Method Statement Pressure Testing

Danet Abu Dhabi

Infrastructure & Roadworks

Contract - 100

2012/MS – 04 Rev 4 16th March 2008 of 14

Method Statement

MS – 04

Proposed Pipeline Works

(Pressure Lines)

4 16/03/08

Engr. Ehab Hassan

Pr.Engr.

KN

N.S.Vijayakumar

QC Engr.

KN

Engr. Mohamed

Ashraf Ahmed

Sr. P.M.

KN

3 08/03/08

Engr. Ehab Hassan

Pr.Engr.

KN

N.S.Vijayakumar

QC Engr.

KN

Engr. Mohamed

Ashraf Ahmed

Sr. P.M.

KN

2 16/03/07

Engr. Sanjaykumar

Sr. QC Engr.

KN

Engr. Amr Fikry

C.M.

KN

Engr. Mohamed

Ashraf Ahmed

Sr. P.M.

KN

1 05/03/07

Engr. Ricky Khosla

(OE)

ADMAC

Engr. Khalid

Assaf (PM)

ADMAC

Mohamed Al

Shabasy (SM)

KN

0 30/09/06 Najjar (QS) ADMAC

Engr. Khalid

Assaf (PM)

ADMAC

Mohamed Al

Shabasy (SM)

KN

Revision Submitted Date Prepared by Checked by Issued by

Danet Abu Dhabi


Contract - 100

Method Statement – Proposed Pipeline Works ( Pressure Lines ) Ref. : MS – 04 Rev 4

2012/MS – 04 Rev 4 16th March 2008 of 14

REVISIONS

4 16-03-08 Consultant, PMT comments incorporated and resubmitted for approval

3 08-03-08 Red sand Bedding and Wrapping Tape Systems Included

2 16.10.07 Consultant, PMT comments incorporated and resubmitted for approval

1 05.03.07

Comments incorporated and resubmitted for approval

0 30.09.06 Issued for Approval

Revision Date Description of Modifications

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

1.0 SCOPE

3.0 REFERENCES

4.0 DEFINITIONS

5.0 RESPONSIBILITIES

6.0 GENERAL

7.0 INSPECTION & TESTING

8.0 HEALTH & SAFETY

9.0 ATTACHMENTS

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

1.SCOPE

This Method statement covers Pressure Pipeline works for

Water and Irrigation Pipeline network for Danet Abu Dhabi

Infrastructure Works project. which include dewatering,

excavation/formation, bedding of granular material, pipe

laying, pipe surround with gravel/red sand and Wrapping

tape for Water pipe line Network.

2. REFERENCES - Material Approval Requests :

Ms-29/Danet-100/KN/RS/06

MS-07/Danet100/KN/RS/06 Rev2

Ms-28/Danet-100/KN/RS/06 Rev 3

- Drawings :

Water Pipeline -Danet/KN/W/2000

Danet/KN/W/PR/2001, 2002, 2003

Irrigation Pipeline Danet/KN/IM/5000, 5001, 5002,

5003, 5004, 5005, 5006 & 5007

- Specifications : Volume 2A, Section 3, 4.21 & 6

- ADWEA Specifications for water works

- RFI/CIVIL/044 Rev. A dated 24 Feb. 2007 for

Working and Test Pressure

3. TOOLS & EQUIPMENT Typical Equipment

Dewatering Equipment

Excavator

Wheel Loader

Dump Trucks

Crane

Trailers

Plate Compactors

Hand Rollers

Warning Tape

Nylon Lifting Slings

Surveying Instruments

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

4. RESPONSIBILITIES

contractor surveyor has to issue and record data such as

levels, alignment, coordinates, existing utilities value for

clearing, grading, excavation, formation, pipe bedding,

pipe laying, surround backfilling and other activities and to

ensure that the work is carried out according to site

engineer instructions.

Contractor Foreman has to supervise/organize the

clearing, grading, excavation, formation, pipe bedding,

pipe laying, wrapping, surround, backfilling and other

activities and to ensure that the work is carried out

according to site engineer instructions.

Contractor Site Engineer for raising/requesting

inspections, monitoring the works, Coordinate with the

Laboratory and site team for conducting all the tests at

various stages and to coordinate with consultant inspector

for inspection.

