Installation of Underground GRP Pipeline

Public Works Authority
DRAINAGE AFFAIRS
DOHA WEST SEWAGE TREATMENT WORKS
EXTENSION # 05
CONSULTANT
egis
CONTRACTOR
Suez Environment- Marubeni JV

SUB CONTRACTOR
Gulf East Engineering, Contg. & Trading Co.

Method Statement for the Installation & Tie-In of UG-GRP
Pipe- 533__ESA103_
00
15-03-2016
21
AJIT CHACKO
ANISH DEV
SHASHI PILLAI
REV.
DATE
PAGES
PREPARED
CHECKED
REVIEWD
APPROVED
CLIENT APPRD
DOHA WEST SEWAGE TREATMENT WORKS EXT#5

Doc No: GE-SUEZ-MS-002
METHOD STATEMENT FOR THE INSTALLATION &
TIE-IN OF UG-GRP PIPELINE 533__ESA103_
TABLE OF CONTENTS
1.
PURPOSE
2. SCOPE
3. APPLICABLE CODES, STANDARDS AND REFERENCES
4.
DEFINITIONS AND ABBREVIATIONS
5. RESPONSIBILITY
6. TRAINING
7. MATERIALS HANDLING AND STORAGE
8. MANPOWER, TOOLS AND EQUIPMENT
9. PROCEDURE
10. SEQUENCE OF INSTALLATION
11. SAFETY PRECAUTIONS
12. LIFTING PLAN
13. ATTACHMENTS
Rev. 0
Page 2 / 21
Date: 15/03/2016

1.
Rev. 0
Page 3 / 21
Date: 15/03/2016
PURPOSE
This Method Statement is prepared to define the procedures that Gulf East Engineering will implement in
process of Tie-in Connection (Tie-in No.38 & 39) for line no. 533__ESA103_. These Tie-Ins are done to
avoid clash with the pipes 539__EFI018_ & 589B_ETT001_, which shall be laid in future.
Where and when required, all the revisions, modifications and additions to this Method statement shall be
submitted to the consultant for information and/or approval.
Area highlighted yellow in Fig 1. below shows the area of work.
Fig 1.
2.
SCOPE
The scope of this method statement covers the minimum requirements, Procedures and Standards that
must be adhered to while installing the UG Pipelines. The activities include material reception from Stores,
Loading, Shifting the material to area of work, Unloading and Installation.
The Scope is limited to the following category of pipelines identified as listed hereunder.
a) 533__ESA103_
- Dirty Water from Existing UF to inlet works.

3.
Rev. 0
Page 4 / 21
Date: 15/03/2016
APPLICABLE CODES, STANDARDS AND REFERENCES

3.1. DOCUMENTATION
1.
QCS 2010
2.
PROJECT HSE PLAN
3.
PROJECT QUALITY PLAN
3.2. INTERCONNECTING PIPE DRAWINGS

1.
DGT-M-DR-000-801-C
2.
DGT-M-DR-000-805-C
3.
DGT-M-DR-000-821-C
4.
DGT-M-DR-000-827-A
3.3. ISOMETRIC DRAWINGS

1.
533__ESA103_ Rev 2
3.4. FLOWTITE Installation guide for buried pipes AWWA.
3.5. Pipe List DGT-X-LT-000-801
4.
DEFINITIONS AND ABBREVIATIONS

4.1. Definition
Pipes
: Circular tubes through which fluid can flow
Installation
: Material transport and handling, pipe laying including the complete operation
of laying, jointing and testing pipes in trenches.
Pipeline
: long, continuous line of pipes and fittings including valves and ancillary structures
Plant
: Doha West STP
Client
: Suez Environment Marubeni JV
Consultant
: Egis.
Contractor
: Gulf East Engineering, Contracting & Trading
4.2. Abbreviation
SUEZ
: Suez Environment
GE
: Gulf East Engineering, Contracting & Trading
HSE
: Health, Safety & Environment
BLDG.
: Building
GRP
: Glass Reinforced Plastic
UG
: Under Ground
PTW
: Permit To work
QA/QC
: Quality Assurance / Quality Control

