You are on page 1of 12

COMPANY: PETRO RABIGH

- 1 -Page 1 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

METHOD STATEMENT
OF
UNDERGROUND RTR/GRE PIPING INSTALLATION
(UNDERGROUND SANITARY SEWER & INDUSTRIAL DRAINAGE LINES)

REVIEWED FOR TECNIMONT


DISCIPLINE
QA/QC

APPROVED BY

REV.NO

CIVIL

KETTANEH ISSUE STATUS


Rev.
0

Date
17 Oct 06

Description

Prepared

Checked

Approved

Under Ground Piping Installation

RUSSEL

Z.A.Molla

CB

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 1 of 12

COMPANY: PETRO RABIGH

- 2 -Page 2 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

CONTENT:
1.

GENERAL INFORMATION
1.1
1.2
1.3
1.4
1.5

2.

EXECUTION
2.1
2.2
2.3
2.4

3.

Reference Standard
Responsibilities
Test and Measurement
Inspection

SAFETY
4.1
4.2
4.3

5.

Materials
Tools & Equipments
Procedure of Work
Responsibilities

QA / QC
3.1
3.2
3.3
3.4

4.

Introduction
Purpose
Scope of Work
Location
Definitions

Guidelines
Responsibilities
Hazard Analysis

ATTACHMENTS

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 2 of 12

COMPANY: PETRO RABIGH

- 3 -Page 3 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

1.0

GENERAL INFORMATION

1.1

Introduction
TECNIMONT Arabia Ltd. (TAL) has awarded KETTANEH Construction Saudi
Arabia Ltd. the subcontract for the construction of PC3 Plant of Rabigh
Development Project, Rabigh K.S.A.

1.2 Purpose
To provide a procedure to be perform throughout the project to ensure
conformity with project specifications and approved drawings.
1.3 Scope of Work
This Method Statement outlined the procedure of the installation of
underground RTR/GRE piping for Sanitary Sewers and Industrial Drainage
System in the Rabigh Development Procect PC3 in accordance with project
specifications and approved drawings.
1.4 Location
The RTR/GRE pipes shall be used for underground piping as specified in the
approved drawings for the HDPE & Butene Area of PC3 Plant Rabigh
Development Project, Rabigh K.S.A.
1.5 Definitions
SAES
PIP
RTR/GRE
QA / QC

:
:
:
:

Saudi Aramco Engineering Standard


Process Industry Piping
Reinforced Thermosetting Resin / Glass Reinforced
Quality Assurance / Quality Control

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 3 of 12

COMPANY: PETRO RABIGH

- 4 -Page 4 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

2.0

EXECUTION
2.1 Materials
a. BONDSTRAND RTR Pipe Series 2400
b. BONDSTRAND RTR Fittings Series 2410
2.2 Tools and Equipments
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.

Pipe shavers
Heating Blankets
Come-along
Band Clamps
Air Blower
Grinders & Drill machines
Various Hand Tools
Mobile Crane
Excavator & Loaders
Dump Trucks, Trailers and Water Trucks
Compactors

2.3 Procedure of Work


2.3.1 Pipe Installers

Installation of RTR/GRE piping shall be done by trained personnel in the


proper handling and usage of applicable tools and equipments prior to
start of installation.
RTR/GRE pipe installer 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 2 hours.
Training Certificates must be obtained from any RTR Piping manufacturer.

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 4 of 12

COMPANY: PETRO RABIGH

- 5 -Page 5 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

2.3.2 Handling and Storage

All pipes and fittings shall be inspected upon receipt at job site. If any
defect or damage is found, it shall be segregated and will be subject for
replacement.
Loading and Unloading of pipes shall be properly controlled by using guide
ropes and proper lifting procedures. Straps, slings and ropes shall be
used.
RTR pipes and fittings shall be stored out of direct sunlight in a building or
under a cover that allows free air circulation.
Racks shall conform to factory shipping packages for each pipe size.
Shelves shall be provided for continuous support of the pipe.
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.
All supporting surfaces shall be free from sharp objects.
Adhesives shall be stored in an enclosure where temperatures do not
exceed 38 C.
Pipes and fittings shall be properly protected from impact especially on
their ends.
Care and protection of RTR Pipes and fittings shall be in accordance with
Manufacturers Instruction in conjunction with Project Specification.

