Mst,Hemp - Hdd

L&T – Galfar Consortium

Main Contract 5 Development of Salalah Airport

METHOD STATEMENT FOR HORIZONTAL DIRECTIONAL DRILLING (HDD) FOR INSTALLATION OF HDPE PIPE

Aconex No: SA-LTG-05EL-MST-0014

Rev No

Date Description Prepared Checked Approved QA QC HSE

111.03.201

2

Horizontal Directional Drilling for High Density Poly Ethylene Pipe Installation

RN / APY RKR / NRVV UKN LKJ

SA-LTG-05EL-MST-0003 of 19


Contents Page No

1.0 Scope ---- 3

2.0 Purpose ---- 3

3.0 References ---- 3

4.0 Definitions ---- 3

5.0 Responsibilities ---- 3

6.0 Resources ---- 4

7.0 Procedure ---- 5

8.0 Quality assurance ---- 10

9.0 Health and Safety ---- 10

10.0 Environmental Issues ---- 11

11.0 Attachments ---- 11



1.0 SCOPE

Horizontal Directional Drilling for High Density Polyethylene Pipe Installation at 132kV Cable Installation in necessary road crossing Area.

2.0 PURPOSE

The purpose of this method statement is to describe the sequential procedure for Installing the HDPE Pipe to be complete in a planned and safe manner by satisfying the project specifications and requirements for MC-5 Development of Salalah Airport.

3.0 REFERENCES

Contract Tender Specification SA-000-O-11139 (3902.132kV Cable Systems)

Approved vendor drawings / documents. Overall Equipment Layout, Plan & Section Details (The approved plan and section details will

be used at site.) Approved Material Approval Submittal (SA-LTG-05EL-MAS-0002) HSE Management Plan (Ref: SA-LTG-05AP-PLN-0003 Rev-2) HSE Guide lines for supervisors (Ref SA-LTG-05SC-PRO-0006).

4.0 DEFINITIONS

Manufacturer

Vendor / Supplier

IFCIRITPMIREngineerHSEQCIHEMPHDD

-

-

---------

The party responsible for the manufacture of equipment and services to perform the duties specified by the Consultant or Company.A party responsible for the supply of equipment, materials or product-related services in accordance with the Purchase Order issued by company or its nominated Purchasing Office.Issued For Construct ionInspection RequestInspection & Test PlanMaterial Inspection RequestCowi-Larsen JVHealth, Safety & EnvironmentQuality Control Inspector Hazards and Effects Management ProcessHorizontal Directional Drilling

HDPEBDAELCB

---

High Density Poly EthyleneBefore, During and After.Earth Leakage Circuit Breaker

5.0 RESPONSIBILITIES

Package Manager: Responsible for overall activities and ensure that the works are carried out as per Specifications, HSE and Quality Requirements.



Construction Manager: Responsible for control of operation and ensure that the works are carried as per the specifications, Drawings and Method Statements. Shall ensure the specifications, Drawings, Method Statements are available on site and is communicated down to Site Engineer.

Project Engineer: Will coordinate with Site Engineers and ensure all the project activities are performed according to the scheduled program, HSE procedures and Quality procedures. Will ensure the Specification, Drawings, Method Statements are available on site and is communicated down to Site Engineer.

Site Engineer: Will be responsible to ensure site Construction activities are being executed as per approved Method Statement, Specifications, latest IFC drawing, relevant QC check list & formats are duly completed as per Inspection & test plan. Materials used at site are as per Approved Material submittal.

Land Surveyor: Shall coordinate with Construction Manager and Site Engineer for setting out (the site controls) using line & levels and approved coordinates as per IFC drawings.

QA/QC Engineer: Will be aware of the daily construction program. Will attend all inspection points, witness the results of the inspection on the appropriate forms and obtain the approval signatures. Compile and maintain all inspection records.

QC Inspector (QCI): Will be aware of the daily construction program. Will attend all inspection points, assist with the QA QC Engineer by record the results of the inspection on the appropriate forms and obtain the approval signatures. Compile and maintain all inspection records.

