GTC-318B-1/2009 PS-2
METHOD STATEMENT VULCATHENE PIPES
INSTALLATION
Doc. No.: 318-B1-10-73-I203
Page: 1 of 9
Rev.: A
Date: 8th June 2011
ESTABLISHMENT OF 66/11KV RAYYAN VILLAGE S/S
AND
URGENT UPGRADE OF EXISTING SUBSTATIONS
GTC-318B-1/2009 PS-2
METHOD STATEMENT VULCATHENE PIPES
INSTALLATION
Doc. No.: 318-B1-10-73-I203
Page: 2 of 9
Rev.: A
Date: 8th June 2011
TABLE OF CONTENTS
1. AIM………………………………...……..…...……….………………..3
2. SCOPE……………………………….......…..…....……....…………...3
3. TERMS AND DEFINITIONS.....………….….…......….…...….…….3
4. SPECIFICATION, CODES & STANDARDS.………….….….…….3
5. RESPONSIBILITY……….……..………….…….….……………...3-4
6. PROCEDURE…….….……………….……..…………….………...4-6
7. RESOURCES.....……………..………………..…………..………..6-7
8. QUALITY CONTROL…………..……………..……….……………..7
9. HEALTH, SAFETY & ENVIRONMENT…..….............…....…… 7-9
10. APPENDICES……….…….……...........…......….......………………9
GTC-318B-1/2009 PS-2
METHOD STATEMENT VULCATHENE PIPES
INSTALLATION
Doc. No.: 318-B1-10-73-I203
Page: 3 of 9
Rev.: A
Date: 8th June 2011
1.0 AIM
The aim of this method statement is to provide a procedure for fabrication, joining and installation of the Vulcathene pipe lines in accordance with Project specifications and applicable Standards and to assure that all required QA/QC procedures are implemented during the works.
2.0 SCOPE
The scope of this method statement is to outline the procedure for fabrication, joining and installation of the Vulcathene pipe lines as per approved construction issue drawings and using approved materials.
3.0 TERMS & DEFINITIONSClient: Qatar General Electric Water Corporation (KAHRAMMA)Contractor: ABB Consortium (ABB)Subcontractor: Kettaneh Construction W.L.L. (KCQ)Project: Establishment of 66/11kV Rayyan Village S/Sand Urgent Upgrade of Existing SubstationsProject Quality Plan (PQP)Inspection Test Plan (ITP)Request for Inspection (RFI)Construction Phase HSE Plan (CPHSEP)Quality Control Inspector (QCI)
Quality Assurance / Quality Control (QA/QC)
4.0 SPECIFICATIONS, CODES & STANDARDS
Technical Specifications For Building Services Section 3.3.15 Rev. 1 and Civil Works Section 3.3.13 Rev 2.
QCS 2007: Qatar Construction Standards. UPC: Uniform Plumbing Code. Relevant Current Revision of Issued for Construction Drawings. Manufacturer Installation Instructions.
5.0 RESPONSIBILITY
Project Manager: Shall be responsible for the proper execution of these procedures and to ensure that works are undertaken in a safe manner as per the defined requirements in this method statement and relevant quality procedures and the agreed timescale. He shall advice and co-ordinate with Contractor and Client as applicable.
GTC-318B-1/2009 PS-2
METHOD STATEMENT VULCATHENE PIPES
INSTALLATION
Doc. No.: 318-B1-10-73-I203
Page: 4 of 9
Rev.: A
Date: 8th June 2011
Safety Manager: Shall be responsible for the implementation of safety procedures on site and to ensure that the Job Safety Analysis within this method statement is followed. He shall assign a competent Safety Officer to enforce these procedures and to provide guidance to the operations where applicable.
Field QA / QC Manager: Shall be responsible for the proper implementation of these procedures and ensure that inspections and tests are carried out according to the relevant approved Inspection Test Plan. He shall assign a competent Quality Control Inspector (QCI) to perform inspections.
Site Engineer: Shall be responsible for the site implementation of these procedures and to provide all necessary resources of competent and trained manpower, tools, equipments and approved materials on a daily basis. He shall coordinate with the QCI for the inspection and issuance of related Request for Inspection (RFI) as per approved Inspection and Test Plan (ITP) and related documents. Supervisor: Shall be responsible for the execution of the works as per approved quality procedures and safe methods of working.
Safety Officer: Shall be responsible for the implementation of all safety requirements and to ensure that the works are undertaken in a safe and proper manner, all in accordance with the approved Construction Phase HSE Plan, the approved method statement and the approved Job Safety Analysis.
Quality Control Inspector: Shall be responsible for inspection and verification that the procedures are properly implemented and that inspections are undertaken in accordance with the approved Inspection Test Plan in a timely manner.
