PROJECT : REPLACE ELECTRICAL EQUIPMENT AT

SOUTHERN AREA GOSPs

LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

METHOD STATEMENT
REPLACE ELECTRICAL EQUIPMENT AT SOUTHERN AREA
Name of Project GOSPs
Name of Customer SAUDI ARAMCO
Name of Main LARSEN & TOUBRO SAUDI ARABIA LLC
Contractor Power Transmission & Distribution (International)
Contract No. 6600037160
Budget Item BI-10-000242-0001
Discipline CIVIL
Document No. MS / GOSP / C 20
Revision No. Rev.01

1 12-Aug-17 Review & approval AK SKS KP ST ZA

0 14-June-17 REVIEW & APPROVAL AK SKS KP ST ZA

Rev. Prepared by Reviewed by Approved by Approved by

Date Description EHS
No. CM/SE QA / QC PM SAPMT

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 PROJECT : REPLACE ELECTRICAL EQUIPMENT AT
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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

This page is a record of all revisions of this document.

PARAGRAPHS REVISED ON THIS ISSUE

Rev: Section Page Description

01 6 13 Addition of the 6.11 : Hydrotest Procedure

TABLE OF CONTENTS
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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

Sr. No. Title Page no.

1.0 PURPOSE: 4
2.0 SCOPE OF WORK: 4
3.0 REFERENCE: 4
4.0 RESPONSIBILITIES: 5
4.1 PROJECT MANAGER 6
4.2 CONSTRUCTION MANAGER 7
4.3 SITE ENGINEER 7
4.4 CIVIL SUPERVISOR 8
4.5 QA/QC MANAGER 9
4.6 QA/QC SUPERVIOSR 9
4.7 QA/QC INSPECTOR 9
4.8 HSE MANAGER 9
4.9 EHS INCHARGE 10
5.0 TOOLS, TACKLES AND EQUIPMENTS: 10
6.0 WORK METHODOLOGY 11
7.0 HEALTH SAFETY AND ENVIRONMENTAL (HSE) REQUIREMENTS: 16
7.1 JOB SAFETY ANALYSIS 16
7.2 TRAINING REQUIREMENTS 16
8.0 QA/QC 16
8.1 INSPECTION AND TESTING 16
9.0 EMERGENCY RESPONSE 17

1. PURPOSE:

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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

To ensure that the assembly instructions of all PVC Pipework for substation buildings & underground
sanitary sewers is carried out safely, efficiently and in accordance with good working practice, as per
SAUDI ARAMCO project specification and standard. The instruction is intended to give general
application guidance and establish controls during the preparation, fabrication, installation, and
testing and final acceptance of the activities.

2. SCOPE OF WORK:

PVC scope includes the assembly instructions cover the assembly procedure of PVC pipes and
fittings for the substation building & underground sanitary sewers .

Activities may be required at below mentioned locations:

1. GOSP – 2, ABQAIQ
2. GOSP – 6, SHEDGUM
3. GOSP -11, UTHMANIYAH
4. GOSP -12, UTHMANIYAH

3. REFERENCE:

 Contract Applicable Codes, Standards & Specifications

 SACSM – Saudi Aramco Construction Safety Manual
 LTSA Construction Safety manual
 IFC Drawings
 GI 2.100, Work Permit System
 GI 8.001, Safety Requirements for Scaffolds
 SAES-Q-001, Criteria for Design and Construction of Concrete Structures
 SAES-Q-012, Criteria for Design and Construction of Precast and Pre-Stressed Concrete
Structures
 ACI 347, Guide to Formwork for Concrete
 ACI SP-4, Formwork for Concrete
 SATIP-Q-001-02, SATIP-Q-001-03, SATIP-Q-001-04
 MS-06: Concrete Casting Works in Yard & site
 SAES – S - 010: Sanitary Sewers
 SAES – S - 060: Saudi Aramco Plumbing Code
 SAES – S – 070: Installation of Utility Piping System
 SAES – L - 125: Safety Instruction Sheet for piping & Pipeline
 SAES – L – 105: Piping Material Specification
 SAES – L - 132: Material Selection for Piping System
 SAES – A – 004: General Requirements of Pressure Testing
 SAES – A – 005: Safety Instruction Sheet