HSE Advisor: Shall advise the line staff & workers on HSE matters; organize / conduct HSE training, facilitate implementation of HSE requirements, monitor compliance and report performance and non-performance.

Vendor Representative: Shall coordinate with site engineer and supervisor for Installing the Transformer and accessories as per the General Arrangement Vendor drawing. Follow the procedures and HEMP control measures.

Foreman: Shall coordinate with the Site Engineer and will be responsible for individual activity. Ensure that latest IFC drawings are being used at site. Organizing all necessary material, tools, equipment to the work site and assigning workers prior to commencement of work. Follow the procedures and HEMP control measures. Ensures that all recommended PPE be used by the workers. Ensure that risk control measures are known to workers by arranging daily toll box meetings.

Technicians: Will receive the work instruction from the supervisor and carry out the activity in line with the IFC drawing & stipulated schedule.

Helper: Will receive the work instruction from the supervisor and carrying out the activity by assisting with the Technicians to complete the specified task in the stipulated period.



6.0 RESOURCES6.1 Manpower

Manpower shall be used for Horizontal Directional Drilling work Includes but not limited to, Site Engineer HSE Advisor Foreman Land Surveyor Machine Operator Welders Helpers

6.2 Tools & Equipment’s

Tools and Equipments shall be used for HDD work, but not limited to:

Drilling System Drill Head Guidance System Drilling Fluid System Drilling Fluids Mud Delivery System Pipe rollers or cranes Welding machine

7.0 PROCEDURE7.1 MATERIAL DESCRIPTION

7.1.1 DRILLING SYSTEM

The directional drilling rig shall consist of a hydraulically powered system to rotate, push and pull hollow drill pipe into the ground at a variable angle while delivering a pressurized fluid mixture to a guidable drill head.

The rig shall be anchored to the ground to withstand the pulling, pushing and rotating force required to complete the crossing.

The hydraulic power system shall be self contained with sufficient pressure and volume to power drilling operations.

Rig shall have an automatic and continuous system to monitor and record maximum pull-back force during pull-back operations.

Pulling capacity of the drill rig shall be at least two times the calculated pulling force.



7.1.2 DRILL HEAD

The drill head shall be steerable by changing its rotation and shall provide the necessary cutting surfaces and drilling fluid jets.

7.1.3 GUIDANCE SYSTEM

An electronic guidance system shall be used to provide a continuous and accurate determination of the location of the drill head during the drilling operation.

The guidance shall be capable of tracking at all depths and in any soil condition, including hard rock. It shall enable the steering engineer and the rig operator to guide the drill head by providing immediate information on the tool face, azimuth (horizontal direction) and inclination (vertical direction) and actual depth & pre-computed depth.



7.1.4 DRILLING FLUID SYSTEM

A self-contained, closed drilling fluid mixing system shall be of sufficient size to mix and deliver drilling fluid composed of bentonite clay,clean water and appropriate additives.

The mixing system shall be able to molecularly shear individual bentonite particles from the dry powder to avoid clumping and ensure thorough mixing.

The drilling fluid reservoir tank shall be sized for adequate storage of the mud. The mixing system shall continually agitate the drilling fluid during drilling operations and

provide the drilling mud directly to the on-board mud pressure pump at the rig.

7.1.5 DRILLING FLUIDS

Drilling fluids shall be composed of clean water, appropriate additives and bentonite.

Water shall have a minimum pH of 8.0. Water of a lower pH or with excessive calcium shall be treated with the appropriate amount of sodium carbonate or equivalent.

Drilling fluid shall be maintained at a viscosity sufficient to suspend cuttings and maintain the integrity of the bore wall.

7.1.6 MUD DELIVERY SYSTEM

The delivery system shall have a minimum capacity to supply mud in accordance with the required drilling equipment and pull-back rating at a constant required pressure.

