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02200016404-D1-CWC - 010gen-Mec-Ms-00654 Rev, A
02200016404-D1-CWC - 010gen-Mec-Ms-00654 Rev, A
A Approval MK 27-AUG-23
Date: 24/08/2023
Version: 0
Document History
Reviewed by Approved by
Prepared by
Document Ref. Rev Issue Date Supervising Project
Contractor
Consultant Manager
02200016404-D1-
CWC -010GEN- A 27/08/2023 MARVEZ KHAN
MEC-MS-00654
REVA
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Table of Contents
1. PURPOSE: ................................................................................................................ 4
2. SCOPE: ..................................................................................................................... 4
3. DOCUMENT CONTROL ......................................................................................... 4
4. DEFINITIONS, TERMS, AND ABBREVIATIONS ................................................. 4
5. RESPONSIBILITY: .................................................................................................. 5
6 REFERENCES ……………………………………………………………….5
7. WELDING PROCEDURE ........................................................................................ 6
8. Work sequence ........................................................................................................ 10
9. Work execution sequence....................................................................................... 156
10. Pipe transportation .................................................................................................... 16
11. EARTHWORK: ..................................................................................................... 199
12. STRING OUT THE PIPES INTO THE TRENCH (PIPE LAYING): ..................... 199
13. PIPELINE FABRICATION AND ERECTION ..................................................... 199
14. WELDING: ............................................................................................................. 20
15. CLEANING, DISINFECTION, AND FLUSHING: ............................................. 2020
16. INSPECTION AND TESTING: .......................................................................... 2020
17. BACKFILLING PROCEDURE ............................................................................... 20
18. HYDROSTATIC TEST ........................................................................................... 20
19. QUALITY RECORDS: ........................................................................................... 21
20. MECHANICAL COMPLETION: ............................................................................ 22
21. SAFETY & HAZARD PLAN .................................................................................. 22
22. EMERGENCY ARRANGEMENTS: ....................................................................... 22
23. ENVIRONMENTAL CONSIDERATIONS AND IMPACT CONTROL MEASURES:... 23
24. MANDATORY PPE FOR THE WORK ACTIVITY: .............................................. 23
25. MONITORING: ...................................................................................................... 24
26. UNSAFE BEHAVIOUR: ......................................................................................... 24
27. RECORDS: ............................................................................................................. 24
28. Attachment: ............................................................................................................. 25
Pipe welding traceability sheet ..........................................................................................................
WPS .................................................................................................................................................
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1. PURPOSE:
The purpose of this document is to lay down safe, fast and professional procedures for the welding
of carbon steel pipes to comply with designated standards and specifications in accordance with
accepted codes of picture.
It is written in such a way that it covers the vast majority of welding situations envisaged.
This method statement or process specification provides the minimum requirements that govern
the shielded metal Arc welding (SMAW) of carbon steel pipes with grades. Design procedural
and quality assurance requirements are given. All work instructions and weld procedure
specification. This documentation also gives the requirements for preparing, qualifying and use
of the procedure qualification records (PQP)
2. SCOPE:
The installation of carbon steel pipes with deferent diameters ranging from 12.5mm up to
unlimited mm at work site in an approved manner by ILF / National Water Company (NWC).
The work includes site preparation, pipe alignment, welding and coating, repair, cleaning and
testing. ABE Est. for contracting Saudi Company shall furnish all the required data regarding
material, manpower, and equipment and commence the work with prior approval by ILF
Consultant / National Water Company (NWC).
This standard covers the requirements for qualifying all welding
3. DOCUMENT CONTROL:
This project procedure is a controlled document as required by the Project Policy and issued in
accordance with the contractual requirements.
Revision of this document shall be issued in accordance with the project procedure and
requirements.