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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

4. RESPONSIBILITIES:
Contractor shall recognize the importance of performing the Work in a safe and responsible manner
so as to prevent damage, injury, or loss to individuals, the environment, and the Work, including
materials and equipment incorporated into the Work or stored on-site or off-site. Contractor assumes
responsibility for implementing and monitoring all Health, Safety & Environment (HSE) precautions
and programs related to the performance of the Work.

GENERAL

A. Each contractor employee working on SA jobs shall comply with the SA GIs, standards, manuals
and other contract documents that are applicable to the work, including the SA Safety Handbook.
B. The contractor’s line management and site supervision shall be fully responsible for compliance
with SA’s safety requirements. This responsibility shall not be delegated to the contractor’s safety
manager/supervisor(s)/officer(s).
C. Contractor supervisory personnel or other qualified staff shall be present at the job site while work
is in progress.
D. The contractor shall remove from the job site any of its employees who refuse or repeatedly fail to
comply with safe work practices or supervisors who fail to enforce compliance, including as
requested by the SAPO.
E. Listed below are some responsibilities associated with specific contractor job categories, as
applicable (e.g., specific management and supervisory job categories may not be required or may
be combined if agreed to by the SAPO). Contractor personnel working on SA jobs shall abide by
these responsibilities.

CONTRACTOR MANAGEMENT

 Ensure compliance with SA’s safety requirements for the control of injury, damage and fire
as stated in the contract, in particular Schedule―D‖ and this document.
 Ensure preparation and submittal of a contract-specific CSSP and/or HIP, as required by the
SAPO.
 Ensure the contractor’s subcontractor selection process includes an evaluation of
subcontractor safety management program and performance.
 Provide the necessary personnel, training, tools, equipment and materials to enable the work
to be performed competently and safely.
 Train and qualify contractor site management and supervision on their job safety
responsibilities, including incident investigation and job safety analysis (JSA).
 Conduct training needs analysis to determine the required training for all levels of contractor
employees.
 Ensure contractor employees are trained and qualified on their safety responsibilities.
 Provide needed PPE and establish training/procedures to ensure proper PPE selection, use
and maintenance.
 Participate in coordination (interface) meetings between SA, subcontractors and any other
contractors that may be working on the same jobsite to coordinate work activities.
Ensure development, SAPO review and implementation of detailed procedures for critical work
activities such as welding, tie-ins, hot taps, loop tests, excavations, confined space entries,
equipment/vehicle access, etc.

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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

Below mentioned personnel with the responsibilities entrusted to them shall be responsible for
carrying out above mentioned works. In addition to the roles and responsibilities disseminated in the
Project Quality & EHS Plan, following activity specific functions shall be carried out.

4.1 PROJECT MANAGER

Shall provide his team with appropriate resources and ensure works are done in accordance
with Project Quality and HSE requirements. He is overall responsible for the site work
management.

Project Manager shall establish the following at the planning stage:

 Safety responsibilities for supervisors, subcontractors and other personnel.
 Fire prevention and protection provisions.
 Emergency vehicle access.
 Specific hazards to be identified in the CSSP and/or HIP.
 Job-skills/craft training and safety training/orientation requirements for personnel.
 Types and quantities of PPE needed.
 First aid, medical and sanitation facilities needed.
 Works permit procedures and requirements, if not already established by the SAPO.
 Emergency Response Plan (ERP) and/or emergency procedures aligned with any
applicable SAPO ERP.