A berm of suitable height shall be maintained around drill rigs, drilling fluid mixing system, entry and exit pits and drilling fluid re-cycling system to prevent spills into the surrounding environment.

7.1.7 OTHER EQUIPMENT

Pipe rollers or cranes shall be of sufficient size to fully support the weight of the pipe during pull-back operations. Adequate number of rollers shall be used to prevent excess sagging of pipe. Rollers shall also have height adjustment feature, where required or the use of side booms or cranes.

Equipment for welding, field joint coating and filed hydro testing shall be used as per specifications.

7.2 WORK PROCEDURE

The working steps of Horizontal Directional Drilling (HDD) are as follows:

7.2.1 SITE SURVEY

A site survey shall be located for existing buried utilities and identify the intended location of the bore path and depths.

Environmental issues shall be addressed and permits shall be obtained for commencement of HDD works.

Crossing Survey shall be identified for clear bore path. Trial holes and utility identification shall be made for HDD works completed in a safe manner.



Excavation shall be done both a launch pit at the entry side of the crossing and a reception pit of the crossing in the desired location according to utility identification and safety parameters of the site environment.

Safety guidelines shall be followed around both launch and reception pits. HDD cross section Profile drawing shall be made available for works to commence.

7.2.2 RIG SET-UP AND PILOT HOLE DRILLING

The directional drilling equipment shall consist of a directional drilling rig to perform the drilling and pullback the pipe, a drilling fluid mixing and delivery system to successfully complete the crossing, a guidance system to accurately guide drilling operations and trained and competent personnel to operate the system.

Equipment shall be made in good and safe operating condition with sufficient supplies, materials and spare parts on hand to maintain the system in good working order for the duration of the work.

Pilot Bore:

Horizontal Directional Drilling activity will involve the installation of 6 nos of 1x200mm HDPE pipe per boring with an estimated total length of 612 metres with 5 nos. of locations.

The pilot bore of the first hole shall be drilled continuously from launch to reception pit. The pilot bore shall be guided and steered throughout the pilot bore using radio location

equipment positioned in the drilling head itself, which indicates the angle and position of the drill head and shows the actual depth of the head and a pre-computed forecast of the drill head position.

The drill string is able tosteer and change direction with the use of a “slant nose” drilling bit. This acts as a wedge when thrusted through the surrounding soil without rotation or a motor for rock drilling.

The change in alignment and pitch shall be monitored by the steering supervisor. The desired deviation has been achieved, the drill stem shall be rotated constantly and thrusted through the soil to follow the new bore path.

During the pilot hole, the depth from ground level to every 3 meters shall be recorded by drilling record sheet.

The depth shall be confirmed with the drill head detector which will be calibrated prior to commencement of drilling and recorded in record sheet.

Note: The minimum clearance under any known existing utility shall be 1.5 meters. Bentonite fluid shall be pumped constantly through the drill string and used to clear the bore of

excavated material and also to fill the annulus around the drill pipe to maintain a positive



pressure within the bore at all times. This shall be monitored visually in the launch pit by the quantity and quality of the bentonite returning to the pit.

Pilot Hole Drilling

HDD equipment shall be made set up approximately 10-15m back from the launch pit and then drills through the launch pit and continues the bore to the reception pit. When the back reaming commences, the launched pit shall be enlarged to receive the pipeline.



7.2.3 COMMENCEMENT OF BACK REAMING STAGE

After the pilot bore has been completed, the drill head shall be removed from the drill string and the first back reamer (12 inches) shall be attached to the string to enlarge the hole.

The back reamer shall be rotated continuously in a clockwise direction through the bore from reception pit to launch pit.

After the back reamer reaches the launch pit, it will remove and the drill head shall be re-installed on the drill string and again rotated clockwise through the bore back to the reception pit.

During this process, the drill head shall be monitored continually and checked with equipment location to ensure that it is in the correct bore path (the reamer shall not be pushed back through the bore).