Rev. 0
Page 5 / 21
Date: 15/03/2016
5. RESPONSIBILITY
MATTHEIU PILLOT
CONSTRUCTION
MANAGER
SUEZ
MANDAL JAGESHWAR
QC INSPECTOR
GUILHEM JOLY
HSE MANAGER
AHMED SHAWKY SITE

ENGINEER UNDERGROUND
NETWORK
KHALED YOUSSEF
GRP ERECTION PIPING
SUPERVISOR
GULF EAST
SAISH K PILLAI
PROJECT MANAGER
SHASHI KUMAR PILLAI
CONSTRUCTION
MANAGER
VISHNU K.V
HSE OFFICER
ANISH DEV.S
PROJECT ENGINEER
SITE SUPERVISORS
WORKERS
AJIT CHACKO
DOC.
CONTROLLER
QA/QC
PLANNING
ENGINEER

Rev. 0
Page 6 / 21
Date: 15/03/2016
The Project Manager- GULFEAST

a) Supervise and coordinate between the project teams.
b) Attend site meetings on regular basis.
c) To ensure the effective implementation for the Quality management system
d) Coordination and comply with project work program.
e) To ensure the overall progress of project to the agreed program.
f)
To ensure availability of the required resources on time.
g) To supervise the Project engineers.

The Construction Manager- GULFEAST
a) Manage and oversee the day to day construction management of the Project.
b) Plan, Develop and Organise the construction effort to formulate the most effective plan for the
timely completion of each activity and in effect the Project.
c) Responsible for implementation of scope of work fabrication, erection, testing, hook-up in
conformance with the project requirements.
d) Monitor and report to PM the project details including progress, risks, Pull backs and Open
opportunities.
e) Investigate reasons for unsatisfactory performance and provide recommendation and institute
measures for improvement.
The Project Engineer- GULFEAST
a) Act as the main contact for the Construction Manager
b) Ensure the progress of Project to agreed Program
c) To coordinate with the design team dedicated to the Project
d) To check all technical details in liaise with the QA QC.
e) To Supervise the Site in all.
QA/QC Engineer/Inspector- GULFEAST
a) Ensure work has been done as per the specification and drawings, inspections are done as per
Quality Control Procedure and the Inspection and Test plan are up to date.
b) Prepare all quality documents and procedures as required.
c) Perform random site inspections on regular basis.
d) Raise RFIs through Site Query (SQ) systems.
e) To raise non- Conformances for any deviations in the materials, installation procedures,
workmanship.
f)
To follow up all non-conformance notices till the closure and maintain logs of all these items.
g) Ensure that the latest approved drawings are being used by the site personnel.
HSE Officer- GULFEAST
a) Confirm that all people working at site are safety inducted.
b) To make sure that all personnels are wearing the proper required PPEs
c) Identify the hazards involved in each work activity and advice the workforce the correct safety
measures to be followed.
d) Perform routine checks for validation of Certificates of trained Manpower and machines utilized

Rev. 0
Page 7 / 21
Date: 15/03/2016
e) Attend weekly meeting with the Client HSE Manager.

f)
Observe that the working hours are strictly followed during Summer.
Construction Manager SUEZ