6.0 PROCEDURE
Detailed procedures are shown below, however; if any element procedure is not detailed herein then those procedures as recommended by the Manufacturer will be followed.
6.1. Vulcathene Pipes Installers
Installation of Vulcathene piping for drainage system in Battery Rooms shall be done by trained competent personnel in the proper handling and usage of applicable tools and equipment.
Vulcathene pipe installers shall assemble a trial joint with the same type of materials and techniques to be used in the actual installation.
The trial joint (test joint) shall be tested to at least 3 meters water head for a minimum of 3 hours.
6.2. Handling and Storage
GTC-318B-1/2009 PS-2
METHOD STATEMENT VULCATHENE PIPES
INSTALLATION
Doc. No.: 318-B1-10-73-I203
Page: 5 of 9
Rev.: A
Date: 8th June 2011
All Vulcathene pipes and fittings shall be handled and stored in accordance with Manufacturers recommendations for handling/receiving permanent material.
All Vulcathene pipes and fittings shall be inspected upon receipt at job site. If any defect or damage is found, it shall be segregated and barricaded to be disposed of within 24 hours. No damaged pipe or fittings shall be used or installed within the works.
Loading and Unloading of pipes shall be properly controlled by using guide ropes and proper lifting procedures. Approved straps, slings and ropes shall be used. Manual loading and unloading can also be done for small pipes and fittings.
Vulcathene pipes and fittings shall be stored as per Manufacturer requirements. Racks shall conform to factory shipping packages for each pipe size. If pipe is stored on racks or bearing boards, the supports shall be at least 75 mm wide. Supports
shall be spaced at 3 meters center maximum with the first support 1.5 meters from the end of the pipe.
Adequate side support shall be provided to prevent slipping or rolling. Vulcathene Pipes and fittings shall be stored off the ground. All supporting surfaces shall be free from sharp objects. Pipes and fittings shall be properly protected from impact especially on their ends. Vulcathene Lubricant shall be stored as per Manufacturer requirements.
6.3. Assembly, Joining & Laying
Before assembly, each pipe and fitting shall be examined to be free from damage. Installation shall be in accordance with the approved issued for construction drawings. The internal surface of the pipe shall be cleaned by rags or by purging air from an air
compressor before assembly. Vulcathene piping shall be of mechanical joint using a molded tongued thermoplastic elastomer
olive in accordance with project specification. All piping components shall be aligned properly without strain, pipe shall not be bent. Slope shall be maintained as shown on the approved construction issue drawings in conjunction
with Project specification.
6.4. Mechanical Joint
Clamp the pipe in a pipe vice. Cut to length using a rotary plastic pipe cutter. All burrs and loose material are removed.
A groove is cut around the pipe with the special grooving tool. After the grooves cutting, olives shall be softened by immersing into the hot water. Assembling the joint. Vulcathene lubricant is used only for 76mm to aid installation. Vulcathene Lubricant shall be put onto the threads of the fittings after having made sure that the
fitting is clean. Loosely assemble the joint and proceed to hand tighten the knurled nut. The nut must be
tightened to its full thread capacity.
6.5. For Above Ground Piping
GTC-318B-1/2009 PS-2
METHOD STATEMENT VULCATHENE PIPES
INSTALLATION
Doc. No.: 318-B1-10-73-I203
Page: 6 of 9
Rev.: A
Date: 8th June 2011
All piping shall be supported in such a manner to maintain its alignment and prevent it from sagging.
Suspended piping shall be supported with metallic hangers of sufficient strength. Plumber’s strap, pipe clamps and brackets shall be used for suspended piping. Hangers and straps shall not compress, distort, cut or abrade the piping and shall allow free
movement of pipe. Pipe, exposed to damage by sharp surfaces shall be protected. Support all horizontal piping at intervals of not more than 1.2 m, at end of branches, and at
change of direction or elevation. Supports shall allow free movement, but shall restrict upward movement of lateral runs so as
not to create reverse grade. Vertical piping shall be supported at each floor level and at maximum of 3 m. Support the trap arm in excess of 1 m in length as close as possible to the trap.
7.0 RESOURCESThe below detailed resources are indicative as to requirements and will be subject to change to ensure that sufficient resources are applied to comply with the approved timelines required.
7.1 Tools & Equipment
Hand Saw Grinders Vulcathene Groove Pipe Cutting Tools Vulcathene Spanners Various Hand Tools Trailers
7.2 Material
Vulcathene Pipes & Fittings Vulcathene Lubricant
The materials shall not be released for fabrication and installation unless relevant Material approval is issued by the Contractor and Client.
The aforementioned UPVC pipes and fittings will be installed inside the building, exposed or buried under the tiles.
