1. GENERAL INFORMATION
1.1 Purpose
1.2 Scope of Work
1.3 References
1.4 Location
1.5 Definitions
2. EXECUTION
2.1 Materials and Tools
2.2 Manpower
2.3 Procedure of Work
2.3.1 Pipe Installers
2.3.2 Handling & Storage
2.3.3 Conduit Fitting
2.3.4 Assembly & Joining
2.3.5 Under Ground Conduit
2.3.6 Trenching, Bedding & Backfilling
2.4 Responsibilities
2.5 Organizational Chart
3. QA/QC
3.1 Documentation
3.2 Inspection
4. SAFETY
4.1 Safety Action Plan
5. JOB SAFETY ANALYSIS
5.1 Job Safety Analysis (JSA)
5.2 Risk Assessment (RA)
1.0 GENERAL INFORMATION
1.1 PURPOSE
The purpose of this method statement is to create awareness and communicate the tasks involved in executing the procedures for PVC conduit installation and to ensure the compliance of these activities with the contract specifications, IFC drawings and with HSE requirements. It is to guide and take precautionary measures and to safeguard traffic within the area of work and possible environmental impact.
This method statement shall be communicated and be understood by all personnel associated with the task before commencing the activity.
1.2 Scope of Work
This method statement outlines the procedure of the PVC piping installation within the Building at Jazan Refinery and Terminal Project, EPC-12 in accordance with project specifications and approved drawings. It encompasses preparations involved in the installation of PVC piping for underground and above ground.
1.3 REFERENCES
• Project Construction Specification for PVC Pipe Electrical Conduit
• Project Inspection and Test Plan
• Approved Project Safety Plan
• Manufacturer’s Material Data Sheet
• Manufacturer’s Material Safety Data Sheet
• SAES-T-911, NEMA-TC8, SAES-P-104
1.4 Location
PVC conduit shall be used for underground piping and above ground piping will be installed within the buildings electrical system as specified in the approved drawings.
1.5 Definitions
CMS: Construction Method Statement.
ITP: Inspection & Test Plan.
RFI: Request for Inspection.
PMT: Project Management Team.
SAES: Saudi Aramco Engineering Standards.
QA/QC: Quality Assurance / Quality Control.
PVC: Poly Vinyl Chloride Plastic Compound.
2.0 EXECUTION
2.1 Materials and Tools
1. PVC Pipe & Fittings.
2. Hand Saw.
3. Pipe Cutters.
4. Various Hand Tools.
2.2 Manpower (Numbers needed shall depend on actual works requirement)
1. Foreman.
2. Electrician.
3. Labors.
2.3 Method Statement for PVC Pipe Electrical Conduit | Procedure of Work
2.3.1 Pipe Installers
• Installation of PVC for water shall be done by trained personnel in the proper
handling and usage of applicable tools and equipment prior to start installation.
• PVC pipe installers shall assemble a trial joint with the same type of materials
and techniques to be used in the actual installation.
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. Manual loading and unloading can also be done for small pipes.
• PVC pipes and fittings shall be stored out of direct sunlight in a building or under a cover that allows free air circulation.
• PVC pipes shall be stored on level and flat ground which is free from stone and sharp projection with acceptable wooden support. While PVC fittings shall be kept in the original shipping container or box and stored on suitable manner.
• Racks shall conform to factory shipping packages for each pipe size. Shelves shall be provided for continuous support of the pipe.
• Adequate side support shall be provided to prevent slipping or rolling.
• All supporting surfaces shall be free from sharp objects.
• Pipes and fittings shall be properly protected from impact especially on their ends.
• Solvent cement, primer and cleaner shall be stored in an enclosure where temperature does not exceed 27ºC.
• Handling of pipes consider the length weight and height of racking, heavy pipes shall be placed at the bottom of the racks. Communication between workers is necessary.
2.3.3 Conduit Fitting
• If the pipe is stored on racks or bearing boards, the supports shall be at least 75mm wide. Support shall be spaced at 2.4 to 3m maximum with the first support required for PVC conduit as per SAES-P-104.
2.3.4 Assembly, Joining & Laying
• Before assembly, each pipes and fittings shall be examined from damages.
• PVC piping shall be solvent cement joint or elastomeric ring joint in accordance with project specification.
• All piping components shall be aligned properly without strain. Pipe shall not be bent or pulled into position.
• Slope shall be maintained as shown in the approved drawings in conjunction with project specification.
• Pipe inside surfaces shall be cleaned by rags before assembly or by purging air from an air compressor after completed assembly and shall be visually checked and recorded. The client representative shall be invited to attend the inspection at his discretion.
• Joint shall be made in accordance with ASTM D2855 for PVC. Solvent cement should be in accordance with ASTM D2564 and primer in accordance with ASTM F656.
• Pipes which exposed in the foundations should covered by bell end and plug.
4.3.5 Under Ground Piping
• 4 inches nominal size EB-35 pipe and less may be assembled next to or in the trench.
• Piping larger than 250mm nominal pipe size shall be assembled in the trench.