Will be in charge to ensure that the works are done in accordance with the project
requirements. He will also make sure about proper between site engineer carrying out simultaneous
activities such as Piping , Equipment etc.. He will be attending the construction meeting with the client
representative and will report to his team the client expectation.
Site Engineer SUEZ
Shall be responsible of the coordination of the works. He will be the one making sure proper
interfaces with civil work partner as well as with the client representative. He will also check and solve the
technical concerns.
Site Supervisor -SUEZ
Is responsible to follow the work at site and to make sure that works happen
according to method statement and project requirements. The site Supervisor will attend to all site
inspection.
QC Inspector -SUEZ
Is responsible to organize and attend site inspection in accordance with the project
specification, QCS and ITP. He will be responsible to follow the inspection up the issuance of the
inspection report dully signed.
HSE Manager -SUEZ
Will make sure that safety requirement as HSE project plan and procedure are fulfilled.
6. TRAINING
6.1. Safety Induction shall be provided to any employee/ Visitor entering the site.
6.2. Before start of any work, VIGIMINUTE to be performed by all work Crew members on a daily basis.
6.3. Only trained and certified personnels shall be engaged in activities demonstrating high risk rate or in
situations where the presence of a trained personnel is mandatory.
7. MATERIALS HANDLING AND STORAGE

7.1. All materials shall be inspected for any fabrication defects, In-transit defects such as deep scratches,
cracks etc.. prior to reception of materials from Stores. Further the person in charge for accepting the
materials should assure that the permanent identification tags denoting the nominal diameter, name of
manufacturer, Spool number etc. are present on each material received.
7.2. Any Visible defects beyond the agreed tolerances shall not be accepted and the anomaly shall be
immediately reported to the concerned Engineer.
7.3. Coordination with the installation team and logistics should go hand in hand to avoid trouble handling
and reduce unnecessary material transfer and time wastage.
7.4. Transportation, Handling and Storage shall be strictly in accordance with the manufacturers
recommendation.
7.5. During Transport
a) Pipes and fittings shall be well secured and adequately supported along their length.
b) Nesting of pipes may be permitted.
c) No pipe shall overhang the end of a vehicle.
7.6. Handling shall be carried out as follows:
a) Pipes should be lifted singly and not handled as bunches

Rev. 0
Page 8 / 21
Date: 15/03/2016
b) Pipes shall be handled only by means of approved hooks or fabric slings

c) Use of wire ropes, chains will not be permitted.
d) Pipes and fittings of diameter smaller than 300mm may be handled manually.
e) Pipes and fittings shall not be dropped or bumped.
f)
6.
Pipes shall not be dragged over the ground.
Storage of jointing material shall be as follows:

a) Under cover
b) Rubber ring gaskets shall be stored in their original packing and not be exposed to sunlight.
c) Rubber ring gaskets must be protected from exposure to grease and oils.
d) Gasket lubricant shall be stored in shade and in the original container.
8. MANPOWER, TOOLS AND EQUIPMENT

8.1. Direct Manpower
-
Supervisor
- 01
Safety Officer
- 01
QA/QC Inspector
- 01
Surveyor
- 01
Fitter
- 04
Helper
- 04
Rigger
- 01
8.2. Tools & Equipment

-
Trailer / Truck
- 01
Crane 25T
- 01
Total Station
- 01
Hand Tools
- Lot
Chain puller
- As per requirement
Webbing slings
- As per requirement

Rev. 0
Page 9 / 21
Date: 15/03/2016
9. PROCEDURE
9.1.1.Preparation for work
- Obtain PTW prior to start of any work.

- Barricade the area to avoid unauthorized/unwanted entry and encroachment.
- Conduct topographic survey of existing pipelines and mark the area for tie-in 38 & 39 as
shown in Fig2.
- As-Built drawings shall be prepared based on this survey. Variations if any with the
isometric drawings shall be noted down and the drawings revised accordingly. The new
drawing shall be submitted to the consultant for approval.
- Check the bottom level and width of trench and make sure it meets the requirements.
- List out the required tools and tackles to carry out the shutdown activity and accumulate
those items in the reserved tool box.
- When all the above requirements are met shift all pipes of portion A to A as shown in Fig3.
- The pipes and fittings shall be transported by using trailer/ Truck and will be offloaded to
the trench using crane in a safe and proper way.
Fig 2.