4. DEFINITIONS, TERMS, AND ABBREVIATIONS:
• Company National Water Company (NWC)
• Consultant ILF Consultant Engineers
• Contractor Civil works Company (cwc)
• Third Party Any third party has approved from NWC
• WPS Welding Procedure Specification
• PQR Procedure Qualification Record
• WPQ Welding Procedure Qualification
• NDT Non-Destructive Testing
• DT Destructive Testing
• RT Radiographic Testing
• UT Ultrasonic Testing
• VT Visual Testing
• MT Magnetic Test
• PT Penetrant Test
• CSWIP Certification Scheme for Personnel
• CWI Certified welding inspector
• WPR Welder Performance Qualification Record
• Shall A provision that is binding (mandatory)
• Should A provision that is optional (non-mandatory)
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5. RESPONSIBILITY:
5.1. Quality Control Manager:
shall ensure that all quality inspection procedure shall done as per the approved MS, the applicable
code and all record maintained.
5.2. Quality engineer
shall supervise all activities in the site as per the approved MS and report to the quality manager.
5.3. Welding Inspector
shall supervise all activities in the site as per the approved Drawing & WPS and report to the
quality manager.
5.4. Coating and Painting inspector:
shall be certified and perform painting and coating activities.
6. REFERENCES:
Standard Title Designation
ASME B16.5 Pipe Flanges and Flange Fittings (NPS ½ through NPS 24)
API 5L Line pipeline Standard specification for the seamless and welded steelpipes
for use in pipeline transportation system
AWWA C200 latest edition Steel Water Pipe, 6 In. (150 mm) and Larger
ASME B16.11 Forged Fittings, Socket-Welding and Threaded.
API Spec. 6D Pipeline Valves
SME B16.47 Pipe Flange and Flange Fittings with Dia. larger than 24’’to 60”
NWC sec. 331419 Valves And Hydrants for Water Utility Service
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Contract specifications & drawings
SECTION 331413 PUBLICWATERUTILITYDISTRIBUTIONPIPELINE.
BS IS0 2531 or BS EN 545 Flanged pipes.
Manufacturers Rubber gasket.
Specification
7. WELDING PROCEDURE QUALIFICATION.
7.1. General
All welding procedure specifications and welding procedure qualification records shall conform
to the requirement of the standard and the applicable codes. The weldment shall prove that a
weldment will provide the desired properties for construction. Where no qualification code is
applicable, the authorized persons of the consultant / company shall decide.
7.2. Procedure Qualification Record (PQR)
Welding procedure specification definition before production welding is started, a written
procedure shall be established and qualified based on applicable codes, standard and good
engineering practice, listing the material detailed method and parameters to be employed during
welding, to demonstrate that given weld will have suitable properties and soundness. The
qualification weld has to be subjected to non-destructive testing (NDT) examination. Welding
procedure specification (WPS) will be performed in accordance to the welding procedure
qualification record (WPQs)
7.3. Qualification of Welding Procedure Specification (WPS)
7.3.1. General
The WPS is intended to provide direction for the welders and shall be readily available. All testing
will be done by one experienced test laboratory to perform all tests required.
7.3.2.Welding Procedure Qualification (WPQ)
• The qualification test welds shall be performed simulating production welding shall be subjected
to non-destructive testing and destructive testing.
• The quality of the qualification test welds shall be determined by the required testing NDT,
including VT, RT, or UT. Tensile test bend in accordance with requirement of referred
codes/standards and contract specification will be carried out by an approved third-party lab.
• The non-destructive testing (NDT) shall only be performed using the approved equipment.
7.3.3.Test of Qualification Welds
• General
a. Test Assembly shall be prepared with pipe material.
b. All qualification welds shall be subjected to NDT after completion of welding.
c. The pipes & fittings shall be supplied with API-SLIANSI B16-25 Bevels.
• Non-Destructive Examination (NDE)
A. X-ray, UT, one of these methods shall be done for welding butt joint.
B. MT or PT shall be done as an additional method test to RT or UT.(If required)
C. The test results obtained from laboratory will be submitted to consultant / Company for approval
and will be kept in records at site office.
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7.3.4.Qualification of Welding Repair Procedure
All repairs welding shall be performed in accordance of the approved WPS and repairs completion
shall be confirmed by using the same NDE method which detects the defect weld; repairs welding
shall be executed by qualified welders.
