kept in a container to
avoid spillage on the ground.
7.1 Personal Protective Equipment
The type of personal protective clothing and equipment will vary depending on type of
protection against chemical hazards whereby the toxicity of and the amount of expected
exposure to the formulated product and physical hazards.
❖ Safety helmet
❖ Safety Shoes
❖ Safety Gloves
❖ Safety Glasses
❖ Ear plug (if necessary)
❖ Mask (Mandatory)
7.2 Safety tape
Safety tape will be used around risky areas which are determined by Risk assessment
7.3 Safety/Warning Signs
During the execution of the works, there will be safety/warning signs around risk works
and general health and safety signs/posters will be located at visible point to warn the
workers.

7.4 General Safety consideration
The following safety precautions will be utilized during construction.
❖ As general, workers shall wear proper personal protective equipment.

❖ All the workers are to be trained and safety inducted prior to commence their work on
site.
❖ Conduct daily tool box meeting for mutual understanding of the works.
❖ Conduct regular or daily check of equipment and machinery prior to the use.
❖ A competent site supervisor shall be present at all times during the works.
❖ First-aider shall be present at site and a first aid kit will be provided in the site office.
❖ Proper side slope during excavation and maintain it regularly.
❖ Before any excavations shall commence a permit to excavate shall be issued by the site
engineer and all the persons involved in the task shall be fully briefed.
❖ For excavation deeper than 1.2 meters confined space permit to work shall be obtained
in addition to all related permit and performing associating shoring work.
❖ Construction plants and equipment shall have valid 3rd party inspection certification and
operators shall have 3rd party assessment certification where applicable.
❖ Proper distance among the labours to be maintained at site for necessary precautions
against Covid-19.
7.5 Emergency Procedure
In the event of any emergency such as collapse of excavation, Structure, Fire or

serious vehicle collision with multiple injuries etc. The HS Manager & HS
representative or ERP Team shall take the following actions:
• In the event of an accident/incident the site HS representative shall activate the
alarm using available alarm points.
• Remove all personnel to safe locations and assist in rescue activities as required
• Secure the area by providing adequate barricading.
• Remove all electrical hazards by isolating power sources;
• Operate mobile and portable fire suppression equipment and systems (if required)
• Ensure that information has been communicated to Project Manager and all
concerned staff.
• Evaluate the scale of the incident and decide whether additional resources are
required to deal with it.
• Liaise with site supervision for the mobilization of any plant and equipment

necessary for dealing with the emergency.

• Ensure to limit access to the affected area with barriers or other means to prevent
unauthorized access.
• Co-ordinate the reinstatement measures following stabilization of incident.
• Site Doctor, Male Nurse and Ambulance are available on site and manning 24 hours
basis. It will take at least 3 minutes to get into site.
• First Aid boxes and designated team leaders/supervisor are the nominated first
aiders can immediately cover of the emergency.
8.0 MATERIALS HANDLING & STORAGE
8.1 MATERIAL STORAGE
8.1.1 The QA/QC Engineer/Inspector shall inspect all material delivered to the site and check it
is stored properly, as per manufacturer recommendations, verifying there is no mark of
damage or deformity of any kind before issuing the material from site store.
8.1.2 Un-approved material or used material shall not be delivered on site only approved
material shall be delivered on site.
8.1.3 Submit Notification of Permanent Material Received on Site (Material Inspection
Request) upon receipt of materials delivery to site. Attach Delivery Receipt, Material
Submittal Approval, Test certificates and other documents to show complete compliance
with specifications and QA/QC Plan.
8.1.4 For temporary storage of the pipes in the site where racks are not provided the ground
shall be level and free from loose stones. Also, the pipes shall be stacked on the wooden
planks to prevent movement.
8.1.5 Rejected Materials shall be stored at a suitable quarantine area with identification label
to prevent unintended use and shall be returned to the supplier f or replacement.
8.1.6 Ensure that valves are dry and internally protected against rust and corrosion. Protect
valves against damage to threaded ends and flange faces.
8.1.7 Do not remove Valves end protectors, unless necessary for inspection; then reinstall
for storage.
8.1.8 While stacking the pipes, it shall be ensured that pipes of bigger sizes are placed at the
bottom and smaller sizes are at the top
8.1.9 UPVC, CPVC HDPE Pipes and fittings shall be stored in the shade to avoid ultra-violet
degradation from the sun lights.