The contractor’s Project Manager shall be fully responsible for implementation of all contractual
requirements at the job site and shall visibly demonstrate the priority of safety in all activities,
including setting a good personal example and as follows:
 Empower all contractor and subcontractor personnel on site to stop their own work and
work related to the contract that they deem to be unsafe and take immediate corrective
actions as needed.
 Understand and implement the safety and health requirements of the contract, in
particular Schedule ―D‖ and SA CSM.
 Implement the CSSP and/or HIP and convey the safety responsibilities of each level of
supervisory staff.
 Use only SA-certified work permit receivers when work will be conducted in SA restricted
areas or where required by the SAPO.
 Implement contractor’s work permit procedures in work areas where SA work permits
are not required or as requested by the SAPO.
 Attend/conduct safety meetings to promote and reinforce proper safety and health
performance.
 Periodically inspect the work site, report any unsafe acts/conditions to the contractor’s
site supervisor and/or foreman, provide recommendations to correct deficiencies and
perform follow-up inspections to ensure corrective actions have been taken.
 Routinely consult with the contractor’s safety manager/supervisor(s)/officers to assess
the job site safety status and identify areas for supervisors and foremen to take
corrective action.
 Provide and maintain a Jobsite Safety Logbook (JSL) at each separate job site (note:
the JSL shall be used by SA and the contractor to document unsafe acts/conditions and
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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

the corrective actions taken). Ensure that the appropriate supervisor or foreman
responds immediately to comments written in the JSL.
 Review work methods and precautions with site supervision before work starts.
 Immediately report all incidents and near misses to the SAPO in accordance with GI
6.007 and Chapter I-2, Incident Reporting and Investigation, of the CSM.
 Ensure incidents and near misses are properly investigated to determine root causes,
make recommendations to prevent recurrence and that corrective actions have been
taken.
4.2 CONSTRUCTION MANAGER
 Co-ordinate with other disciplines or functions for interface works.
 Ensure the approved work permit available at the site during execution stage, and work
permit requirements have adequately been met and provided for prior to start of the
work.
 Ensure method statement is prepared, approved by customer representative and
execute work as per method statement and has the duty of care to ensure that all site
management staff have communicated the respective JSA and other related safety
documentation prior to start of work.
 Ensure approval and available of material as required by contract.
 Ensure proper access, receipt, storage, identification & disposal of materials.
 Obtain necessary approvals as required by contract.

Construction manager, shall establish the following at the planning stage:

 Safety responsibilities for supervisors, subcontractors and other personnel.

 Fire prevention and protection provisions.
 Emergency vehicle access.
 Specific hazards to be identified in the CSSP and/or HIP.
 Job-skills/craft training and safety training/orientation requirements for personnel.
 Types and quantities of PPE needed.
 First aid, medical and sanitation facilities needed.
 Work permit procedures and requirements, if not already established by the SAPO.
 Emergency Response Plan (ERP) and/or emergency procedures aligned with any
applicable SAPO ERP.

4.3 SITE ENGINEER

 Prepare method statement and ensure approval by customer representative.
 Orient/train the team to implement the method statements effectively before start of the
activity.
 Obtain clearance from all concerned Departments before start of the works.
 Supervision of site area and work all related execution activities.
 Quantifies productivity of workmen allocated for work and maintain related records.
 Co-ordinate with Surveyor for survey related works.
 Making of daily site reports
 Schedule inspection of work and ensure approval of work from client.

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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