Weld repairs shall be made under the direct control of the Welding Supervisor. The Welding
Supervisor, or a welding foreman, personally controls all weld repair activities. These include:
a. Lay out of area to be repaired
b. Selection of welder(s) who will perform the repair (for repairs grinding is considered to be an
activity)
c. Provide direction to the repair personnel
d. Inspect the repair cavity prior to any required re-welding by using (VT)
e. Gives permission to proceed with repair welding
f. Visually inspect the completed weld
g. Perform or arrange the required NDE of the joint after the repair.
h. RT or UT inspection acceptance criteria to determine the unacceptable defect is API Standard
1104.
7.4. Procedure Qualification Record
The Procedure Qualification Record (PQR) is a unique numbered written document containing
all the information concerning the welding of the qualification joint, procedural information as
run parameters, detailed methods and condition.
7.5. Qualified Procedure
When all the required tests have been accepted and procedures have been qualified, WPS & PQR
will be submitted to the client after approval by consultant (ILF)/main contractor.
7.6. Qualification of Welders
• Welders who passed the Procedure Qualification Test welds are confirmed as a qualified
welder.
• Qualified welder (visual test) of their weld run or specimen will be tested by NDT at the weld
location.
• Welder Performance Record (WPR) shall be maintained
• Each welder shall identify the position of each weld with his ID.
7.7. Documentation and certificates requirement
1. The changes in essential variables like process and material group needs separate
qualification.
2. This document covers the construction, installation and welding of CS pipelines.
3. The contractor shall prepare and submit the legible copies of WPS, PQR and test certificates.
4. Welding may not commence until the written approval of the consultant to National Water
Company or Representative has been obtained. Copies of the approved WPS, PQR and test
reports shall be retained to contractor.
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8. Work sequence
Material
Pipe: Type and Length Spirally welded steel pipe with beveled ends (30°angle),6-12 m, as filed.
Internal Lining Fusion Bonded Epoxy Lining Of Steel Pipes/ liquid epoxy coating to
AWWA C210;Minimum DFT 600 microns. Painting recommendation will
be applied.
External coating Three-layer polyethylene to DIN 30670; prepare surface to ISO 21809
and add coating in three layers as follows:
1st layer 250 microns FBE (fusion bonded epoxy) to ISO 21809.
latest edition
Date of manufactured
Manufacturer name
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Flange Bolts and Nuts Shall comply with ASME B18.2.1, carbon steel requirements,
unlessotherwise indicated.
8.2.7.Closing
The welder who start the work and the welders following shall meet each other at the end of the
weld joint
8.2.8.Cleaning
Removing the flux craters, welding irregularities slag etc. by Grinding
8.2.9.Removal of Clamp
8.2.10. Clamp shall be disengaged and taken out of the second pipe. For line pipe welding only
after the root and hot pass is finished.
8.2.11. Hot Pass
Welding progression shall be same as root pass second pass shall start within the time qualified
during procedure qualification.
8.2.12. Fill and Cap
a)Soon after cleaning the hot pass, filling and capping starts within the time qualified during
procedure qualification. Two weld beads shall not be started from the same location, if required;
welding may be suspended after the completion of the third pass or 50% of pipe wall thickness,
whichever is greater so as to allow the joint to cool down
b)Arc strikes outside the bevel surface shall not be permitted. If any such arc strikes are caused
accidentally, such areas shall be repaired as per the method approved by ILF. The skids used in
during welding shall be removed only, after completion of full welding.