8.2 MATERIAL HANDLING
8.2.1 Deliver component parts t o site, completely identified in accordance w i th

shop and certified drawings prepared for this work. Store in accordance with
manufacture instruction, above ground, properly protected from the weather and
construction activities.
8.2.2 Manufacture recommendation must be followed while shifting the material from main
store to site & also to store the material that would be used day after or later on.
8.2.3 Protect stored piping from moisture and dirt. Elevate above grade. Do not exceed
structural capacity of floor when storing inside.
8.2.4 Do not store materials under direct sunlight.
8.2.5 All material to be used shall be approved in material submittal
9.0 DETAILED CONSTRUCTION SEQUENCE (METHODOLOGY)
9.1.1 Mobilization of Plant/Equipment and Manpower: Mobilization of

Plant/Equipment/Machinery and Manpower shall be as per finalized and approved
construction schedule / Programs.
9.1.2 Survey and Setting out Works: After completion of the preliminary original ground level
by GPS system the area shall be marked in grid system. Before commencing this work all
underground and existing services and obstruction are clearly marked and dealt with
approved method statement
• Surveyor shall ensure that all survey equipment is calibrated and having valid calibration
certificate and he shall also ensure that the pipe laying is done to the require line and
level.
• Survey check Report / Other relevant data shall be recorded
• Original ground level for the whole construction site will be surveyed and recorded, After
the completion of the daily joint survey, the data collected will be printed in hard copies
for joint signature, Work shall only be commenced in area surveyed where survey sheet
are jointly signed. After establishing full survey record, plan will be prepared and
submitted for approval.

• Work location shall be designated well ahead according to Programmed to enable

achieving the planned production.
• Existing services shall be located by use of cable detectors and trial excavation; they shall
be clearly marked at site.
9.1.3 Pipe Handling Pipe: Care shall be taken not to damage the pipe when handling. Pipes
shall not be stored on rough or rocky ground. Pipes shall be placed without timber locking
on pipe barrels. Pipes has to be inspected and any damage has to be recorded and
notified. Damaged goods shall be marked and removed from site. Pipes shall be handled
and stored as per manufacturers recommendations.
9.1.4 Cutting pipe: Pipe shall be cut using milling type cutter, rolling pipe cutter or abrasive
cutter. Do not use flame cut.
9.1.5 EXCAVATION:
➢ Excavate trenches to indicated gradients, lines, depths, and elevations.
➢ Excavate trenches to uniform widths to provide the following clearance on each side of
pipe. Excavate trench walls vertically from trench bottom to 300 mm higher than top of
pipe unless otherwise indicated.
• Clearance 300 mm each side of pipe or unless otherwise indicated on drawings. Unless
otherwise indicated on the Drawings, trench widths up to 300mm above the crown
pipe shall not exceed the following:
• For pipes over 65mm and not exceeding 600mm diameter: nominal diameter +
500mm.
• For pipes over 600mm diameter: nominal diameter + 1000mm.
➢ Trench Bottoms: Excavate and shape trench bottoms to provide uniform bearing and
support of pipes. Shape subgrade to provide continuous support for bells, joints, and
barrels of pipes and for joints, fittings, and bodies of. Remove projecting stones and sharp
objects along trench subgrade.
• For pipes less than 150mm in nominal diameter, hand-excavate trench bottoms and
support pipe and, on an undisturbed subgrade.
• For pipes 150mm or larger in nominal diameter, shape bottom of trench to support
bottom 90 degrees of pipes, circumference. Fill depressions with tamped sand backfill.

➢ Trench Bottoms: Excavate trenches 100 mm deeper than bottom of pipe elevations to
allow for bedding course. Hand-excavate deeper for bells of pipe.
• Excavate trenches 150 mm deeper than elevation required in rock or other unyielding
bearing material to allow for bedding course.
➢ Pits and trenches shall be kept free from water until footing concrete has been placed or
pipes have been installed. The Contractor shall minimize, to the maximum extent
practicable, the length of time excavated areas is open. The Contractor will be held
responsible for damage due to weather, equipment, and other causes during periods
when the excavations are left open.
➢ Foundation material supporting the bedding structure shall be compacted to 95%
AASHTO T-180 (Method D) maximum density.
9.1.6 TRENCH BACKFILL
➢ Place backfill on subgrades free of mud, frost, snow, or ice.
➢ Place and compact bedding course on trench bottoms and where indicated. Shape
bedding course to provide continuous support for bells, joints, and barrels of pipes and
for joints, fittings.
➢ Trenches under Footings: Backfill trenches excavated under footings and within 450 mm
of bottom of footings with satisfactory soil; fill with concrete to elevation of bottom of
footings. Concrete is specified in Section 033000 "Cast-in-Place Concrete
➢ Trenches under Roadways: Provide 100 mm thick, concrete-base slab support for piping
less than 750 mm > below surface of roadways and vehicular pavement. After installing
and testing, completely encase piping in a minimum of 100 mm of concrete before
backfilling or placing roadway subbase course. Concrete is specified in Section 033000
"Cast-in Place Concrete
➢ Backfill voids with satisfactory soil while removing shoring and bracing.
➢ Place and compact initial backfill of satisfactory soil, free of particles larger than 25 mm in
any dimension, to a height of 300 mm over the pipe or,
• Carefully compact initial backfills under pipe haunches and compact evenly up on both
sides and along the full length of piping, to avoid damage or displacement of piping.
Coordinate backfilling with utilities testing.