 Site Engineer shall visibly demonstrate the priority of safety in all activities, including
setting a good personal example and as follows.
 Be empowered in writing by their management to stop their own work and work related
to the contract that they deem to be unsafe and to take immediate corrective actions as
needed.
 Understand the safety and health requirements of the contract — in particular Schedule
―D‖ as well as the contractor’s CSSP and/or HIP and this MS and related JSA.
 Assess the workplace and work activities to determine hazards that are present or are
likely to be present, in consultation with the safety manager/supervisor(s) or field safety
officer as needed.
 Evaluate hazardous operations and implement needed precautions to ensure the safety
of all affected personnel
 Understand the safest method of performing each job activity in their area of
responsibility.
 Provide instructions to their personnel on proper work methods, sequence of operations,
potential hazards at each stage and precautions to follow.
 Inform their personnel of safe work methods and safety requirements detailed in the
CSSP and/or HIP prior to beginning a different work activity (i.e., conduct pre-job
―toolbox‖ craft safety meetings).
 Use only trained personnel who are properly qualified for the work to be performed.
 Ensure that equipment operators operate only the specific equipment for which they
have been trained and/or certified.
 Coordinate with subcontractors and other contractors on-site to avoid confusion in areas
with joint or overlapping responsibility or joint occupancy.
 Provide the required PPE and ensure proper use.
 Provide immediate assistance as requested by the contractor’s safety
manager/supervisor, emergency response organizations, SAPO, etc., during
emergencies.
 Conduct weekly safety meetings for their personnel.
 Conduct daily work site inspections to identify and immediately correct unsafe acts,
conditions and/or equipment.
 Document and coordinate safety inspection activities and findings with the safety
manager/supervisor.
 Participate in incident investigations, safety meetings, drills, etc., and conduct/facilitate
safety training sessions.

4.4 CIVIL SUPERVISOR

 It is the site supervisor’s duty to organize the work in safe and to ensure that safety and
protective equipment are being properly utilized.
 He must also assure the method statement procedure is followed and must observe any
hold-points and notify the consultant for inspection. Ensure compliance by all labor &
equipment operators and other associated craftsmen during the concrete pouring works
to the requirements of this procedure, Project Quality Control procedures / test plan,
relevant drawings, Safety procedure and the ARAMCO Project Specifications. Secure all
necessary work/confined entry permits.
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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

4.5 QA / QC MANAGER
 Quality Control Manager shall review this method statement and ensure all QA/QC
requirements are included.
 Quality Control Manager shall coordinate with construction manager for obtaining further
approvals.
4.6 QA / QC SUPERVISOR
 He shall be responsible for implementation of approved method statements and inspection
test plans as per specifications, codes, standards and guidelines specific to the activity.
 He shall guide QC inspectors and ensure inspections & test of the activities as per ITP.
 Review QC records and ensure correctness.

4.7 QA / QC INSPECTOR
 Monitor Inspection work as per Client Specification, Standards, Method statement & IFC
Drawings
 QC Inspector responsible for check the activities as per ITP & checklist and prepare
records and obtain approval. Inspect the materials and ensure those are stacked &
protected properly.
 Identify and prepare Preventive actions reports and Proactive Notifications.

4.8 HSE MANAGER

Safety manager shall visibly demonstrate the priority of safety in all activities, including setting a
good personal example and as follows:

 He will be responsible for reviewing this MS and prepare JSA for the activities to be
performed under this MS.
 Be responsible and accountable for the proper performance of field safety officers under
his authority.
 Be empowered in writing by his management to stop their own work and work related to
the contract that they deem to be unsafe and take immediate corrective actions as
needed.
 Understand safety and health requirements of the contract- in particular Schedule and
CSSP/HIP and CSM.
 Conduct safety kickoff meetings with subcontractors to explain site specific safety
requirements and expectations.
 Ensure all contractor and subcontractor personnel attend site safety orientations, including
as required by the SAPO, and ensure contractor and subcontractor personnel attend
applicable safety training.
 Communicate safety rules and standards to the contractor and subcontractor workforce.
 Provide/assist with safety training for personnel.
 Periodically inspect the work site, report any unsafe acts/conditions to the area supervisor
and/or foreman, provide recommendations to correct deficiencies and follow-up to verify
corrective actions have been taken.
 Keep a record of safety meetings, including agendas and personnel attendance records.
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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

 Keep a permanent record of job-related injuries/illnesses, near misses, fires, motor vehicle
accidents, property damage, crane and heavy equipment incidents, etc.
 Participate in incident investigations, safety meetings, drills, etc., and conduct/facilitate
safety training sessions.
 Ensure general safety rules are printed in languages understood by contractor and
subcontractor personnel and are posted in areas where they are clearly visible.

