Contractor: Employer: Engineer:

AJMAN WWTP SLUDGE-TO-ENERGY

METHOD STATEMENT- INSTALLATION OF STAINLESS-STEEL PIPES
Project
ASE Rev: Date:
Ref.:
Doc Ref.: ASE SIX MST GEN ME 00 00024 - 00 20-Aug-20

METHOD STATEMENT- INSTALLATION OF STAINLESS-STEEL PIPES

This page is a record of all revisions of this document. All previous issues are hereby superseded.

00 20-Aug-20 For Approval First Submission JK KA RVA

Rev Date Purpose Description Prepared by Checked by Approved by

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 TABLE OF CONTENTS
1 SCOPE OF WORKS.................................................................................................................3
2 REFERENCES..........................................................................................................................3
3 DEFINITIONS/ABBREVIATIONS..............................................................................................4
4 PERSONNEL-RESPONSIBILITIES:............................................................................................5
4.1 Tasks and Responsibilities................................................................................................5
5 SUBCONTRACTORS...............................................................................................................6
6 TOOLS REQUIRED..................................................................................................................6
7 ENVISAGED MANPOWER REQUIREMENTS............................................................................6
8 ENVISAGED CONSTRUCTION EQUIPMENT REQUIREMENTS..................................................7
9 WORKING TIME....................................................................................................................7
Working time.............................................................................................................................7
10 INTERFACES WITH EXISTING PHASE-1 &2 FACILITIES.............................................................7
11 HSE CONSIDERATIONS..........................................................................................................7
11.1 Health & Safety............................................................................................................7
11.2 Environment................................................................................................................7
11.3 Permits to Work:..........................................................................................................8
12 PROCEDURES........................................................................................................................9
12.1 STORAGE OF MATERIALS.............................................................................................9
12.2 TRANSPORTATION & HANDLING..................................................................................9
12.3 TRENCH EXCAVATION..................................................................................................9
12.4 PRE-INSTALLATION CHECK.........................................................................................10
12.5 INSTALLATION............................................................................................................10
12.6 JOINTING....................................................................................................................11
12.7 WELDING...................................................................................................................11
13 APPENDICES:.......................................................................................................................12
Appendix 1: Risk Assessment...................................................................................................13
Appendix 2: Inspection & Test Plan.........................................................................................14

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1 SCOPE OF WORKS

The purpose of this method statement is to detail the procedure installation of SS pipes at site. This
method statement describes the details of stainless-steel pipes installation, field quality control and
testing in order to execute a quality job confirming to the client’s requirement, specification and
Engineer's approval.

2 REFERENCES

 Project Safety Plans

Construction, Environment, Health & Safety Environment Plan (CEHSMP) Ref# Project Health and Safety Plan
(ASE-SIX-CHP-GEN-HS-0001-01)

 Project Quality Plan

Quality Assurance Plan (QAP)

 Project Specification

Volume: 3 PART 1 & PART 4

 Approved Material Submittal.

ASE-SIX-MAS-GEN-ME-02212 Material Submittal-Stainless Steel Pipes & Fittings

 Method Statement for SS Pipes underground wrapping

ASE-SIX-MST-GEN-ME-00005 Underground SS Pipes

 Approved drawings:

Approved GA shop drawings (general)

ASE-SIX-PID-GEN-PR-2001-01- P&ID

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3 DEFINITIONS/ABBREVIATIONS

Employer : Ajman Sewerage (Private) Company Limited

Engineer : Halcrow International Partnership
Contractor : Six Construct Ltd.
Phase 1 : Existing Wastewater Treatment Facilities incorporating UASB Treatment
Phase 2 : Existing Wastewater Treatment Facilities
Upgrade Works (CUW) Contract
MS : Method Statement
TS : Technical Specification
PTW : Permit to Work
S2E : Sludge to Energy Works

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4 PERSONNEL-RESPONSIBILITIES:

 Employer: Ajman Sewerage (Private) Company LTD

 Engineer: JACOBS
 Main Contractor: Six Construct LTD
 Operator: MOALAJAH

4.1 Tasks and Responsibilities

This section is intended to clearly define the responsibilities and communication procedure between
all the key personnel involved in the activities:

 Project Manager:

Overall responsibility for the management of the works

Official point of contact for all correspondence
Overall responsibility for Safety Management on the site

 Construction Manager:

Overall responsibility for managing the construction activity at site

Communication with Project Manager.