2.3.3 Assembly, Joining & Laying

Before assembly, each pipes and fittings shall be examined from


damages.
Pipe inside surfaces shall be cleaned by rags or by purging air from an air
compressor before assembly.
RTR/GRE piping shall be installed according to Manufacturers Instruction
in conjunction with project specifications and approved drawings.
Bondstrand RTR/GRE Manufacturers Assembly Instructions for
Taper/Taper adhesive bonded joints (see attachments) to include cutting
& shaving, preparation & cleaning of bonding surfaces, mixing of
adhesives and curing agents, application of adhesives and curing
requirements shall be strictly followed and implemented.
Adhesives shall be mixed in their entirely of the mixing kit.

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 5 of 12

COMPANY: PETRO RABIGH

- 6 -Page 6 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

250 mm nominal pipe size and less may be assembled next to or in the
trench.
Piping larger than 250 mm nominal pipe size shall be assembled in the
trench.
For trenches 2 meters deep or less, pipe assembled next to the trench
shall not be moved within three pipe lengths of an uncured joint. The
pipeline shall be lowered into the trench progressively.
Crane and (or) labors shall be used for placing pipes into the trench using
proper tools and equipments such as ropes, straps and slings to control
and maintain proper handling procedure.
Before start of the pipe laying, the bottom of the trench shall be dry,
continuous, smooth, free of rocks and to the line and grade shown on the
installation drawings.
The clean sand bedding shall be compacted according to SAES-S-070.
Pipe location, elevation and slope shall be maintained by a surveyor. A
survey report shall be made after final installation.
Sand bags shall be placed at the bottom of pipes to meet the exact
elevation and slope of the pipe being installed. The sand bed shall be then
adjusted accordingly to maintain the pipe on the ground is on a firm bed
for its entire length.
Excavation a little deeper on the place where the pipe is to be joined shall
be done to allow access for the installer for proper joining method.
Pipe shall be installed continuously downhill without low points and high
points.
At the end of every work shift, personnel performing the pipe installation
shall ensure that the pipe ends are capped to prevent entry of foreign
materials.
Pipe is to be anchored by partial sand covering of the pipe to prevent
floatation and to maintain its alignment and level.

2.3.4 Trenching and Bedding

Prior to start of excavation, make sure that the pipe line coordinates and
elevation has been checked and verified by the surveyor.
Excavation and sand bedding shall be done mainly by equipments
(excavators and loaders).

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 6 of 12

COMPANY: PETRO RABIGH

- 7 -Page 7 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

Manual excavation is required in cases where equipments are not


possible or are not allowed due to safety reasons or where manual
excavation is more convenient in a specific area.
Excavated materials shall be placed at a suitable distance from the edge
of excavation so that materials do not fall back into the trench or
excavated materials will be put directly to a dump truck and will be
unloaded to a designated area away from the trench.
Loaders shall be used for placing sand bedding materials into the trench
while labors will spread manually to meet the correct elevation and slope
throughout the trench.
The minimum trench width from the bottom to 300 mm above the top of
the pipe shall be 300 mm for pipe size 90 mm & below and 300 mm +
Outside Diameter for pipe size 100 mm & above.
Depth of trench shall be dug deep enough to provide a ground bed of at
least 150 mm from the bottom of the pipe.
Clean sand bedding layer of 150 mm thickness shall be compacted to at
least 70% relative density or 95% Proctor density.
The trench bottom shall be continuous, smooth, free of rocks and to the
line and grade shown on the approved installation drawings.
If trench de-watering is necessary, no pipe installation shall start until the
design of the de-watering system has been approved.
Trench de-watering system shall be done in accordance with SAES-S114.
De-watering system shall be done by trained personnel only.