4.9 FIELD SAFETY OFFICER

 The field safety officers shall visibly demonstrate the priority of safety in all activities,
including setting a good personal example and as follows:
 Be empowered in writing by their management to stop their own work and work related to
the contract that they deem to be unsafe and take immediate corrective actions.
 Understand the safety and health requirements of the contract — in particular Schedule ―
as well as the CSSP/HIP and this MS and related JSA.
 Conduct Toolbox Meeting Communicate safety rules and standards to the contractor and
subcontractor workforce.
 Inspect the work site daily; report any unsafe acts/conditions to the supervisor and/or
foreman, provide recommendations to correct deficiencies and follow-up to ensure
corrective actions have been taken.
 Ensuring the workmen is wearing the necessary personal protective equipment respective
to the job.
 Ensure that the identified unsafe conditions in the work area are rectified.
 Ensure the work area neat & clean.
 Know the critical activities of his job based on the Group Risk Assessment and ensure
implementation of the Risk control measures.
 Participating with the Safety Manager / Supervisor or the committee Members in the
Project Inspection.
 To follow all work permit system as per Permit to work requirements.
 To inform all accidents / incidents / dangerous occurrences at site to Safety Manager /
Supervisor immediately. And participate in the incident investigation.
 He will be supportive to safety manager and supervisor in helping to sort out
environmental issues.

5. TOOLS, TACKLES AND EQUIPMENTS:

The following are the tools and tackles and Equipment identified for the scope of the work and shall
be deployed as per the requirements:
 Cutting Tool (Pipe cutting saw, PVC cable saw, Band saw, Circular saw, Hand saw)
 Deburring Tool, Knife, Half Round File (Coarse)
 Measuring tape
 Pencil / Pentel pen
 Pipefitter’s Wraparound
 Sandpaper
 Spirit Level
 Applicator Can or Bucket
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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

 Tool Tray
 Notched Boards
 Paint brush
 Rags (non-synthetic, i.e., cotton)
 Any other as per the Manufactures recommendations & requirements (if any)

For Hydrotesting:

 Hydrotest Manifold, with isolation and bleed valves

 Pressurizing pump (for water flushing of pipes)
 Pressure Gauges (with 30-80% full range of Testing pressure)
 Pressure Relief valve (For Hydrotest manifold)

6. WORK METHODOLOGY

This shall be common for all the Substations areas:

6.1 Cutting Pipe.
Cut the Pipe to length, measure the desired length and scribe the pipe using a pipefitter’s wrap-
around. Place the pipe in a jig / vise, using rubber pad. Cut pipe with PVC pipe cutting saw, PVC
cable saw, Band saw, Circular saw or Handsaw. A circumferential speed of about 6,000 ft/min. is
suitable for circular saw; band saw speed should be approximately 3,000 ft. /min. carbide-tipped
blades are preferable when quantities of pipe/tube are to be cut. A jig / vise with a rubber pad
prevent damage of the pipe will be used to insure square-end cuts.

6.2 Beveling
All burs, chips, filings etc., shall be removed from both the pipe /tube I.D. and O.D. before joining.
Use a knife, de-burs tool, or a half –round coarse file to remove all burrs. All pipe/tube ends shall be
beveled for ease of socketing and to minimize the chances of wiping the solvent cement from the
I.D. of the fittings as the pipe is socketed. The beveling can be done with a coarse file or a beveling
tool as per manufacturer’s instructions.

6.3 Fitting Preparation

Prior to solvent welding, all fittings and couplings shall be removed from their cartons and exposed
for at least one hour to the same temperature conditions as the pipe/tube in order to assure that they
are thermally balanced before joining.

6.4 Cleaning
Using a clean, dry cotton rag, wipe away all loose dirt and moisture from the I.D. and O.D. of the
pipe/tube end and the I.D. of the fitting. Do not attempt to solvent weld wet surfaces.