➢ Controlled Low-Strength Material: Place initial backfill of controlled low-strength material

to a height of 300 mm over the pipe. Coordinate backfilling with utilities testing.
➢ Place and compact final backfill of satisfactory soil to final subgrade elevation.
➢ Controlled Low-Strength Material: Place final backfill of controlled low-strength material
to final subgrade elevation.
➢ Install warning tape directly above utilities, 300 mm below finished grade, except 150 mm
below subgrade under pavements and slabs.
10.0 PREPARATION
➢ All materials to be used shall be approved in material submittal

➢ Check all the materials to be used have approved status from QA/QC Inspectors.
➢ Obtain the approved shop drawing with the latest revision in preparation of carrying out
the works.
➢ Method of statement, ITP & Inspection checklist shall be approved prior to start of
activity.
➢ Work shall be carried out by the site staff under strict supervision and guidance of the
concerned supervisors / foremen /engineers.
➢ Ensure the operatives are trained on Method Statement / Risk Assessments and project
specifications.
➢ The site supervisor / foreman will check that proper tools and equipment are available to
carry out the works
➢ Ensure that Trenching is done as per the project specification
➢ Ensure that the work area is ready and safe to start the installation.
➢ Ensure that grid lines, reference level etc. are marked on site
➢ Ensure that the installations of the UPVC, CPVC & HDPE pipes and fittings are carried out
in accordance with manufacturer's installation recommendations, requirements of
applicable standards and in accordance with the recognized institutions and specified in
Drawings, project specification and MTR to ensure that the installation complies with
requirements contracted.
➢ Prior to start the installation, refer to the approved shop drawings related to the area of

installations and ensure the required materials are available at site as per approved
material submittals. Any discrepancies, damage etc. found will be notified and reported
for further action.
11.0 INSTALLATION PROCEDURE
11.1 Pipe Laying:
a) All pipes shall be installed in trenches at variable depth below surface depending on
the architectural, shop drawing and road details.
b) Pipes crossing the streets shall be well protected and embedded in sand.
c) All pipes fitting valves etc. shall be carefully lowered into the trench with suitable
equipment in a manner that will prevent damage.
d) Open ends of the pipe shall be closed whenever pipe laying is not in progress and at
the end of the day to prevent entry of any foreign matter.
e) Install all items in accordance with recommendation of the manufacturer, installing
each item firmly in position, level, plump and properly connected.
f) Special foundations or other fixing supports/ blocks shall be provided as required.
g) Care shall be taken to ensure pipeline is clear and free of all foreign matter at all times.
Sufficient backfill shall be placed on the pipe to prevent floatation. Any pipe that has
floated shall be removed from the trench and re-laid in a dry trench.
h) As the installation of the various system components are completed, they shall be
adequately cleaned before final closing. All foreign materials shall be removed from
equipment and surrounding areas.
11.2 Pipe Jointing:

Butt Fusion Welding of HDPE Pipes Work Procedure
A pipeline is as good as its weakest point. Accordingly, it is not only important that quality
pipes and components are used in a piping system, but also the methodology used to join the
pipes and other components.
Butt Fusion is the most important and widely used method of connection for HDPE pipes
larger than 110 mm. It is a method of jointing pipe ends by way of heating and cooling under
pressure, resulting in pipe joints as strong as the pipe itself.
The principle of butt fusion is to heat the pipe ends to a designated temperature (200-220 C)
under pressure for a specified amount of time, then the pipe ends are fused together under
pressure for a period of time.

STEP WORKING PROCEDURE

Preparation of welding: before you start the operation, it is important to prepare the work area. Select the
1. operation area that is suitable for the work.
• the welding zone against rain, sunshine or bad weather (if required Install the protection tent or other
equipment to protect)
• Set up the welding machine with all the accessories according to the welding pipe size. Check if the
machine is functioning.
• All of the problems or missing parts must be fixed prior to the start of the welding operation.
• Insert two pipes ends on both side of the machine clamps, protrude approx. 3-5 cm. from each shell side,
2. clamping and adjust the pipe or piping part, the surfaces to be welded should be parallel to each other.
• Adjust the alignment of pipe line by tightening or losing bronze nuts on the top aluminum clamps.
• Secure longitudinal movement of the parts to be welded by taking appropriate measures.
• Clean outside and inside pipe surface.