8.2.13. Cleaning and Restarting
Every pass shall be cleaned by power-brush, grinding machine and chisel, starting and finishing
point shall be staggered for every pass
8.2.14. Capping and Inspection
Capping shall be max 3 mm over the surface of the pipe. Spatters shall be removed and cleaning
shall be done by power brush and any remedial grinding necessary, shall be performed limited to
dressing
8.2.15. Weather Protection
Wind shelter shall be provided to cover the welders and joint during welding, if
necessary to protect against rain/drizzling/wind
8.2.16. Visual Examination
Welded joint acceptance criteria as per pa 7.13
8.2.17. FOR TIE-IN WELDING
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a)Field welding of pipelines TIE-IN joints shall be done by method as approved WPS after
qualification
.b)Qualified welding procedures shall be used for welding of TIE-IN joints after due approval
from ILF.
c)Only ILF/IPIC approved brands of welding consumables as specified for each run int he WPS
shall be used.
d)A TIE-IN pit of suitable length, depth and width shall be cut to enable to work freely inside the
trench. Proper care shall be taken so as not to allow pit to collapse or pit wall caving in. Necessary
supports shall be used wherever required.
e) In connecting pipes, special items, fittings on joints of differing material thickness as supplied
transition piece with 1:4 taper shall be used and the welds shall be subjected to
Ultrasonic examination
.f)Cut pipe ends shall be examined wherever for laminations by Ultrasonic over
distance of 25 mm minimum. Defective pipe length shall be cut back until laminated section is
removed and re-beveled For pipe which have been cut, Pipe no., Heat no., Coating yard no.,
Balance length has to be transferred on to remaining pipe length.
g) Alignment of the TIE-IN joint shall be done using external clamp capable of removing offset
and misalignment shall be minimized.
h) Seam orientation of welded pipe shall be selected to ensure that the longitudinal welds shall be
staggered in the top 120º of the pipeline or 254 mm. whichever is the less and shall be positioned
in the upper half of the pipe. In case the seams come closer than as defined above, a pup piece of
minimum 2.0 m shall be used. For pipes of same wall thickness.
i)TIE-IN shall be done in such a way as to leave minimum stress in the pipe. If any pup end is
required for TIE-IN, the minimum length shall not be less than 750 mm.
j) TIE-IN joint welding including necessary cutting, beveling, grinding and line up etc. shall be
carried out as per this procedure and approved WPS.
k) The new field bevels shall be examined visually before offering for MPI and LPT. All reports
of TIE-IN along with NDT reports shall be prepare. Cleaning, Priming, coating and other
activities shall be performed as per approved procedures.
l)The root gap shall be accurately checked and shall conform to the qualified welding procedure.
All spaces between bars or at least 50% of first pass shall be welded before the clamp is released
and pipe remaining adequately supported on each side of the joint.
m)Segments thus welded shall be equally spaced around the circumference of the pipe. Slag etc.
shall be cleaned off and the ends of the pass shall be prepared by grinding, so as to ensure
continuity of the weld bead
. n) Qualified welders shall carry out welding. While welding is in progress, care shall be taken
to avoid any kind of movement of the components / pipe, shocks vibration and stresses to prevent
occurrence of weld cracks.
o) Electrode starting and finishing points shall be staggered from pass to pass.
p) Arc strikes outside the bevel on the pipe surface shall not be permitted. Accidental arc strikes
shall be repaired as method approved by CLIENT.
q) All finished welds shall be visually inspected for parallel and axial alignment of the work,
welds, surface porosity and other surface defects.
r) Parts being welded and the welds shall be protected by windshields made of metallic frame
covered by Canvas, whenever necessary, to protect from rain and strong winds.
s) The completed welds shall be covered with asbestos cloth covered by GI sheets, whenever
necessary, to protect from bad weather conditions.
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t) For TIE-IN of adjacent sections of pipeline already pressure tested also called golden joints
and for final joints, a single length pup or off cuts, which have been hydrostatically
pre-tested shall be used.
u)All quality records generated during the welding of TIE-IN joints shall be reviewed and
approved by ILF.
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11.When surfaces are wet or exposed to rain.
12.When welding personnel exposed to inclement conditions.
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10.1.2 Materials Handling and preservation of carbon steel pipe & fittings.
The received materials at site shall be handling and preservation under the approved procedure
and will be controlled and recorded the concern department of materials (Materials controller or
main store) the preservation inspection will be performing two time in a month.