6.5 Priming
The function of purple primer is to penetrate and soften the bonding surfaces of PVC pipe/tube and
fittings. It is a product that penetrates rapidly. It is very effective on the hard-finished, high gloss
products now being produced.
Apply primer freely in the socket, keeping surface and applicator wet and in motion 5 to 15 seconds
re-dip applicator as necessary. Avoid peddling in the socket.
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TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

Apply again to the fitting socket. The second application is especially recommended for belled-end
pipe and fittings fabricated from pipe stock, for many of them have especially hard inside-surfaces.
For checking penetration, Personnel involve should be able to scratch or scrape a few thousandths
of an inch of the primed surfaces away. Repeated application to either or both surfaces may be
necessary. Weather conditions affect priming action. In cold weather more time is required for
proper penetration.
Note: The pipe/tube ends can be rested on notched boards to keep them clean and for ease of
solvent cement application.

6.6 Solvent Cement Application

Using the proper applicator proceed as follows;

6.6.1 Apply a full even layer of cement on the pipe O.D. for a distance slightly greater than
the depth of the socket of the fitting.

6.6.2 Coat the fitting socket with a medium layer, avoid paddling. On bevel end pipe or
fabricated fittings, do not coat beyond the socket depth or allow cement to run beyond the
bell.

6.6.3 Put a second full even layer on the pipe/tube O.D. Cement Layers must be without
voids and sufficient to fill any gap in the joints.

6.7 Handling of Primer and Cement

Note: Observe the “use prior to” date. Cement has a limited shelf life. Do not permit solvent cement
cans to stand open. Do not use cement that has dried to the point where it becomes lumpy and
stringy. Dispose of properly. Do not attempt to thin out sluggish cement with thinner or primer. The
solvents in the primer and cement are highly flammable, like a fast drying lacquer, and should not be
used near an open flame. Use them in a well-ventilated area and avoid prolonged breathing of the
fumes. Prolonged contact with the skin could cause minor irritation.

6.8 Joining
6.8.1 Immediately upon finishing cement application and before it starts to set, insert the
pipe/tube to the full socket depth while rotating the pipe or fitting a ¼ turn to insure complete
and even distribution of the cement. Hold joint together for a minimum of 10 to 15 seconds to
make sure that pipe/tube does not move or back out of the socket.

6.8.2 For pipe sizes 6” and larger, a jointing crew consisting of two persons is
recommended and the following additional steps necessary:

6.8.2.1 Rotation of the pipe in the fitting may be omitted.

6.8.2.2 Hold joint together for 1 to 3 minutes depending on pipe size.

6.8.2.3 As an aid for joining in these larger sizes it is recommended that a come-long or pipe
joining tool per manufacturer’s instructions.

6.9 Excess Cement

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TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

Immediately after joining and before joint is set, gently place it backs onto a level surface, wipe off all
excess cement from the circumference of the pipe and fitting.

6.10 Drying Period

Joint integrity depends greatly upon an infinitely wide unpredictable, and uncontrollable set of
product and environmental conditions that go into determining the length of drying times, before a
joints should be moved, handled or whether intended for low or high working pressure applications.
Because of the uncontrollable and unpredictable variety of drying conditions that can exist from job-
to-job and moment-to-moment, the drying times and solvent-welding conditions specified below:
6.10.1. When exposed to direct sunlight, solvent-welding joining should not be done in
atmospheric temperatures below 40 F or above 90 F.
6.10.2. 24 hours of joint drying time shall elapse for all sizes of pipe and drying temperatures,
before the joint is moved or subjected to any appreciable internal or external pressure.

6.11 Hydrotest procedure

6.11.1 Preliminary Inspection

1) Prior to start water flushing, a number of preliminary activities should be undertaken.

These includes the following:
a) Identify the pipe circuit to be prepared for cleaning and determine the lines included in
the circuit registered in the P&ID.
b) Verify the mechanical completion of included lines. All control valve, orifice plates
have been removed and dummy spools installed.
c) All inspection blinds are in correct position. Verify all safety requirements such as G.I.
1021.000 and G.I. 002.102.