The reaming process shall be done until the desired final bore diameter has been achieved (during all the reaming stages, bentonite shall be pumped constantly through the drill pipe and the back reamer shall be prevented by wear and clears the bore of excavated material and the entire bore path shall be maintained a positive pressure).

NOTE: The reaming stages could vary depending on the ground conditions on each individual crossing.

7.2.4 PIPE PULLING

HDPE pipes shall be joined together to make one for continuous installation.

The approved pipe shall be inspected by Engineer prior to installation. The HDPE pipe shall be lowered into a trench in line with the prepared bore and

connected to the back reamer with the use of a pulling swivel and steel pulling head which is fabricated onto the front of the pipeline.

The pipe shall be installed carefully into the bore behind the reamer. Bentonite shall be pumped continuously through the reamer to allow smooth insertion of

the pipe into the prepared bore path and allow enough access material to flow from the bore.

During this stage of works, the flow of bentonite from pipe side and rig side shall be monitored carefully for no undue build-up of pressure within the bore path.

The annulus between the pipe and the bore shall be grouted with a mixture of bentonite and the surrounding soil which quickly starts to set after completion of works.



The bentonite shall be made for set and provide protection around the HDPE pipe. Bentonite is also used for lubrication to reduce the amount of friction enforced upon the HDPE pipe.

7.2.5 DEMOBILIZING SITE

After HDPE pipe has been installed, the HDD machine shall be disconnected from the pipe and safely removed.

while all other works are completed, The launch and reception pits shall be poured by surplus bentonite material.

The pulling head shall be removed from the installed pipe.

8.0 QUALITY ASSURANCE

The Quality Assurances encompass of following.

1. Check, hold points are followed and Works Execution inspection and Tests shall be monitored, witnessed and recorded as per ITP SA-LTG-05EL-ITP-0001

2. Work shall be executed as per the IFC drawings and specifications.3. Ensure materials used are as per approved Material Approval Submittals ( SA-LTG-05EL-

MST-0002)4. Inspection Request forms (IR) will be raised and approval from engineer will be obtain before

proceeding the next activity as per ITP.



5. Marked up drawings, Final As built Drawing will be prepared and approval will be obtain from Engineer.

9.0 HEALTH AND SAFETY

All employees involved in the activity shall undergo site HSE induction course prior to deployment to the work site.

Site activities shall be carried out in a safe manner according to the approved “Project Health, safety and environment plan”.

9.1 Training (Workers & supervisors).

The following HSE training shall be delivered to the crew but not limited to:

Awareness about emergency response. Use of hand tools. Excavation Hazards. Hazards of HDD Rig operation. Access / Egress. Hot work. MSDS awareness.(Drilling Fluids)

9.2 Risk Assessment and control – through HEMP.

HSE Hazards involved in the activity has been assessed through Hazards & Effects Management Process (HEMP) for each and every activity and the outcome is recorded. (Refer attachment)

The contents in HEMP Register shall be disseminated within the crew by the shift supervisor / foreman, through Toolbox Talk.

Any new hazards identified other than in the HEMP with reference to site conditions shall be assessed and control measures shall be taken by the Site Engineer/Supervisor prior to commencement of any activity.

Following control measures generally apply to all hazards that shall be adopted as a proactive measure in addition to the specific controls identified in the HEMP Register: Correct use & maintenance of tools and equipment. Deployment of competent personnel for the task. Conduct daily toolbox talks prior to work commencement Provision of adequate hazard warning signage/ barricades etc. Provision of first aid and fire fighting appliances. Good Housekeeping. Adequate and effective supervision. Use of necessary PPE. Provision of welfare facility.



9.3 Additional Personal Protective Equipment (PPEs).

Cotton hand Gloves – for manual handling, rubber hand gloves for handling of hazardous materials etc.

Ear plug if welder noise is above action levels.

Use of dust mask if required.

9.4 First Aid / Medical Facility / Emergency Response

Availability of First Aiders, with ready access to first aid boxes kept at site shall be ensured at worksite.