3. • Insert the facing tool or trimmer between the two pipes

ends into the lock position on the welding machine.
• Start the facing tool or trimmer by turning on the control

switch.
4.
• Slowly approach the pipe ends towards the facing tool or
• trimmer by controlling the directional valve on hydraulic
• control unit while keeping control pressure a little higher.
• The cutter will cut the surface of both pipe ends making them
• clean, plane and parallel.
• When the pipe ends had been trimmed squarely and with an even thickness, slowly decrease the pressure
before switching off.
5.
• Remove the facing tool or trimmer from welding machine to the support frame and clear the facing
scraps from pipe ends.
• Inspect the ends, they must be clean and plane; otherwise repeat the step 3 – 5 again.
• During the clearing and inspection, avoid any contact with the surface of pipe ends.

• Recheck the alignment of the pipeline by bringing the pipe ends closely together and measure the actual
6. tolerance.
• The misalignment value between both pipe ends should not be more than 10% of the pipe wall thickness.
• The gap width is the allowance between the treated pipe end, should not exceed the value shown on
Table 2.
• If they are not in the control tolerance, then repeat the steps 2;) again.
• During the alignment checking in step 6, the welder team must measure the force or pulling pressure
7. (drag pressure) by looking and recording the data found at the pressure indicator device
• The pressure must be created to pull the whole work piece moving in between welding process.
• The drag pressure is the additional value that must be added up to the alignment pressure (P1) and
joining pressure (P3) from calculation or machine pressure data for each operation area and every
welding joint.
8.
• The welding team to prepare the welding parameter by calculating using the recommended values
according to Table 1, Table 3 or machine data for the welding operation control.
• Check the heating plate temperature on the setting range according to step 1; cleaning both heating plate
side
• with cleaning agent and insert its back to support while waiting for welding operation to start.
9. • Bring the pipe ends apart, to clean both pipe ends using coat with an ethyl-alcohol or other suitable
cleaning agent and avoided any contact to the surface after cleaning.
• Repeat the cleaning process, if necessary.

• To start with the welding process, begin with the alignment stage by inserting the heating plate between
10. the two pipe ends, moving both pipe ends close together until contact with the heating plate.
• Start the buildup pressure to the alignment pressure level (P1 + drag pressure), maintain the pressure
until there are welding seam appear.
• In this stage, the uniform bead should had been created between the heating plate throughout the whole
11.
circumference of both pipe ends.
• The pressure must be maintained until the bead height according to the calculation value in table 1 by
visual inspection.
• Continue to the heating-up stage by reducing pressure and maintaining the heating-up pressure level (P2)
along heating-up time (T2).
• Open both pipe ends, carefully remove the heating plate without touching the melted area and see to it
12.
that the removing time should not be longer than the changeover time (T3), insert heating plate to the
support.

• Immediately increase pressure up to the joining pressure level (P3 + drag pressure) within the joining
13. pressure built up time (T4)
• Uniform beads must be created throughout the whole circumference of the pipe joints.
• Maintain or keep the joining pressure constant throughout the cooling time (T5) or until the welding
joint cools down. Avoid forced cooling down by applying water.
• Remove the clamps after the cooling stage is complete.

14. • Welding bead of each jointing has to be visually inspected and measured based on the following:
• Both ends should be almost equal in dimension
• The bead surface should be smooth and do not shine.
• Bead width must be according to the limit dimension
• Possible differences in the formation of the beads may be justified by different behavior of the joined
materials.
15. • All the welding information must be recorded into the data logger, log sheet or welding protocol form.
Table1. Welding Parameter and control for calculation method and recommended
values to be used
Recommend
Description Parameter Calculation
ed Values
1. Heating temperature 200 - 220 0C - -
0.15 ± 0.01
2. Alignment pressure (bar) (P1) A1 / A2 x 1.5 _
N/mm2
Until bead created Until bead created

3. Alignment time (Bead Created) (T1) Table3
follow item 4 follow item 4
4. Bead height (mm.) 0.5 + (0.1 x e) 0.5 + (0.1 x e) -
5. Heating-up pressure (bar) (P2) ≤ 0.02 N/mm2 A1 / A2 x 0.2 -