Contractor’s QA/QC, receives request from site engineer

and issues to consultant further on agreeing about the

time, Date and to ensure that the quality of the work is as

per specification.

contractor’s site Laboratory Technician, to provide the

laboratory all samples required at various stages

according to instructions from laboratory manager and

consultant.

contractor’s Laboratory Engineer/Manager, to ensure that

all samples provided at various stages are tested

according to specification and certified prior to forwarding

it to the consultant (Engineer/QA-QC) for approvals.

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

5. Procedure

The work will be carried out accordingly in the following phases:

- Dewatering (If required) (Method Statement – MS 02)

- Excavation/Formation (Method Statement – MS 03)

- Bedding – Red sand (Water Pipeline) (Method Statement – MS 03)

- Bedding – Red Sand (Mar/Ms/104/Danet/100/KN/Mas/08/0)

- Pipe Laying

- Pipe Wrapping

- Hydrostatic Pressure Test (in accordance with Contract specifications Clause 4.21 and RFI /

044 Rev. A)

- Pipe Surround – Red sand (Water Pipeline) (Method Statement – MS 03)

- Pipe Surround – Red Sand (Irrigation Pipeline, Ms-044/Danet-100/KN/RS/07)

- Backfilling (Method Statement MS 03)

- Embankment (Method Statement MS 03)

5.1 Surveying will be conducted according to MS-01.

5.2 De-watering (if required) will be conducted according to MS-02.

5.3 Excavation (including trial holes) will be conducted to the proper formation level

according to MS-03.

5.4 The soil at the formation level will be compacted as per MS 03.

5.6 After formation compaction is confirmed, compliant bedding will be prepared using

approved material (i.e. Red sand for Water pipeline – Ms-05/Danet-100/KN/RS/06 Rev1

& Redsand for Irrigation pipeline – Ms-044/Danet-100/KN/RS/07) according to the

specifications and as indicated in the approved shop drawings.

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

5.7 Pipe Laying

a. Pipe shall be laid after the Wrapping tape System according to clause 6.0 by lowering it

manually (for light weight pipes) or by crane (using nylon slings to hold, for heavy weight

pipes) on the Red sand bedding.

b. The socket of the previously placed pipe will be cleaned, lubricated by putting the rubber

ring in the socket and applying liquid soap on the rubber rings, spigot and socket as per

specifications.

c. The spigot side will be pulled into the socket with the come-along jack until it is impeded

to the end of the socket.

d. After the pipe has been released to rest on the bedding, the joint gap, line and level are

checked.

6.0 Procedure for Anticorrosive pipe Wrapping Tape Systems

a. Ensure the outside of pipe and fitting is clean and dry.

b. Nylon brushes to be used for any cleaning.

c. Ensure the primer is thoroughly mixed and stored in clean containers.

d. Using the clean dry brush. Pre measured quantity of primer will be used for each pipe

length and applied evenly to achieve the coverage specified by the manufacturer.

e. When the primer is nearly dry (tack to touch) wrap the pipe using approved self adhesive

wrapping tape securing the required overlap securing sufficient tension.

f. Wrapping tapes shall be applied with 55% overlap and ensure the least 150mm overlap

when splicing the roll ends. Spigot ends of pipes will be free from wrapping for the length

required for connection purposes. No air pockets or separation underneath the wrapping

tape is allowed.

g. During the pipeline installation, the pipeline is covered with polyethylene sleeving as per

the specification. Joints and all uneven surface shall be covered with approved non shrink

non-drying mounding mastic filler compound compatible with tape to form a smooth

R4

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

surface. For tape application the maximum slope of profile is 45 degree. Application of

filler will be on dry and clean surface and manufacturer’s recommendation will be applied.

6.1 Protection of flanged Joints in Buried Conditions

a. Lines area to be wrapped is extended 400mm on both side joint i.e.(800mm total length

irrespective of the diameter of the piping)

b. Clean and dry the outside surface.

c. Use clean dry brush apply the primer evenly on the prepared clean area.

d. Uneven surface of all joints and fitting shall be filled with approved non-shrink, non

drying mounding mastic filler.

e. Wrap the prepared joint with self adhesive tape of 55% overlap. The pipeline is covered

with polyethylene sleeve as per specification.