6.11.2 Water Quality

Depending on situation, flushing may be performed with dematerialized water, filtered raw
water, filtered raw water or drinking water.

6.11.3 Water flushing inspection

1) Equipment which is sensitive to damage during water flushing shall be removed, blocked
off or isolated. A list of equipment to be isolated shall be prepared and be part of the flushing
procedure. Ball valves shall be flushed in fully open position.
2) Water flushing requires large volume of fresh water and adequate sized pumps, since
flushing is often done when paving is not complete and these increases operating difficulties.
Steps shall be taken to ensure where possible water disposal to drains or temporary pits.
3) Once the preliminary is completed and all safety measures are taken, water flushing can
start.
4) QC plumbing inspector shall check that the feed water pipe circuit gradually to prevent
pipe hammering and increase the water flow until required flushing speed is reached, flush
downward or horizontally and flush through all drains and vents.

6.11.4 Pre-Hydro Test Punch List.

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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

1) QC plumbing Inspector will conduct individual piping / utilities punch list to ensure
conformance of constructed piping / utilities to construction drawings and other international
standards, and to ensure all components of the piping / utilities are properly installed, and
ready for hydrotesting.
2) If all listed punchlist items are satisfactorily completed, the Quality Control Inspector will
issue a Request for Inspection to Saudi Aramco SAMPT and PID.

6.11.5 Water-Filling.

1) The construction supervisor / In-charge will be responsible for preparing resources for
water filling this includes but not limited to, fabrication and installation of spool piece of pipe
with flange for watering filling point, installation of invasion piping(if required) connection from
water source to water filling point, delivery and positioning of filling pump and hydrotest pump
to site, delivery and positioning of water tanker (if necessary) and other resources not
mentioned necessary for water filling operation.
2) QC plumbing inspector will verify readiness of the operation, and if there is no non-
conformance discrepancy, the Inspector will issue a request for Inspection to Saudi Aramco
Representative.
3) Construction personnel in conjunction with the QC plumbing Inspector will verify and
confirm the following:
a) All mainline vents located at high points are open, before and during water filling
operation.
b) All blinds (if any) to isolate the section are properly installed.
c) Ensure that all lateral valves (if any) are in partially open position to protect from
the applied pressure during hydrotest.

4) Water will be injected at the lowest portion of the line. Safely vent the air being displaced
from the line at high points.
5) Continue water filling until all air in the line is vented from high points. After completing the
water filling, shutdown and isolate the water supply and allow to stabilize.

6.11.6 Hydro testing

1) Pipe or equipment shall be pressure tested as per below table and referenced:

Item Line Material Specification Test Pressure Referenced

Standard
1 Fire Water Line RTR Pipes 200 psi SAES-B-017
2 Raw Water Line RTR Pipes 150 psi SAES-S-070
Drinking Water SAES-S-060 &
3 CPVC Sched 80 pipes 150 psi
Line SAES-S-070

2) Utility piping shall be hydrostatic test as per SAES-S-070 Section 18. Quality control
inspector will fill up the required Saudi Aramco Inspection checklist as per Saudi Aramco
Typical Inspection Plan and will issue a Request for Inspection (RFI) to Saudi Aramco /
Representative for Hydrotest of Piping / utilities. RFI indicates the time and date of
Hydrotest.

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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