Site clinic will be manned with Doctor during working hours. In case of any emergency, call LTG emergency number 93216576 for help. Follow project wide LTG emergency response arrangements.

10.0 ENVIRONMENTAL ISSUES

Dust.

Noise.

10.1 Mitigation Measures

Dust control by water spraying around the area.

Ensure use of Ear plug, if required.

11.0 ATTACHMENTS

HSE Hazards and Effects Management Process (HEMP)


MC-5 DEVELOPMENT OF SALALAH AIRPORT


Activity: Horizontal Directional Drilling for High Density Poly Ethylene Pipe Installation MS: SA-LTG-05EL-MST-0012

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SIGNIFICANT SAFETY HAZARD

HAZARD EFFECT

HDD route survey for road crossing.

Health Dehydration /

sunstroke.2 B L

Drinking water at a rate of up to 1 liter / hr if condition required it.

Ensure to use survey umbrella / Shade net shelter wherever required.

Intermittent rest breaks ensured. Eye protection and wearing of dust protection

ensured shall be worn if condition required it.

L

Medical Aid. (while out in the heat and son.)

Safety Hit by vehicle Vehicle collision Slip, trip and fall Bites from poisonous

creatures

3 B M

Provide appropriate sign board, caution board, diversion boards wherever necessary.

Ensure to have flagman with red / green flag and whistle to control the traffic.

Awareness on the site geographical nature. Awareness training to crew on the territorial

dangerous creature and safety precautions and emergency responses.

Ensure a vehicle presence at the survey site for emergency requirements.

First aid facility is available at place. The access / egress shall be free from obstacles. Stop job in the event of adverse weather

conditions.

L

Emergency response

EnvironmentNA

NA NA

Manual handling.

Health Body pain. Strain / Fatigue.

2 B L Intermittent rest breaks. Access to welfare facilities along the survey route. L

Medical Aid

Safety Injury due to sliding of

tray.

3 B M Refer the HSE Guidelines to supervisors – Ref: SA-LTG-SC-PRO-0006– Item No. 7.0 ( 1 )

Tool box talk prior to start of job.

L Medical Aid and Emergency response





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HAZARD EFFECT

Slip, trip and fall injury. Injury from sharp ends. Property damage.

Appropriate hand gloves use for the task. Entry restriction to other personnel. Display of caution / warning signage at site. Awareness training ensure to site personnel.

EnvironmentNA

NA NA

Access / Egress.

(General)

Safety Ergonomic issues Slip, Trip and fall

Injuries. Injury to other

personnel working nearby.

Cut injury due to contact with Sharp edges.

4 B M

Refer the HSE Guidelines to supervisors – Ref: SA-LTG-SC-PRO-0006– Item No. 7.0 ( 7 )

Ensure suitable access with handrails and intermittent landings is provided to reach work locations.

Ensure intermittent rest breaks. The access / egress shall be free from obstacles. HSE monitoring. Good housekeeping shall be maintained at site.

L

Medical Aid and Emergency response

Unloading the HDD Rig Machine and accessories..

Health Strain / Fatigue. 2 B M

Intermittent rest breaks. Ensure welfare facility on site. L

Medical Aid

Safety Crush injury. Property damage Property damage Injury / fatality to

operatives in the area. Injury from sharp ends.

4 B M Competent equipment operator for the unloading activities.

Proper access & egress arrangements. Ensure Yellow flashing beacon on the vehicle

cabin. Provide guidelines while unloading of Rig. Restrict access to authorised personnel only.Good housekeeping shall be maintained at place.

L Medical Aid and Emergency response





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HAZARD EFFECT

EnvironmentNA

NA NA

HDD Rig set -up.

Health Fatigue Body pain

2 B L Intermittent rest breaks. Welfare facility available at site. L

Medical Aid

Safety Slip, Trip and fall. Injuries Finger pinch, pierce

and crush injury. Cuts from Sharp

edges.