• Crane and (or) labors shall be used for placing pipes into the trench using proper tools and equipment such as ropes, straps and slings to control and maintain proper handling procedure. Use of a crane would require use of Saudi Aramco certified rigger and crane operator.
• Before start of pipe laying, the bottom of the trench shall be dry, continuous, smooth and 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 exact elevation and slope of the pipe being installed. The sand bed shall be then adjusted according to maintain the pipe on the ground is on a firm bed for its entire length.
• Excavation a little deeper (not less than 500mm) 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.
• Pipe is to be anchored by partial sand covering of the pipe to prevent floatation and to maintain its alignment and level.
• 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.
2.3.6 Trenching, Bedding & Backfilling
• Quality & Safety requirements and procedure for trenching, bedding and backfilling enumerated and mentioned in the project specifications shall be properly and strictly followed in executing this Construction Method Statement. Check out this article about conduits also.
TECHNICAL SPECIFICATION FOR CONDUITS METALLIC, PVC COATED AND NON-METALLIC
2.4 RESPONSIBILITIES
2.4.1 Site Manager
o He shall be the over all in-charge of all site procedures and shall ensure that required resources are attained.
o He shall ensure that all related quality and safety requirements associated with this activity are in line with the project specifications and standards.
2.4.2 Site Engineer
o He shall be responsible for planning & daily site implementation of this procedure including manpower, equipment, materials, tools, etc.
o Arrange safe Working Plan and ensure the safety of execution crew.
2.4.3 QC Manager
o He shall review this Construction Method Statement for quality compliance.
o To issue approved Construction Method Statement to Construction Site Manager/Engineer for implementation.
o Be responsible for monitoring of effective implementation of this procedure.
o Ensure necessary inspections / monitoring is being done.
2.4.4 QC Inspector
o Coordinate with QC Manager for necessary routine tests if any.
o Report non-conformities to QC Manager.
o Submit Request for Inspection (RFI) to Contractor / Company, 24 hours in advance during week days & 48 hours in advance during weekends, if necessary.
o Be present at site during the execution of work and shall ensure that all related works are being done in accordance with this Method Statement and all other applicable Standards.
2.4.5 HSE Supervisor
o He shall review this Construction Method Statement for safety compliance.
o He shall be responsible for monitoring of effective implementation of this procedure.
o He shall ensure necessary inspections/monitoring is being done.
2.4.6 Safety Officer
o Ensure that only certified operators and approved equipment, where required, shall be working at site, and regularly inspect all equipment.
o Report immediately any accident / injury / near missed to the appropriate authorities.
o Check / verify and confirm that all safety measures have been taken and all approved procedures are being followed.
o Have the responsibility to stop the work and inform Alfanar site management as it occurs and also inform Contractor / Company Safety officers of his action any time he feels that the safety of the job or conditions in the area do not meet the conditions on the work permit.
3.0 Quality Control
3.1 Documentation
The following documents are needed in order to comply with this Method Statement.
Input document;
o IFC drawings
o Risk Assessment / Job Safety Analysis
Output document;
o RFI
o Inspection records
3.2 Inspection
o Saudi Aramco Typical Inspection Plan (SATIP) will be used during inspection.
o Request for Inspection shall be issued to Contractor/Company Project Inspector 24 hours in advance on weekdays and 48 hours in advance for weekends and holidays.
o Inspection shall be done in accordance with the QC Plan.
o During Inspection, all exposed pipes, joints and fitting shall be carefully examined for leakage.
o Initial mandrel test will conducted for pipe installed in duct bank prior to concrete pouring and a final mandrel test after concrete pouring.
o There will be red color painted on the top surface of duct bank after surface preparation of concrete.
4.0 SAFETY
4.1 Safety Action Plan
o Person working with PVC shall wear the Personal Protective Equipment at all times on the job site, such as leather hand gloves, safety glass with face shield and respiratory mask.
o Proper access such as ladders and ramps shall be provided at designated areas where workers can go in and out the excavated area.
o Excavation Permit shall be provided before start of any excavation.
o Excavations shall be shored or sloped (wherever required) to prevent engulfment from earth collapse.
o Excavated soil shall be located a minimum of 1.5 meter from the edge of excavation.
o This conduit is already barricaded by the hard barricading.
o Erection and Dismantling of Scaffolding System shall be fully supervised by competent Scaffolding Supervisor as required Contractor/Company HSE Department.
o Barriers shall be constructed from materials of substantial strength such as scaffold tubing.
o All barricades and obstructions shall be illuminated by means of warning lights from sunset to sunrise.
o All barricades, signs, lights and other protective devices shall be installed and maintained properly. Information and warning signs shall be clear and visible to the vehicles and pedestrians.
o Signs, signals and barricades shall be removed when the hazards no longer exists.
5.0 ATTACHMENTS
5.1 Job Safety Analysis (JSA) for PVC Pipe Electrical Conduit.
5.2 Risk Assessment (RA) for PVC Pipe Electrical Conduit.