Rev. 0
Page 10 / 21
Date: 15/03/2016
Fig 3.
9.1.2.Joining of GRP pipes:
Joining of pipes shall be made as per the procedure and directions of pipe supplier. The
following steps to be followed during installation of GRP pipes. There are different types method
of joining and the following joining method and procedure shall be applied;
All the pipes as per the required length shall be joined with coupling, which is called as double
bell coupling joint. The following steps shall be followed;
- Foundation & Bedding: The bed must be over excavated at each joint location to ensure
that the pipe will have continuous support and does not rest on the coupling. The
coupling area must be properly bedded and backfilled after the joint assembly completed.
- Cleaning of Coupling: All the coupling grooves and other parts shall be thoroughly
cleaned to ensure no dirt, presence of oil and any other unwanted particles inside the
coupling and its groove. (see below cleaning method)

Rev. 0
Page 11 / 21
Date: 15/03/2016
Install Gaskets: Insert the rubber gasket in to the coupling groove leaping loops (typically
two to four) of rubber extending out of the groove. And it is restricted to apply any kind of
lubricants in the groove or on the gasket at this stage of assembly. Water may be used to
moisten the gasket and groove to ease positioning and insertion of the gasket. (See below
picture). Apply uniform pressure and push each loop of the rubber gasket in to the gasket
groove. After insertion pull carefully in the radial direction around the circumference to
distribute compression of the gasket.
Lubricate Gaskets: Apply a thin layer of lubricant to the rubber gaskets (see below picture)
in order to get flexibility and easiness to insert the pipe.
Clean and Lubricate Spigots: Clean thoroughly the pipe spigots to remove any dirt, grit,
grease and other unwanted/foreign materials (see below picture). Inspect the spigot sealing
surface for possible damage and apply a thin layer of lubricant to the spigots from the end to
the black alignment stripe. Keep clean both the coupling and spigot until completion of
insertion.

Rev. 0
Page 12 / 21
Date: 15/03/2016
Coupling shall be mounted on one pipe, prior join two pipes together, by using clamp or
sling around the pipe at a distance of 1 to 2 meter from the spigot on to which the
coupling will be mounted.
Make sure that the coupling as well as the pipe should have enough gaps from the
ground or at least 100 mm above the ground level to keep away from dirt. Other
techniques may also be used to joining the coupling/pipes.
Fixing of Clamps: Clamp/slings shall be fixed on the first pipe or left in the position from
the previous joint. (See below pictures). Clamp contact with the pipe shall be padded or
otherwise protected to prevent damage to the pipe surface.
Join Coupling: Come alone jacks or any other alternative mechanism placed on the pipe
and connected to the clamps. Pipe shall be pulled into position in to the coupling until it
reaches the home line or touches the centre register. Then it shall be moved on to the
next pipe to be joined.
Home line = (Width of coupling- Gap between adjacent pipes)/2.
Normally the pipes we are using at site have either single spigot (SP) or double
spigot (DSP).
Refer the Table 1 below for spigot dimensions

Rev. 0
Page 13 / 21
Date: 15/03/2016
Table 1
The final spool or the closure spool to be installed will be DSP spools, in some cases it will be
the rocker pipes with DSP.
Select two couplings to be installed and place one coupling square onto the end of closure
pipe (with DSP) so that the gasket is in contract around its entire circumference. Push or pull
the coupling uniformly onto closure pipe until the entire coupling is resting on the spigot end. It
may be necessary to gently help the second ring over the chamfered end of the pipes. Repeat
with the second coupling on the other end.
Set the closure pipe (with DSP) in the trench aligned with the adjacent pipes and with equal
clearance on either side.
Keep the closure pipe centred and minimize pipe end contact. Pull the coupling till it touches
the home line of adjacent pipe.
All this have been shown in the drawing below.

Rev. 0
Page 14 / 21
Date: 15/03/2016
Flanged Joints: GRP flanges shall be joined according to the following procedure;
1. Clean the flange face thoroughly and the O-ring groove as well
2. Ensure the sealing gasket / O-ring is clean and undamaged.
3. Position the sealing gasket/ O-ring in the cleaned groove and be secured with small
strips of tape or adhesive.
4. Align flanges to be joined and tightened with required bolts, nuts and washers.
5. Tighten all the bolts by using proper spanners/torque wrench and check the torque
value with Manufacturer.
6. Check all the bolts once again after one hour to ensure the bolts are properly tightened
or to adjust to get the required torque value if necessary.