 Site Superintendent:

Close supervision of works.

Communication with Construction Manager.

 Surveyor:

Provision of area boundaries and the exact location for installation of temporary and permanent
works items. General setting out and daily survey checks.
Communication with Construction Manager and Site Superintendent.

 QA/QC Inspector:

Inspection and testing of materials in coordination with the Site Superintendent to fully comply with
specifications and Quality Control Plan. communication with Project Manager and Technical Manager.

 HSE Manager & HSE Officer:

Inspection and close monitoring of working procedures to ensure all works are conducted in a safe
manner. Communication, guidelines, and advice to construction team.
5 SUBCONTRACTORS

There is no requirement for subcontractors to perform the work related to this method statement.

6 TOOLS REQUIRED

Below table lists the minimum requirements of tools and machineries to perform the work:

SN EQUIPEMENT

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 1 Mobile crane
2 Excavator
3 Hand tools
4 Plate Compactor

5 Puller and chain pulley block

6 Excavator / JCB

7 Welding machine
8 Grinder.
7 Wheel loader

8 Equipment for hydro testing & Air leak test which

include: End Cap (Male/Female) or
Blind Flange, Coupling, Water Tanker, Manometer,
Calibrated Pressure Gauges, Filling Line, Air Release
Line, Low Pressure Air Filling Pump / Compressor (For
Air Testing), Water Test Pump, Jacks, drain point.
9 Cable detector (if required)

Note: The quantity of equipment will be adapted to suit the program of work.

7 ENVISAGED MANPOWER REQUIREMENTS

Below required manpower are envisaged for the work:

Site Superintendent,
Pipe fitter
Masons, carpenters, helpers
QA/QC Engineer/ Inspector
Safety
Welder

Note: The Number of the manpower will be adapted to suit the program of work

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8 ENVISAGED CONSTRUCTION EQUIPMENT REQUIREMENTS

The major materials are summarized below:

Permanent Materials:
MATERIAL NOTES
SS PIPES & FITTINGS As per the respective shop drawings

Welding rods

Pipe supports Refer the respective shop drawings

Warning Tape

9 WORKING TIME

Working time
Normal working time : from 7:30 AM to 17:00 PM
During summertime : from 2:00 AM to 12:00PM

10 INTERFACES WITH EXISTING PHASE-1 &2 FACILITIES

Not applicable

11 HSE CONSIDERATIONS

11.1 Health & Safety

 This section covers the safety requirements for the operations described in this Method
Statement. All works will be subject to the safety principles and rules of the Project.
 The various risks have been identified by a detailed Risk Assessment is included in the appendix
2.
 All Six Construct Safety Work Procedures and Work instructions to be followed.
 Measures of controlling the dust will following as per Six Construct CEHSMP
 Maintaining and cleaning the site road and highway will follow as per Six Construct CEHSMP plan
 Health & safety instructions in the Material safety data sheet for all chemical material to be
followed strictly.
 Health and safety instructions will be followed for handling sludge /sewage and relevant gases
applications.

11.2 Environment

 All environment issues shall be reported to the engineer and the safety department for further
investigation.
 Toolboxes talks shall be given regularly to reiterate the environmental hazards of an existing
work activity or to highlight the risks of a new activity and working with chemical material, and
existing sludge lines. All briefings and toolbox talks are to be given to the workers in a manner
and language, so the information is fully understood.

11.3 Permits to Work:

The following permits are considered:

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 Excavation Works Permit
 LOTO Permit from Six Construct
 If any existing services are found during the trial pit. The permit to work near the existing lines to
be obtained.
 Hot work permit

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12 PROCEDURES

12.1 STORAGE OF MATERIALS

 The pipes shall be stored with proper stacking and shall not be directly kept on the ground.
 Ensure the safety of pipes through limited and controlled movement of material and
Vehicles around
the storage area.

12.2 TRANSPORTATION & HANDLING

 While delivering pipes to the site or from one place to another, pipes shall be supported
with saddles
 Pipe ends, fittings and specials shall be protected with lateral supports during transportation
 All pipes and fittings are securely fastened on the truck to prevent movement and avoid
damages.