6. Heating-up time (sec.) (T2) 10 x e 10 x e Table3
7. Changeover time (sec.) (T3) 3 + (0.01 x OD) 3 + (0.01 x OD) Table3
8. Joining pressure built-up time (sec.) (T4) 3 + (0.03 x OD) 3 + (0.03 x OD) Table3
0.15±0.01
9. Joining pressure (bar) (P3) A1 / A2 x 1.5 -
N/mm2
10. Minimum cooling time (min.) (T5) 3+e 3+e Table3
11. Minimum bead width (mm.) 3 + (0.50 x e) 3 + (0.50 x e) -

12. Maximum bead width (mm.) 5 + (0.75 x e) 5 + (0.75 x e) -
Remarks:
OD = Outside Diameter (mm.), e = Wall Thickness (mm.)
A1 = Pipe section area (mm2) by calculation formula: [□(OD2– ID2)/4]
A2 = Hydraulic cylinder section area (mm2) by calculation formula: [(Number of hydraulic cylinder) x
(iD2Cylinder– OD2Shaft)/4]
Alignment of Pipe and Gap Width

• The joining areas have to be plane with a clean and grease-free tool directly before the welding,
so they are plane-parallel in clamped condition. The gap width and the misalignment have to be
controlled. The misalignment of the joining areas on the pipe outside respect may not pass the
permissible value of 0.1 x wall thickness of pipe. The permissible gap width under alignment
pressure is show on Table2.
Table2. The maximum gap width is allowance between the treated welding zones.
Pipe outside diameter Gap width (mm.)

range (mm.)
< 355 0.5
400…< 630 1.0
630…< 800 1.3
800…< 1000 13
> 1000 2.0

P Bead Pressure Welding Pressure
Soaking Pressure
Time
t1 t2 t3 t4 t5
Table3. Recommended values for the heating tool butt-fusion welding of pipes
and fittings from HDPE, at an ambient temperature of approximately 20 □C and
moderate air flow (Interim values have to be interpolated).
1 2 3 4 5
Nominal Alignment Heating-up (T2) Changeover (T3) Joining
wall Bead height on Heating- up (second)
Thickness heating tool at time =10x wall maximum time (T4) Joining (T5)
(mm) the end of the thickness Pressure Cooling time under
alignment time (heating-up build-up
(alignment with with < 0.02 time joining
0.15 N/mm²) N/mm²) (second) pressure
(mm) minimum (second) P=0.15 N/
mm² + 0.01
values
(minute)
minimum
values
≤ 4.5 0.5 45 5 5 6
4.5… 7 1.0 45…70 5…6 5…6 6…10
7 … 12 1.5 70…120 6…8 6…8 10…16
12 … 19 2.0 120…190 8…10 8…11 16…24
19 …26 2.5 190…260 10…12 11…14 24…32
26 … 37 3.0 260…370 12…16 14…19 32…45
37 … 50 3.5 370…500 16…20 19…25 45…60
50 … 70 4.0 500…700 20…25 25…35 60…80

12.0 TESTING
HDPE Piping Hydro-testing Procedures:
• Proper backfilling should be provided to the testing pipe & keep the Joints open for inspection.
• It is necessary to fill, pressurize and test the section within the allotted time for the test.
• One end of the test section to be closed with the End cap or blind flange and the other end of the
test section to be connected with the testing flange having water inlet connected to the calibrated
pressure gauge & air out let.
• Fill the test section slowly with water and ensure that no air is trapped in the test section.
• Air release valve to be connected to the system at the highest point to expel the trapped air and to
get the system completely filled with water.
• During pressure testing, gradually increase the pressure in the test section to the required test
pressure.
• Add make up water as necessary to maintain maximum test pressure.
• Monitor the test section at test pressure for the test duration.
• As per ISO standard, pressure test can be conducted 1.5 times the rated pressure for 2 hours
at20°C.
Testing Procedures for HDPE Pipe Lines
It is common practice to pressure-test a pipe system. Tests may be conducted using hydrostatic or
pneumatic pressure. However, the Plastics Pipe Institute does not recommend pneumatic pressure
testing after installation, for which the test should be conducted hydrostatically, using a non -
hazardous liquid such as water. Safety is of paramount importance when conducting pressurized
internal fluid (liquid or gas) leak tests. Liquids such as water are preferred as test fluids be cause less
energy is released if the test section fails catastrophically.
Testing Procedure:
• Fill the pipeline with water after it has been laid; bleed off any trapped air. Subject the lowest
element in the system to a test pressure that is 1.5 times the design pressure, and check for any
leakage. When, in the opinion of the engineer, local conditions require that the trenches be
backfilled immediately after the pipe has been laid, apply the pressure test after backfilling has
been completed
• The test procedures consist of two steps; the initial expansion and the test phase. When test
pressure is applied to a water filled pipe, the pipe expands. During the initial expansion of the pipe
under test, sufficient make-up water must be added to the system at hourly intervals for 3 hours to
maintain the test pressure. After about 4 hours, initial expansion should be complete and the actual
test can start.
• When the test is to begin, the pipe is full of water and is subjected to a constant test pressure of 1.5