Samples to be provided within the site sample room for verification and compliance to approved material submittals.
7.3 Manpower
Site Engineer
GTC-318B-1/2009 PS-2
METHOD STATEMENT VULCATHENE PIPES
INSTALLATION
Doc. No.: 318-B1-10-73-I203
Page: 7 of 9
Rev.: A
Date: 8th June 2011
Safety Officer Plumber Pipe Fitters. Pipe Braziers
Helper Holewatch Person (if Confined Space)
8.0 QUALITY CONTROL
8.1 ComplianceSite Engineer, Supervisor and Quality Control Inspector shall ensure full compliance with the approved procedures.
8.2 Inspections and TestsInspections and tests shall be in full compliance with the approved Inspection and Test Plan (ITP) and in accordance with Project Specification, QCS 2007 and relevant Standards.
9.0 HEALTH, SAFETY & ENVIRONMENT (HSE)
9.1 Compliance
9.1.1 Kettaneh and his subcontractor shall comply with this method statement and follow the rules and guidelines as set out in the approved Construction Phase HSE Plan.
9.1.2 Kettaneh to keep Contractor and Client fully informed at all times of any issues regarding HSE.
9.2 Safety Instructions
9.2.1 All personnel involved in the activity shall undergo KCQ and Contractor safety induction courses as required.
9.2.2 All personnel involved will use necessary PPE as required for the task.
9.2.3 The workers will be made fully aware of safety requirements related to the activity through Daily Task Instruction prior to works commencing.
9.2.4 All required Permit to Work (PTW) and supporting documents shall be acquired and kept available at respective work locations.
9.2.5 No personnel shall roam across limits of work, or roam adjacent to or come nearby live equipment installations.
9.2.6 Existing utilities and facilities are not to be used unless specifically approved to do so by Contractor and Client.
GTC-318B-1/2009 PS-2
METHOD STATEMENT VULCATHENE PIPES
INSTALLATION
Doc. No.: 318-B1-10-73-I203
Page: 8 of 9
Rev.: A
Date: 8th June 2011
9.3 Job Safety Analysis
Job Safety Analysis shall be conducted for Vulcathene Pipes Installation and the findings communicated to all personnel involved.
See Appendix A.
9.4 Personal Protective Equipment
The following Personal Protective Equipment (PPE) shall be used during the execution of the work:
Safety Helmet Coverall with reflective stripes (or Hi-Vis Vests) Safety Shoes Hand Gloves (as required) Dust Mask (dusty conditions) Safety Glasses (as required)
Further PPE as required by the task will be used.
9.5 Protective Measures
9.5.1 Provision of Personal Protective Equipment (PPE).
9.5.2 Safe means of access to be provided at all times.
9.5.3 All materials to be stored strictly in accordance with Manufacturers recommendations and shelf life will be closely monitored and verified/checked before use.
9.5.4 Material Safety Data Sheet for all materials shall be available at site and the workforce will be specifically advised of the health and safety implication, hazards and precautions before handling such material
9.5.5 All empty tins and packaging shall be safely stored and disposed of in accordance with the approved Waste Management Procedures.
9.5.6 During night works (if any), sufficient task and access lighting will be provided around the excavations and working areas. Any night work to be approved by Contractor and Client.
9.5.7 Spillage containment trays to be placed under generators and similar equipment. Generators to be properly earthed.
9.5.8 During Hot Weather Working ensure operatives take regular breaks and drink water as per the General Heat Stress Index.
9.5.9 Holewatch Person to be provided if Confined Space working.
9.5.10 In severe sandstorm work to be suspended.
GTC-318B-1/2009 PS-2
METHOD STATEMENT VULCATHENE PIPES
INSTALLATION
Doc. No.: 318-B1-10-73-I203
Page: 9 of 9
Rev.: A
Date: 8th June 2011
9.6 Access to Site
9.6.1 Kettaneh, subcontractors and suppliers shall strictly follow the approved procedures for site access for plant, equipment and operatives.
9.6.2 All the traffic rules set by Contractor and Client shall be obeyed strictly.
9.7 Plant & Equipment Control
9.7.1 All drivers and operators shall be competent persons and have a Qatari Drivers License and 3rd Party Certification where appropriate.
9.7.2 Plant and equipment to be fully licensed and regularly serviced and inspected.
9.7.3 Transportation of materials, plant and equipment to and from site to comply with the transportation Laws of Qatar.
9.7.4 In case of emergency alarm, pull vehicle/plant/equipment to a safe location, render the vehicle/equipment safe, switch off ignition and proceed to nearest muster point on foot.
10.0 APPENDICES
Appendix A: Job Safety Analysis