Rev. 0
Page 15 / 21
Date: 15/03/2016
Other Joining Methods: Mainly there are two kinds of other methods are there to join
two pipes or to join 2 different kind of materials. In this case we have to follow the below
mentioned procedure/steps.
Flexible steel Coupling method (See below picture): When a GRP pipe connecting to
other pipe materials with different outside diameter, the flexible steel coupling joining
method shall be applicable. These couplings consist of a steel mantle with an interior
rubber sealing sleeve.
It is important that to control the bolting torque of the flexible steel coupling. Do not over
tight/torque these coupling bolts and follow only manufactures recommended assembly
instructions, but with the pipe suppliers recommended bolt torque limits.
Mechanical Steel Couplings: Mechanical couplings have been successfully to join pipes
of different materials and diameters, and to adapt to flange outlets. If a mechanical
coupling is used to join GRP to another pipe material then only mechanical coupling with
dual independent bolting system shall be used (see below picture). This allows for the
independent tightening of the GRP pipe side, which typically requires less torque than
recommended by the coupling supplier.

Rev. 0
Page 16 / 21
Date: 15/03/2016
- Joints shall be capable of withstanding the various tests specified for the appropriate class
of pipe. Joints shall withstand, while maintain the specified test pressure ,a deflection of
not less than 1.5% in any direction.
- After completing the pipeline installation the entire system shall be tested according to the
procedure submitted separately as well as pipe list DGT-X-LT-000-801 B.
- Clear the area and do the house keeping properly prior to handover to civil for backfilling.
- A joint inspection shall be made along with the consultant and main contractor Engineer
as per ITP/RFI for final approval and hand over to civil contractor.
10. SEQUENCE OF INSTALLATION

a) Pipe installation shall commence in portion A-B (Ref Fig 4) .Pipes shall be laid in
sequence as shown in fig 4. This installation shall be done without disturbing the
existing lines nearby.
b) Pre-assemble the spool from B to C and A to D (Ref Fig 4) . This is done to save time
during the actual installation process during tie-in.
Fig 4
c) Partial backfilling of portion A to B shall be done by the civil contractor. The joints shall
be exposed for detection of any leaks during operation.

d) Existing pipe shall be emptied of fluid and valves to be isolated shall be locked out.

Rev. 0
Page 17 / 21
Date: 15/03/2016
This shall be done in coordination with O&M.

e) Obtain PTW and LOTO before commencing any cutting or modification works on the
existing pipe. The Supervisor should confirm that the correct valves have been shut as
mentioned in the LOTO sheet.
f)
Upon reception of the PTW, Cut out the existing pipe from the previously marked area
to a length favorable for the installation of new pipe. Two teams shall work
simultaneously for this activity.
g) Pre-assembled spools shall now be placed inside the trench. The connection at point
A & B shall be made via GRP Bell coupling and at point C&D where the connection to
existing pipe occurs, shall be done through Steel Coupling. The data sheet for steel
coupling is attached here with this MOS.
11. SAFETY PRECAUTIONS

a) Isolate the area with proper barrier and warning tape in order to control unauthorized entry to
the working area.
b) Provide common safety equipment at site (fire extinguisher, bucket with sand, fire watch etc.)
in accordance with fire and safety regulations.

c) Prior to start the activity; ensure that all work permit have been obtained from concerned
authorities as per the general site requirements.

d) Ensure that all lifting equipment shall be certified and the lift/drop zone shall be barricaded
with warning tape and sign boards.

e) Daily tool box talk shall be conducted by the supervisor prior to commencement of each day
activity.
f)
Make sure that there shall be adequate air circulation or proper ventilation for the working
area.
g) A dedicated safety officer and supervisor shall be responsible to ensure all safety precautions
and requirements.
h) Ensure proper PPEs for all working groups at all time.