6.2 Cable / Pipe Connections

Welded stud and soldered cable / pipe connections shall be coated to the same standard as

the pipe to which it is attached. After completion of cable connection, the cable tail shall

be secured to the pipe with a lap of tape. The cable connection shall be cleaned, primed

and profiled with mastic before tape wrapping. Cleaning and priming shall be as detailed

above. The tape wrap shall have a minimum of three and a half circumferential overlap.

6.3 Bonding / Overlap of Backing

Where required the tape shall be capable of being cigarette wrapped around the pipe and

with the adhesive removed, the PVC backing shall be bonded over its full overlap to PVC

layer beneath with suitable PVC adhesive.

6.4 Inspection

a. Inspection of coated pipe joints, fittings etc. shall be visual for satisfactory adhesion and

100% holiday inspection by a holiday detector set at the working voltage. Third party is

the responsible for carrying out the holiday detection test for the pipe wrapping.

R4

R4

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

a. The applied tape shall be inspected to confirm that effective bond is formed between the

pipe surface and the tape. This inspection shall be carried out not less than 24 hours after

application. The working voltage shall be set at least twice per working day.

b. Specific inspection upon completion of works may be required by certain project

specifications.

6.5 Points To Note

a. Wrapping must be done in shaded area and wrapping should not be done under direct

sunlight. Whilst this may not affect the product’s performance properties, this makes the

SBS modified bituminous compound extremely sticky and cumbersome to handle.

Workers may also find difficulty in peeling off the release film in high ambient

temperatures.

b. Wrapping by hand or machine must be undertaken by experience personnel under proper

supervision. Unsatisfactory workmanship shall be rejected especially where overlaps are

not consistent and where rucking is evident.

c. Rucking, especially at in-situ joints is to be avoided. Awkward and abrupt changes in

shape shall be the subject of special attention and care during wrapping, ensuring

elimination of entry paths for ground water and ground salts. Angle and speed of

automated machines should be agreed upon (for necessary overlap as per specification)

and locked to ensure continuity and uniformity of wrapping.

d. Handling after wrapping, Cotton belts shall be used for lifting purpose.

e. Wrapped joints shall not be subject to pressure from lifting devices. All skis used to

support pipes shall be thoroughly padded.

f. Wrapped pipes must be supported on unwrapped ends of pipe and not laid on the ground

except as necessary in the trench for final positioning and laying.

g. Wrapped pipes shall be protected from direct sunlight at all times and laid in the trenches

as far as possible immediately after wrapping procedure is completed, and necessary

inspection / checks done.

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

h. All Polybit Bitutape Pipe Wrapping Tape and its ancillary products (Bitutape Primer,

Bitutape Moulding Paste, Bitutape Outer Wrap) should be stored in cool, dry / conditioned

stores, covered, away from sunlight, at less than 30 deg. C temperature. Stocks should be

rotated on a first in / first out basis.

i. Tapes should be taken out from the conditioned stores just prior to application. Storing of

tapes at project site / wrapping yard without proper storage facility is not acceptable and

may affect application performance of the tape.

6.6 Backfilling

a. Once several pipes have been laid and checked for alignment and level, pipe surround

(Red Sand surround for Water pipeline & sand dune surround for Irrigation pipeline) shall

follow in layers of 150 mm thickness (compacted with hand rammers) until the required

level is reached as per the approved shop drawings.

b. Testing of laid pipe shall be carried out prior to the placement of pipe surround in

accordance with Contract specifications Clause 4.21 and RFI/44 Rev. A for pressure test

for water line and according to Contract specifications Clause 6.60.8.1 for Irrigation line.

c. Subsequent to pipe surround, backfilling will be done in accordance with MS – 03.

d. Followed by the backfilling, embankment construction will be carried out as per MS – 03.

7.0 INSPECTION & TESTING:

7.1 Hydrostatic Pressure Test

Testing of laid pipe shall be carried out prior to the placement of pipe surround in

accordance with Contract specifications Clause 4.21 and RFI/44 Rev. A for Water line

and according to Contract specifications Clause 6.60.8.1 for Irrigation line.

Pressure and Leakage Test of Water Supply Network & Irrigation Pipeline

Preparation before commencing the Test

a) Each section of pipe under test will be properly sealed off and stop ends temporarily

anchored.

b) The pipeline to be partially backfilled with all joints and sockets to be exposed.