12.3 TRENCH EXCAVATION

 Prior to the excavation works for the trenches, the surveying work has to be completed with
the layout of the corridor, marking of the co-ordination points with reference to the other
services and finally the demarcation of the trench area to be excavated.
 Once the trench area demarcation is finalised, the soil investigations will be conducted to
check the level of water in the ground, If the level of water is less than 30cm below the
profile level of the trench, dewatering must be done with the pumping equipment and
appropriate modus operandi Of the activity will be followed to lower the water level,
Nevertheless, if the water level is more than 30cm, proceed for the excavation works with
optimum method suggested by the soil investigation report.
 Except where concrete surround is specified, either granular bedding material or approved
selected excavated granular material (normal backfill) shall be introduced at bed, surround
the pipe and compacted until it has been brought up to at least 100-150nnm above the
crown of the pipe. The method of selecting excavated material may include sieving either in
bulk or above the trench.
 Bedding shall be pushed under the pipe haunches as well as the couplers; special Care shall
be taken to place the bedding. It is recommended to compact the bedding using hand
rammers at these locations

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12.4 PRE-INSTALLATION CHECK

 All materials and documentation relevant to a particular section of works will be checked
prior to commencement of work ensuring that the materials are as per approved shop
drawings and submittals.
 Prior to commencement of any work, areas and access shall be inspected and to confirm the
readiness to start the work.
 All stainless-steel pipes and fittings material shall be as per approved shop drawing
specification and material submittals.
 It is to be ensured that all stainless-steel pipes installation is co-ordinated with other service
in order to avoid any clashes at site.
 It is to be ensured that all pipework supports are in accordance with approved shop
drawings.
 It is to be ensured that pipe supports are adequately provided and near to the pipe joints
and any change in direction. Heavy equipment will be supported independently as per
approved shop drawings and requirements.
 The spacing of supports shall be maintained as per approved drawings for above ground
pipes.

12.5 INSTALLATION

 All the pipes while installation shall be handled with the crane and operation has to be
supervised by the site engineer with professional crane operators and pipe installers.
 Where SS pipes are installed underground the pipe spools shall be lifted and lowered to
trenches using crane
 It is to be ensured that all stainless-steel pipes are free from burns, rust, scale and other
defects and will be thoroughly cleaned before erection and closing.
 To check adequate access provided for valves, pumps etc installed in the stainless-steel
piping system for operation as well as future maintenance.
 During installation open end of pipes will be protected by caps, which will be only removed
while the adjoining section is ready for installation. Check nuts, bolts, screw's, brackets,
drop rods, etc are tight and aligned properly.
 Ensure identification, flow directions and valve tags are provided as per specifications.
 Warning tapes will be laid at appropriate level below the finished ground level and
backfilled with the material approved by engineer
 Back filling shall be carried out after testing the pipeline.

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12.6 JOINTING

 To ensure that all pipes are to be cut properly, clean and all burrs shall be removed before
jointing.
 All flanges shall comply with SS316L and approved drawings.
 To ensure that all flanges shall be used with gasket, bolted together with necessary bolt/ nut
and washers, and tightened properly.
 Welding as required shall be carded out at site as per welding procedures and specifications.

12.7 WELDING

 Prior to start of any welding works, the piping material shall be checked as per BOQ in
approved drawings.
 The material shall be checked for size, schedule, type or any visual defects as per material
specification
 All fit up shall be checked to verify and confirm dimensions of groove such as bevel angle,
root face, root gap and alignment
 Tack welds shall be made by qualified welders only.
 Welder qualification validity shall be checked prior to allocation of welders on the job.
Welder's pre-qualification shall be valid for a period of one year and is subject to retesting
as required by engineer, during and after expiry of validation period.
 On completion of welding, pipes shall be tested at site
 Welding shall be done with covered tarpaulin area to reduce dust and contamination
 Welding shall not be done in dusty and windy weather.
 Make sure all carbon steel materials or debris are removed from the area of welding to
prevent contamination.
 After the welding, the pipes which are installed underground in trenches shall be lifted and
lowered to trenches using crane
 All buried pipes shall be wrapped with Denso tape with 55% overlap, after testing,

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13 APPENDICES:

Appendix 1: Risk Assessment

Appendix 2: Inspection and Test Plan

Note: site installation team shall always refer to the latest approved shop drawings, the drawings
attached to this method statement may not be the latest approved ones. Approved shop drawings can
be obtained from the document controller on site.

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Appendix 1: Risk Assessment

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Appendix 2: Inspection & Test Plan

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