2.3.5 Backfilling

Make sure that Inspection & Testing has been done and approved before
any backfilling works starts.
Backfilling shall be done mainly by equipments (loaders & compactors)
while some labors spreading manually the sand and backfill materials
wherever required.
The pipe shall be covered to at least 300 mm clean sand above the top of
the pipe and shall be compacted by water flooding and hand tamping only.
Backfill above 300 mm sand cover shall be on site excavation or borrowed
materials.

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 7 of 12

COMPANY: PETRO RABIGH

- 8 -Page 8 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

Backfill above sand cover shall be compacted according to SAES-S-070


Table-5 Minimum Compaction.
Minimum cover on top of pipe shall be in accordance with SAES-S-070
Table-2.
If it is impossible to achieve the minimum cover as specified, the piping
shall be protected by concrete slab or metallic casing in accordance with
SAES-L-460.

2.3.6 Gravity Test

Gravity sanitary sewer and Industrial drainage system shall be tested with
potable water, well water or sea water.
Gravity test shall be done from manhole to manhole or a column of water
equivalent to the rim elevation of the upstream manhole if pipe is to be
tested separately.
Gravity test shall be maintained for a period of 4 hours for lines whose
joints have not been backfilled or are above ground piping while 24 hours
shall be maintained for lines whose joints have been backfilled.
If manholes are not part of the test or a section of pipe is to be tested, the
pipe ends shall be covered with plumbers test plugs.
An extension pipe is provided on the test plugs at selected location for
water filling and drain points and at least one pipe riser for the water head
required that shall be accessible for visual inspection.
Plumbers test plugs that are not used for other purposes shall be kept
open while filling of water to release air inside the system and shall be
closed when the system has been properly vented.
Water filling into the pipe being tested shall be from a water truck or a
ground level water tank with electric or engine-driven pump. A water hose
shall be placed direct to the manhole, to the pipe being tested or to a pipe
connection provided at the plumbers test plug.
All joints shall be exposed and cleaned for visual inspection.
Partial sand covering and backfilling on the body of the pipe being tested
shall be done to prevent floatation during test.
Drain valve shall be provided at the lowest portion of the pipe being tested
for safe draining after inspection.
Water used for testing can be re-used for another gravity test, for water
flooding of pipe sand covering, for water spray of trenches or discharge to
a designated area.

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 8 of 12

COMPANY: PETRO RABIGH

- 9 -Page 9 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

2.4

Responsibilities

3.0

Repair methods for leaking pipes, joints and fittings shall be in accordance
with SAES-S-070.

Site Engineer shall organize, manage and supervise all activities related to
the installation of RTR/GRE piping with regards to safety, quality and
productivity of the over-all performance of the work.
Site Supervisor and Foreman shall arrange all the necessary manpower,
tools and equipments and implement the approved working procedure for a
proper execution of the work with regards to safety, quality and productivity.
Surveyor shall provide all necessary coordinates and elevation at the start of
excavation up to final installation of pipes.

QA / QC
3.1 Reference Standards

SAES-S-010
Sanitary Sewers
SAES-S-020
Industrial Drainage and Sewers
SAES-S-060
Saudi Aramco Plumbing Code
SAES-S070
Installation of Utility Piping system
SAES-L-610
Non-Metallic Piping System
SAES-L-460
Pipeline Crossings Under Roads and Railways
SAES-A-114
Excavation and Backfill
PIP CVS02700 Underground Sanitary Sewer Specification
PIP CV102720 Sewer Details
PIP CVS02100 Site Preparation, Excavation and Backfill
Material Submittal MS-C-033 Rev. 0
Kettaneh QA / QC Plan

3.2 Responsibilities

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 9 of 12

COMPANY: PETRO RABIGH

- 10 -Page 10 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

QA / QC Inspector shall make sure that all activities related to the piping
installation are carried out in accordance with the project specification and
approved drawings. He shall arrange Inspection & Testing required with
TECNIMONT and PETRO Rabigh in accordance with the QA/QC Plan. He
shall maintain and keep records for all QC Documents.
Site Engineer, Supervisor and Foreman shall assist the QA/QC Inspector
whatever he required in relation to the quality of works, procedures or
documents.