2 B M

Competent personal for the task Proper access & egress arrangements. Restrict access to authorised personnel only. Ensure use of suitable hand gloves. Ensure Rig set-up place shall be well compacted

and leveled. Barricade the Rig set-up area and display caution/

warning signs. Good housekeeping shall be maintained at site.

L

HDD Drill Machine Operation.

Health Dehydration Fatigue

2 B L Ensure the use of appropriate PPE Provision of welfare facility on site Periodic rest breaks for the operators.

L Medical aid

Safety Injury due to flying

objects. Property damage Personal Injury Personal injury Slip, Trip and falls Contact with sharp

bends. Injury /fatality due to

entrapment in rotating parts.

4 B M Competent personal for the task Proper access & egress arrangements. Restrict access to authorised personnel only. collection & disposal of wastes Keep material at 1 Meter away from the edge of

the pit Inspect excavations daily and subsequent to rain

or ingress of water from other sources to confirm stability of the sides prior to allowing personnel to work.

Barricade the area & place caution/ warning signs Ensure emergency response awareness to the

L Emergency response





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HAZARD EFFECT

Adverse weather Loss of reputation Splash of chemical

(bentonite)

crew Equipment and tools are inspected and certified

prior to deployment. High visibility jacket shall be used always. Awareness against the use of mobile phone

during road crossing. Reflective sticker and flickering lights to be used

during nights. Prior inspection and authorization to start the HDD

Drill machine and the machine is serviceable. A floor is compacted for keeping the HDD

machine and operates. HDD rig operator is competent and experienced

for the task for drilling fluids. MSDS kept at site and the content is known to all

site operatives. No oil leak is ensured from machine and spill trays

are kept stand by for use. Environment Waste generation Noise Dust

2 B L

Waste collection and periodic disposal Periodic water spraying to suppress the dust

nearby area. Ensure Dark glass & dust mask usage for the site

personnel if site condition required it. Use of ear plug ensured and used if require.

L

Waste Management

Hot Work.(Welding & Grinding)

Health Fatigue 2 B L

Ensured welfare facilities on site. Intermittent rest breaks. L

Medical Aid

Safety Personal injury Contact with hot

surface

4 B H

Refer the HSE Guidelines to supervisors Ref: SA-LTG-SC-PRO-006, Ref.No:7.0 –.Item 11 on Guidelines on Hot works.

Competent Personnel for the task

L

Emergency response





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HAZARD EFFECT

Fire hazard Electrocution. Adverse weather

Obtain applicable LTG permit prior to start of hot work.

Ensure ELCB fitted in power distribution board. Use of appropriate hand gloves for handling hot

surfaces. Remove reflective jacket during hot work. Ensure used face shield during grinding operation. Ensure Fire extinguisher is available at site. Ensure fire warden is available at site. Barricade the area & display caution/ warning

signs. Access restricted to authorised personnel only. Awareness training on emergency response. Good housekeeping shall be maintained at site.

Environment Noise 2 B L

Ensure use of ear plug if required.L

Environment management .

Pipe pulling in underground hole.

Health Fatigue Body pain

1 B L Intermittent rest breaks. Welfare facility available at site. L

Medical Aid

Safety Injury to personnel. Property damage. Finger pinch, pierce

and crush injury Slip, trip and fall. Injury to other

personnel working nearby.

Bites from poisonous

4 B M Selection of workers with respect of competency and health fitness.

The access / egress shall be free from obstacles. Barricade the area & display caution/ warning

signs. Provision of adequate supervision and HSE

monitoring. Emergency response to be known to all people. Care shall be taken while working near to other

services.

L Emergency Response





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HAZARD EFFECT

creatures. Keep the materials properly and away from work site.

Ensure use of suitable hand gloves. Awareness training on emergency response. Good housekeeping shall be maintained at place.

EnvironmentNA.

NA NA

APY MK UNK

HSE Advisor HSE Manager - PABS HSEM - LTG

Prepared by Checked by: Approved by

Revision Date Hemp ref:

1 11.03.2012 PABS / SA-LTG-05EL-MST-0012


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