times the system design pressure. The test phase should not exceed 3 hours, after which time any
water deficiency must be replaced and measured. Add and measure the amount of make -up water
required to return to the test pressure and compare this to the maximum allowance in the table
below.
• An alternate leakage test consists of maintaining the test pressure (described above) over a period
of 4 hours and then dropping the pressure by 10 psi (0.69 MPa). If the pressure then remains within
5% of the target value for 1 hour, this indicates there is no leakage in the system.
NOTES:
• Under no circumstances shall the total time under test exceed 8 hours at 1.5 times the system
pressure rating. If the test is not complete within this time limit (due to leakage, equipment failure,
etc.), the test section shall be permitted to “relax” for 8 hours prior to the next test sequence.
• Air testing is not recommended. It shall be the responsibility of the contractor to ensure that
appropriate safety precautions are observed during hydrostatic testing.
ALLOWANCE FOR EXPANSION UNDER TEST PRESSURE

NOMINAL U.S. GALS/100 F.TOF PIPE(2) NOMINAL U.S. GALS/100 F.TOF PIPE(2)
PIPE SIZE(1) 1 HOUR 2 HOURS 3 HOURS PIPE SIZE(1) 1 HOUR 2 HOURS 3 HOURS
2" 0.08 0.12 0.15 20" 2.80 5.50 8.00
3" 0.10 0.15 0.25 22" 3.50 7.00 10.50
4" 0.13 0.25 0.40 24" 4.50 8.90 13.30
5" 0.21 0.41 0.63 28" 5.50 11.10 16.80
6" 0.30 0.60 0.90 30" 6.20 12.60 19.10
8" 0.50 1.00 1.50 32" 7.00 14.30 21.50
10" 0.75 1.30 2.10 36" 9.00 18.00 27.00
12" 1.10 2.30 3.40 42" 12.00 24.00 36.00
14" 1.40 2.80 4.20 48" 15.00 27.00 43.00
16" 1.70 3.30 5.00 54" 18.00 30.00 50.00
18" 2.20 4.30 6.50 — — —
(1) mm=0.03937, (2) multiply by 11.53 to convert to liters/100 meters of pipe.
Construction of Appurtenances
As the pipeline installation progresses, thrust blocks, valves, valve chambers, wash out chambers, etc.,
will be constructed in accordance with the approved for construction drawings.
Construction of Piping within the pump house and valve rooms
• The piping will be installed using flanged joints in accordance with the Approved shop drawings and
shall be hydrostatically tested to the specified pressure.
• The flange gasket shall be centrally located and the flange bolts shall be properly tightened in
accordance with the manufacturers and the mechanical requirements. A torque wrench should be

used securing the needed compression. Proper supports shall be installed in accordance with the
drawings giving importance to its elevation and location. Torque shall be as per manufacturer’s
recommendation if applicable
13.0 Warning Tape: To be applied as per M.I.R & Project specifications.
A. Acid- and alkali-resistant, polyethylene film warning tape manufactured for marking and
identifying underground utilities, (150 mm) wide and (0.1 mm) thick, continuously inscribed
with a description of the utility; colored as follows:
1. Red: Fire Fighting
2. Yellow: Gas, oil, steam, and dangerous materials.

3. Orange: Telephone and other communications.
4. Blue: Water systems.
5. Green: Sewer systems.
B. Detectable Warning Tape: Acid- and alkali-resistant, polyethylene film warning tape
manufactured for marking and identifying underground utilities, a minimum of (150 mm) wide
and 0.1 mm thick, continuously inscribed with a description of the utility, with metallic core
encased in a protective jacket for corrosion protection, detectable by metal detector when
tape is buried up to 750 mm deep; colored as follows:
1. Red: Fire Fighting.
2. Yellow: Gas, oil, steam, and dangerous materials.
3. Orange: Telephone and other communications.
4. Blue: Water systems.
5. Green: Sewer systems.
14.0 Flushing, Tagging & Identification:
14.1 CLEANING AND DISINFECTION
A. Clean interior of piping system. Remove dirt and debris as work progresses.
B. Protect drains during remainder of construction period to avoid clogging with dirt and
debris and to prevent damage from traffic and construction work.
C. Place plugs in ends of uncompleted piping at end of day and when work stops.
D. Exposed ABS and PVC Piping: Protect plumbing vents exposed to sunlight with 2 coats of