3) Test manifold shall be separately pressure tested to at least 1.2 times the system test
pressure but not less than the discharge pressure of the pump used for the pressure
testing prior to the actual system pressure test as per SAES-A-004 Paragraph 5.5.4.
4) Prior to hydro test, QC plumbing inspector will verify existence of the following
documents:
a) Calibration certificates of relief valves and pressure gauges and test manifolds.
b) Controlled copy of Saudi Aramco Approved piping / utilities hydrotest procedure.
5) Hydrotest personnel will conduct final check on the tightness of bolts on all flanges
connected to the pipings / utilities to be hydrotested, and install all instruments and
equipments at designated area in accordance to Saudi Aramco approved piping / Utilities
hydrotest procedure.
6) The system will be pressured initially to 50% of the required strength test pressure, hold
for ten minutes for hydrotest personnel and Quality Control Inspector to check for leaks.
7) If there is evidence of leak, the pressure shall be depressurized to zero to allow repair of
leak or weaknesses.
8) If no leak were found, the pressure will be increased in steps, with every increase no
greater than 1/5 of the test pressure with ten minutes hold at each increase or step to
allow for inspection or leaks or weaknesses and maintained for 4hours.
9) After attaining the required strength test pressure, closed the isolation valve between the
test manifold and the system under test and disconnect the pressurizing pump. All
exposed welded connections will be inspected for leaks, the pressure in the system will
be observed and maintained for two hours.
10) QC plumbing Inspector will record the activity by completing Hydrotest package
checklist. Record will be kept in the appropriate project.

6.11.7 Inspection for Hydrotest

1) During hydrotest, all exposed pipe, joints, fittings, valves, and hydrants shall be carefully
examined for leakage.
2) If during hydrotest leak appears, the line will be depressurized to zero and flush the
water. The leaking pipe, joints, and fittings shall be in accordance with SAES-S-070
section 20.
3) The hydrostatic test shall be repeated after the repair of any defects until the system is
proved satisfactory.
4) The piping shall be considered satisfactory if there is no evidence of leakage or pressure
loss after the specified test period.

6.11.8 Dewatering

1) Test water will be disposed at Saudi Aramco designated containtment pond or to water
truck, Project Manager / Construction In Charge will secure approval of Saudi Aramco to
use any existing pond if available. Test water will be disposed in accordance to SAEP-
327(Disposal of Waste water from cleaning, flushing and Hydrostatic Test).
2) All vents will be opened to facilitate drainage and to prevent formation of vacuum, check
to ensure no test fluids will remain at low points. Draining will commence with the
approval of Saudi Aramco approval.
3) Continue draining piping/utilities until the system is free of standing water.

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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

6.11.9 Hydrotest Manifold Diagram

7. Health Safety and Environmental (HSE) Requirements:

All works shall be executed in accordance with the approved HSE plan for the project and
necessary precautions shall be made to ensure HSE requirements, and associated Traffic
Management Plan, Emergency response Plan, HIP, EMP, Waste Management Plan etc.

7.1 Job Safety Analysis (JSA)

Job Safety analysis shall be prepared for the works & shall be submitted as a separate
submittal and shall be followed

7.2 Training Requirements:

1. Personal safety training through Tools box talk shall be conducted.

2. Ensure First aider awareness training shall be given to the workers.
3. Method of statement explained to all team members.
4. Plumbers (Certified by Manufacturer to be used at the site).

8. QA/QC

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LARSEN AND DOCUMENT TITLE: PLUMBING & UG PIPING WORKS

TOUBRO SAUDI
ARABIA LLC Document No. : MS /GOSP/ C 20 Rev-01

8.1 Inspection and Testing

 Quality shall be maintained by ensuring the systematic implementation of this Method Statement
and ensure that necessary quality records are maintained.
 Approved ITPs to be followed.
9. EMERGENCY RESPONSE
In case of any emergency please contact following.

FIRE 998
AMBULANCE 997
POLICE 999
CONSTRUCTION MANAGER PARVEZ AHMED 056 884 3792
CONSTRUCTION MANAGER NADIMUR RAHMAN 059 693 9049
CONSTRUCTION MANAGER PRAKASH B. 059 626 0281
CONSTRUCTION MANAGER NADEEM KHAN 059 286 1071
CONST. SUPD MAQSOOD KAZI 055 218 4974
PROJECT MANAGER SUBUKTAGIN TAJ 053 245 7243
PROJECT EHS INCHARGE SURESH S. 056 461 4602
PROJECT ACCT & ADMIN INCHARGE H. SYED 054 732 0169

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