3.3 Test and Measurement

No special device or equipment to be used for the gravity test of underground


RTR/GRE piping.
By simply marking the water level at the manhole or pipe being tested at the
start of the test, the piping being tested shall be considered satisfactory if no
reasonable drop on the water level after the specified test period and if no
evidence of water leakage on the body of the pipes, fittings and to the joints.

3.4 Inspection

4.0

Request for Inspection shall be issued to TECNIMONT / PETRO Rabigh


Project Inspection 24 hours in advance on weekdays and 48 hours in
advance for weekends and holidays.
Inspection shall be done in accordance with the QA / QC Plan.
During Inspection, all exposed pipes, joints and fittings shall be carefully
examined for leakage.
The piping being tested shall be satisfactory if there is no evidence of
leakage or reasonable drop in the water head after the specified test period.
Leaking pipes, joints and fittings shall be replaced and test shall be
repeated until the system is proven satisfactory.

SAFETY
4.1 Guidelines

Person working with RTR/GRE piping shall wear the Personal Protective
Equipments at all times on the job site.

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 10 of 12

COMPANY: PETRO RABIGH

- 11 -Page 11 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT

All trenches shall be provided with proper barricades such as physical


barriers and safety tapes.
Warning sign boards and lights shall also be provided where necessary.
Proper access such as ladders and ramps shall be provided at designated
areas where workers can go in and out the excavated area.
Spotter shall be present at the job site whenever excavators and loaders
are working.
Rigger shall be present at the job site whenever pipe is to be lifted by crane.
Spotter and Rigger shall wear reflective high visibility vest.
Excavation Permit shall be provided before start of any excavation.
Dust mask shall be provided to workers whenever they are cutting, shaving
and grinding of the RTR pipes.
All equipments shall have Aramco stickers or safety tags to ensure that said
equipments are approved for a safe working condition.

4.2 Responsibilities

Safety Inspector / Officer in conjunction with the site supervisor or foreman


shall physically check and conform that all safety requirements had been
provided and implemented.
Operators, riggers and spotters of heavy equipments shall follow and
implement proper safe working procedure at all times.

4.3 Hazard Analysis


Job Description
1. Pipe shaving, cutting
and grinding

Preventive Measures

Responsibilities

1. Injury to worker from


moving parts

Hazard

1. Only trained personnel


are allowed to operate

Engineer, supervisor
and foreman

2. Electrical shock

1. Check cables and


voltage

Engineer, supervisor
and foreman

2. Curing of joints

1. Electrical shock

1. Check cables and


voltage

by heating blanket
3. Excavation &
Backfilling by

Engineer, supervisor
and foreman

1. Injury to worker and


damage to structure

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

1. only licensed operator


are allowed to operate
Date: 8-May-14

Engineer, supervisor
Foreman, operator
Page N. 11 of 12

COMPANY: PETRO RABIGH

- 12 -Page 12 of 12

RABIGH DEVELOPMENT PROJECT, PC-3

METHOD STATEMENT
equipments

or other equipment

4. Pipe laying by mobile


crane

2. spotters to be provided

and spotter

2. Fall of equipment
into the trench

1. only licensed operator


are allowed to operate
2. spotters to be provided
3. physical barriers to be
provided near the trench

Engineer, supervisor
Foreman, operator
and spotter

1. Injury to worker and


damage to structure
or other equipment

1. only licensed operator


are allowed to operate
2. rigger to be provided
3. check hoist, slings, belts

Engineer, supervisor
Foreman, operator
and rigger

2. Fall of equipment
into the trench

1. only licensed operator


are allowed to operate
2. rigger to be provided
3. physical barriers to be
provided

Engineer, supervisor
Foreman, operator
and rigger

5.0 ATTACHMNETS
5.1
5.2

BONDSTRAND RTR PIPE Assembly Instructions for Taper/Taper


Adhesive bonded joints.
RTR Training Certificates of KETTANEH RTR Installers

5.3

CV of Piping Sections Key Personal for this Project.

KCS/ MS/HDPE-BUTENE-1/CIV-010

Rev. 00

Date: 8-May-14

Page N. 12 of 12