water based latex paint.
14.2 LABELING AND IDENTIFYING PIPING SYSTEMS
A. Install pipe markers on each system. Include arrows showing normal direction of flow.
B. Marker Type: Stenciled markers complying with ASME A13.1.
15.0 COMMISSIONING
❖ The commissioning team will witness the testing of “Fire Fighting piping Network”
works to ensure that they are correctly installed and capable of proper operation.
❖ The team will witness start up and running each item of equipment separately until
they are satisfied that it is capable of proper operation.
❖ After each item of equipment has been tested separately, the various items will be run
concurrently to commission the complete system.
16.0 ATTACHEMENTS / ENCLOUSERS
➢ Risk Assessment

Permit required Persons affected Catastrophic (5) Critical (4) Serious (3) Marginal (2) Negligible (1)
Excavation/Ground Works Operatives Frequent (5) High (25) High (20) High (15) Medium (10) Medium (5)
Confined Space Members of Public Probable (4) High (20) High (16) Medium (12) Medium (8) Medium (4)
Hot Work Site Visitors Occasional (3) High (15) Medium (12) Medium (9) Medium (6) Low (3)
Work at height Other Workers Remote (2) Medium (10) Medium (8) Medium (6) Low (4) Low (2)
Radiography Managers Improbable (1) Medium (5) Medium (4) Low (3) Low (2) Low (1)
Pressure testing Young Persons High Not acceptable. Apply mitigation to eliminate or reduce risk - Seek approval if significant risk remains.
Grating Removal Delivery drivers Medium Eliminate or reduce risk - Seek approval if risk cannot reasonably be reduced below this category.
Low May be accepted if all reasonably practicable control measures are in place.
Scope Of the Risk Assessment (Element or Work Section):

HDPE INSTALATION
Ref. Current and planned prevention measures to reduce Likelihood and Severity Residual
Work Method Step Hazard / Risk Initial risk
No. (EliminationSubstitutionEngineeringAdministrativePPE) Risk
 Miscommunication.  Provide native speaking Supervisor/Foremen based on

L(4)
1 Language  Misunderstanding. H(15) workforce employed and ensure workforce understood
 Wrong interpretation. requirements through Tool box talk and training
 Supervisor to ensure that irrelevant persons are not present in

Incident / Accident
 Presence of irrelevant personnel the area.
2 Involving non- M(12) L(2)
 Area shall be barricaded at a distance of approx. 20 M away
employee
from working point and signs posted to identify work hazard.
 Electric power supply for all power tools must be through

 Electrocution ELCB
 Ensure the power pack is properly grounded
HDPE Butt Fusion
3 L(2)
Welding
 Hot surface  The area shall be cordoned off and only personnel
associated with HDPE fusion welding operation shall be
allowed in the work area


HDPE INSTALATION
 Ensure the power pack is properly grounded

 Fire extinguishers to be placed at site Welding machine.
 Fire hazard  Deploy only skilled worker who have formal training
 Proper/ damage free insulated handle should be ensured for the
H(15)
heated plate.
 Heater plate to remain in the canvas sheath when not in use.
 Involved personnel should wear appropriate PPE’s (leather hand
gloves, sleeves etc.)
 HDPE installation for pipeline shall be in accordance with

 Not following methodology of work H(15)
method statements, approved by Company
 Ensure only competent/authorized personnel are carrying out the

 Untrained personnel
H(15) task Authorized personnel to operate and work as minimal as
possible near or around the equipment
 Do not leave the HDPE Welding process unattended

 Incompetent supervision H(15)
 Ensure good communication between the workers


HDPE INSTALATION
 Don't handle snake/insects by yourself, call security person

Working outdoor in  Biological Hazards  Apply insect repellents
4 remote location  (Snakes, Bees, wasps, mosquitoes & H(15)  Don't put hand where you cannot see L(4)
Other insects)  Avoid working alone
 Avoid working in poor light areas
 In case of unavailability of mobile network signals RAPCO shall

provide satellite phone on the site for emergency communication
and give awareness to all employees that where will be the
 Untrained Supervisor to handle location of satellite phone and how to use the satellite phone
emergencies  Emergency Response Team will include RAPCO Site Manager,
 Poor communication in case of Job Execution Supervisor, Emergency Coordinator and a 1st
Response to injury emergency Aider.
5 / illness etc.  Personal Injury to a person on the activity M(12)  Supervisor & 1st aider will be permanently stationed at job site. L(3)
- Heat Stress  In case of an emergency, Supervisor will inform RAPCO Site
- Heat Exhaustion Manager & will take control of situation till emergency
coordinator reach there and take over.
 RAPCO Site Manager will be on daily basis with a dedicated cell
phone number
 RAPCO Site Manager in case of emergency will contact the
appointed Emergency coordinator (HSE Manager/HSE officer) to