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

c) Any valve included in the section shall be set in the open position.

d) Blank flanges shall be installed.

e) All concrete anchors or thrust blocks included in the section must have reached their

required 7 days strength.

Testing Procedure

a. The section of the pipeline shall be filled with normal drinking water or chlorinated water

at the lower end.

b. Pressure Gauge shall be fixed at the lowest point.

c. During the filling operation care will be taken to ensure that there is no entrapped air in

the section of the pipeline. It will be ensured that water cross section is fully flowing

through the air valve / nearest fire hydrant units before closing the system and applying

pressure. All peak points of the pipeline shall be adequately vented during the filling

operation to expel as much air as possible.

d. The pressure shall be raised to a test pressure of 13.5 bars and a graph of actual pressure

against volume of water used at intervals of 0.5 bars will be prepared. The pressure at the

lowest point of the section under test shall not exceed the above test pressure.

e. The test pressure shall be maintained for a period of 1 hour (by pumping if necessary).

f) The pump will then be disconnected and no further water be permitted to enter the

pipeline for a further period of three (3) hours.

g) At the end of this period the pressure shall be recorded and if the pressure is less than 12

bars, then pump shall be used and required quantity of water to be filled to restore the test

pressure shall be measured in litres.

h) The maximum acceptable leakages shall not exceed the following,

- For Water Network Supply - 0.02 litres per millimetre of nominal pipe diameter per

kilometre of pipeline per 24 hours for each bar head of test pressure applied.

- For Irrigation line – 3 litres per 1000m length per 25 mm nominal bore per 24 hours.

- The test procedure will be carried out in full coordination with ADDC and will be

according to ADWEA Specifications.

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

Leakage Repair

a. Initially, locations of leakage (whether from the fittings used for testing or from the

pipeline joints) will be confirmed.

b. Once location of the leaks’ is/are confirmed, suitable measures will be taken to solve /

repair the same.

c. After repair works are completed pipeline will be re-tested according to the above

mentioned testing procedure (Point No. 2 of section 6).

Note:

See attached (Sketch 1 & 2) as attached detailing the Testing Equipments for Water Supply

Network & Irrigation line respectively.

7.2 Disinfection and Flushing (Only for Water Network Supply line)

Introduction

a. The quantity of water for flushing has to be calculated as 3 (three) times of volume of the

pipeline, the quantity available chlorine for disinfection has to be calculated as 20 mg/l.

b. Granular hypochlorite will be used with 62% available chlorine according to the required

quantity of the available chlorine of 20 mg/l.

Procedure

a. The pipeline is disinfected at the same time as the hydrostatic tests performed.

b. One end of the new installed pipeline has to be connected to the source of water (existing

pipeline, all water used for testing shall be of drinking quality).

c. The second end of the pipeline will be plugged with adequate flange, stop valve &

discharge hose.

d. Required quantity of granular hypochlorite is mixed with sufficient quantity of water.

e. Water is started to fill from the source and at the same time hypochlorite mixture is

injected from adjacent point to the source.

f. When the chlorine reaches at the second end of the line, stop valve is closed and to stop

further filling.

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

g. Leave the chlorine inside the pipeline for 24 hours after which the line is flushed and

values for free chlorine and PH checked.

h. Samples will then be taken to the laboratory for testing.

i. The flushed water will then be discharged in to the Municipal Storm Water manhole

through a flexible hose pipe after obtaining necessary approval from the competent local

authority.

Note:

Acceptable value for free chlorine is 0.2 to 0.5 mg/l and for PH, it is 6.5 to 9.2 mg/l.

8.0 Prevention of fire Hazard

a. Bituminous wrapping tape, primer, solvents etc are fire hazardous materials these shall be

stored separately under closed store.

b. Fire extinguishers shall be kept in vicinity of wrapping stores.

c. No smoking sign/Fire hazard sign boards shall be visibly installed.

8.1 Confined Space

a. Continuous communication with the external outdoor personnel must be established.

8.2 Avoidance of eye and skin irritation

a. Wear eyes of face protection shield and hand gloves, Contact with the eye shall be

immediately attend by medic as per manufacturer safety data sheet.