Rev. 0
Page 18 / 21
Date: 15/03/2016
12. LIFTING PLAN
The Lifting Plan describes the List of Equipments and Safety measures deployed for the
installation of GRP underground Pipe identified as 533__ESA103_
As outlined in this method statement, any activity shall commence only after the reception
of a valid work permit.
The concerned Work Supervisor shall coordinate with the Lifting team in arranging all
required tools and tackles for the work. He must ensure that the Crane Operator, Rigger
and Banks man are competent and are holding a valid training certificate. It shall be
confirmed in advance that the crane and all associated vehicles have safe and unimpeded
access and egress to and from site.
Communication between the crane operator and Lifting crew shall be via hand signals.
The following Equipments are purposed for the activity
o
o
Crane - 50 T Capacity, Model No. NK 500 E-V, Manufacturer - KATO

Trailer/ Truck
Once the approval for work is validated, Crane shall be positioned to Stages as shown in
Fig 5.
Fig 5.
The area shall be cordoned off with barrication tape and Proper Cautionary Signage. This
step shall be followed for positioning cranes in different stages based on the installation
Progress.

Loading Chart
Rev. 0
Page 19 / 21
Date: 15/03/2016

Rev. 0
Page 20 / 21
Date: 15/03/2016

13. ATTACHMENTS
Isometric Drawings
ITP
Risk Assessment
Particular Technical Specification for Couplings
Crane Catalogue KATO NK-500 EV
Rev. 0
Page 21 / 21
Date: 15/03/2016

Installation of Underground GRP Pipeline

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Installation of Underground GRP Pipeline

Hochgeladen von

Copyright:

Verfügbare Formate

Public Works Authority

Suez Environment- Marubeni JV

Gulf East Engineering, Contg. & Trading Co.

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

DEFINITIONS AND ABBREVIATIONS

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

- Dirty Water from Existing UF to inlet works.

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

APPLICABLE CODES, STANDARDS AND REFERENCES

PROJECT HSE PLAN

PROJECT QUALITY PLAN

3.2. INTERCONNECTING PIPE DRAWINGS

3.3. ISOMETRIC DRAWINGS

DEFINITIONS AND ABBREVIATIONS

: Circular tubes through which fluid can flow

: Doha West STP

: Suez Environment Marubeni JV

: Gulf East Engineering, Contracting & Trading

: Gulf East Engineering, Contracting & Trading

: Health, Safety & Environment

: Glass Reinforced Plastic

: Quality Assurance / Quality Control

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

AHMED SHAWKY SITE

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

The Project Manager- GULFEAST

To ensure availability of the required resources on time.

g) To supervise the Project engineers.

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

e) Attend weekly meeting with the Client HSE Manager.

Construction Manager SUEZ

7. MATERIALS HANDLING AND STORAGE

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

b) Pipes shall be handled only by means of approved hooks or fabric slings

Pipes shall not be dragged over the ground.

Storage of jointing material shall be as follows:

8. MANPOWER, TOOLS AND EQUIPMENT

8.2. Tools & Equipment

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

- Obtain PTW prior to start of any work.

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

9.1.2.Joining of GRP pipes:

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

10. SEQUENCE OF INSTALLATION

during the actual installation process during tie-in.

be exposed for detection of any leaks during operation.

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

This shall be done in coordination with O&M.

11. SAFETY PRECAUTIONS

the working area.

in accordance with fire and safety regulations.

authorities as per the general site requirements.

with warning tape and sign boards.

DOHA WEST SEWAGE TREATMENT WORKS EXT#5

12. LIFTING PLAN

The following Equipments are purposed for the activity

Crane - 50 T Capacity, Model No. NK 500 E-V, Manufacturer - KATO

DOHA WEST SEWAGE TREATMENT WORKS EXT#5