HDPE INSTALATION
deal with emergency.
 Emergency coordinator to immediately reach emergency location
and stay there till the situation becomes normal.
 Emergency coordinator to remain in touch with RAPCO Site
Manager and update him about situation.
 RAPCO Site Manager and HSE Manager will be responsible for
communication with BECHTEL in case of emergency.
 1st aider/safety officer to attend Emergency Response Training
 Supervisor to have cell phone available with him for
communication.
 Supervisor to have all emergency contact number in his cell
phone memory (refer to incident reporting chart posted on site &
RAPCO bulletin boards)
 Use of proper PPE’S as per job requirement
 Ensure availability of 1st aider, 1st aid kit and list of 1st aiders at
job site and location shall be posted
 Immediate 1st aid to be given to the injured only by trained 1st
aider
 If needed call BECHTEL paramedic for help.
 A vehicle to be there at job site for help in case of an emergency
 If required, help will be requested from BECHTEL

Method Statement For Hydro Test (Hdpe Pipes, Fire Fighting Pipeline, Manholes & Domestic Water and Drainage Network)

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NEOM-11 Regional Infrastructure

RAPCO FOR CONTRACTING AND INDUSTRIAL SERVICE CO

Contract No. 4800000642

Contract Title RAPCO - NEOM ROAD PROJECTS TEAM OFFICES (NRPTO)

Work/Service Order No. 000

Work Order Title N/A

4800000642-000 - METHOD STATEMENT AND RAMS FOR FIRE FIGHTING

04A – Mobilization Ubaidullah / Rana Faheem / Samson David/

04A – Mobilization M. Rasheed / Velavan A / Samson David/

Document Review Status Date: Name/Signature:

1 - Work May Proceed

11-600000-4800000642-RCI-FPR-MST-000002_02 REV_02 Page 1 of 32

4800000642-RAPCO- NEOM ROAD PROJECTS TEAM OFFICES (NRPTO)

METHOD STATEMENT AND RAMS FOR FIRE FIGHTING

©NEOM [2023]. All rights reserved.

11-600000-4800000642-RCI-FPR-MST-000002_02 REV_02 Page 2 of 32

Revision code Description of changes Purpose of issue Date

01 FIRST ISSUE FOR APPROVAL 20.06.2023

02 SECOND ISSUE FOR APPROVAL 25.11.2023

Prepared by Reviewed by Approved by

Name MD. Rasheed Velavan A Samson David

Job Title MEC QC Inspector QC Manager Project Manager

11-600000-4800000642-RCI-FPR-MST-000002_02 REV_02 Page 3 of 32

METHOD STATEMENT AND RAMS

Prepared by: Reviewed by QA/QC Approved by: Project

Date: 25.11.2023 25.11.2023 25.11.2023

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2.0 SCOPE OF WORKS

3.0 REFERENCE DOCUMENTS & CODE

❖ Neom/ Pioneer Camp Project Specification – Section 014000 Quality Requirements.

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❖ Client- NEOM Saudi Arabia

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6.0 EQUIPMENT TOOLS AND MATERIAL

6.1 EQUIPMENT AND TOOLS

• Fusion welding equipment

7.0 HEALTH, SAFETY & ENVIRONMENT

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7.1 Personal Protective Equipment

7.2 Safety tape

7.3 Safety/Warning Signs

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7.4 General Safety consideration

The following safety precautions will be utilized during construction.

❖ As general, workers shall wear proper personal protective equipment.

7.5 Emergency Procedure

In the event of any emergency such as collapse of excavation, Structure, Fire or

11-600000-4800000642-RCI-FPR-MST-000002_02 REV_02 Page 11 of 32

necessary for dealing with the emergency.

8.0 MATERIALS HANDLING & STORAGE

8.1 MATERIAL STORAGE

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8.2 MATERIAL HANDLING

8.2.1 Deliver component parts t o site, completely identified in accordance w i th

9.0 DETAILED CONSTRUCTION SEQUENCE (METHODOLOGY)

9.1.1 Mobilization of Plant/Equipment and Manpower: Mobilization of

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• Work location shall be designated well ahead according to Programmed to enable

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➢ Controlled Low-Strength Material: Place initial backfill of controlled low-strength material