R4

Danet Abu Dhabi


Contract - 100


2012/MS – 04 Rev 4 16th March 2008 of 14

9. ATTACHMENTS

a. Inspection & Testing Plan (ITP/Pipeline/P/04 Rev. 1)

b. Complete safety shall be maintained during the execution of works as per reference

"Safe/01" (as attached).

c. Drawing No. DANET/KN/MISC/SK/302 - Water pipeline test method

d. Drawing No. DANET/KN/MISC/SK/303 - Irrigation pipeline test method

e. Water Network Pressure Test Certificate

f. Irrigation Line Pressure Test Certificate

g. Material Acceptance Certificate Form No : Mar 05

h. Material Receipt Inspection Report Form No : MRIR/01

i. Certified Applicators, Letter Ref No:2012/A1-2/MAA/419-07

j. Wrapping Tape Check List Form No:19

k. Survey and Setting out Check List No.24

l. Bedding and Pipe Laying Report Check List No.01

ITP Reference Number:

ITP/Pipeline/P/04

Rev. 3

Date: 16-03-2008

1Establishing method

statementSubmit to Engineer Before work Approved document 1.37.2 (Volume 2A) H A R

2Material submittal /

approvalsSubmit to Engineer Before work Approved document 1.3 (Volume 2A) H H A S

3 Shop drawings Submit to Engineer Before work Approved document 1.5 (Volume 2A) H A R S

4 Material received on siteverifying the compliance of

received materialFor each Item Approved MAR & MRIR Form 1.3 (Volume 2A) H H S

Att Form No.MIRIR/01 & MAR

05

5 Surveying ITP/Survey/01 Rev. 2 1.4 (Volume 2A) Att Form No.24

6 Excavation/Formation ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S Att Form No.24

7 Red Sand Bedding ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S S Att Form No.24

8Anticorrosive pipe

WrappingHoliday Test ADWEA Spec w-p-ss-010

ADWEA Spec w-p-ss-

010H W S S Att Form No.19

9 Pipe LayingChecking levels &

Alignment

For every length

of Inspection

raised

Will be carried out according

approved shop drawingsSection 3 & 6 H H S S Att Form No.19, 24

10Pipe surround and Pipe top

LevelITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S S

11 Hydro test of Pipe Hydrostatic Pressure Test

For every length

of Inspection

raised

Will be carried out according to

specification & RFI/44 Rev A

Section 4.21 &

RFI/44 Rev AH H S S

Test Certificates (E-07.56.017,

Rev 0, MAR, Dated 05.01.2003 &

Form: Danet/IRR/PT/01, Rev 0)

12 Backfilling ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S S

12.1Placing of selected Backfill

in LayersITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S

12.2 Field Compaction ITP/Earthworks/03 Rev 5Section 1.28.3.2

(Volume 2A)H H H S

13Disinfecation / Flushing for

water Pipes

Laboratory Test for chlorine

and PH value

Acceptable value for free chlorine is

0.2 to 0.5 mg/l and for PH, it is 6.5 to

9.2 mg/l

Section 7.2 H H S S

14 Embankment ITP/Earthworks/03 Rev 5 Section 2, 4 & 5 H H S Att Form No.19

Consultant

SIGN: SIGN:

NAME: NAME:

DATE: DATE:

Contractor

Contractor:

Inspection and Test Plan for:

Inspection Points: H= Hold Point, W= Witness Point, R= Review Point,

S= Surveillance, A=Approval, WAT=Water Net Works Consultant

Item No. Activity Description

Project Managers: Engineer / Engineer Representative:

Contract No: 100

KN Project No: 2012

Project Title: Danet Abu Dhabi

Infrastructure Works

ITP SIGN OFF – POST COMPLETION OF WORKS

Verifying Document / ReportContractor Consultant WATTesting Laboratory

Inspection Points

Legend: ITL= Independent Testing Laboratory, ITP= Inspection and Test Plan, CI= Comments

Incorporated

Proposed Pipeline works ( Pressure lines )

Inspection and Test

ActivityAcceptance CriteriaFrequency

Specification

Reference

Location (for Post Completion signoff):

PMT

Method Statement Pressure Testing

Documents

Transcript of Method Statement Pressure Testing