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For big pipe dia >800 mm:
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11 EARTHWORK:
The contractor shall comply with Section 312000 "Earth Moving “excavating, trenching, and
backfilling. Simultaneously with the approved Excavation Method of Statement as well as
Backfilling Method of Statement. Excavation by machine shall be carrying out if the working
space is within the safe limit against the existing facilities. Manual excavation shall be performed
if the working area is too close to the existing underground facilities.
12 STRING OUT THE PIPES INTO THE TRENCH (PIPE LAYING):
Prior to the pipe string out, make sure that civil work for the trench is complete. Pipe joints shall
be laid individually in the trench on sandbags, suitably spaced to support the length of the pipe
being installed. On long pipe lengths, sandbags shall be spaced on five-meter centers. To avoid
damage to the coating always follow the accepted construction practices. Pipe shall be installed
in the trenches using wide sling belts and/or hands.
Before the commencement of laying the following are required to be carried out:
• Check the pipes routing are as per the approved shop drawings.
• Check the alignment & level of pipes.
• Check if any damage has occurred during offloading.
• Check that the location of pipe routings has been excavated with the required depth and
dimensions
13 PIPELINE FABRICATION AND ERECTION
Contractor shall ensure that, PIPELINE spools and fitting are free of rocks, sand, dirt, and foreign
objects. PIPELINE shall systems shall be kept clean during fabrication.
Pipe spools shall string parallel and adjacent to or above the trench.
The pipe shall be supported on padded skids during welding and inspection of joints as
appropriate. Protective coating shall be inspected and repaired prior to lowering the pipe into the
trench.
During the lowering, care shall be taken to prevent damage to the pipe. All pipes’ spools and
fittings shall be air-blow before installation.
Fit-Up Shall be built on an acceptable alignment.
Welding commencement after approval for PIPELINE fit-up and compliance with the approved
WPS. Flange joints assembly Shall conduct in accordance with the approved Bolt Torque
procedure.
The contractor Shall implement a warning tape according to NWC specifications and BS EN
10255 and ISO 65 requirements.
The contractor Shall comply to install PIPELINE according to the approved drawing and
manufacture recommendations further any national or international relevant standards.
The contractor Shall implement wrapping in accordance with an approved procedure. The
contractor Shall comply with backfilling an approved Method of Statement.
14 WELDING:
Welding preparation, fit-up inspection applicable WPS verification shall be carried out in
accordance with project specifications for PIPELINE fabrication for each welded joint. All
surfaces to be welded shall be free from oxides, scale, oil, or other foreign matter. Production
joints shall be made using qualified welding procedures and welders. Visual inspection shall be
done by the welding inspector during and after welding. Fully clean is required before
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commencing assembly and PIPELINE shall be welded in accordance with qualified procedures
using performance-qualified welders and qualified Procedures (WPS) and welders Shall be
qualified in accordance with AWWA C506/ASME BPVC section IX (Welding and Brazing
Qualification). Welding repair shall be re-welded according to the similar procedure which was
used before in the original weld.
Non-Destructive Examination NDE
NDE shall be requested and carried out in accordance with approved NDE Third Party
Procedures. All NDE requests shall be transmitted to the subcontractor by QA/QC manager. The
contractor shall transmit hard copies of NDE information to the consultant. The NDE Summary
sheet shall maintain updated on a daily as described at Pa 7 to 8.
15 CLEANING, DISINFECTION, AND FLUSHING:
Disinfection and flushing procedure shall be submitted for review and approval from ILF and
NWC then shall be implemented in line with NWC requirements.
16 INSPECTION AND TESTING:
Visual inspection and testing will be as described in pa7
17 BACKFILLING PROCEDURE
Backfilling work shall be carried out in accordance with the approved Method of Statement. Pipe
padding should go after pipe bedding by filling with suitable materials 300 mm thick from the top
of the pipe. Subsequently after completing the pipe padding backfilling of suitable excavated earth
material shall be placed 300 mm in layers and compacted in accordance with the approved
compaction Method of Statement
18 HYDROSTATIC TEST
shall be carried out after completion of all NDE (if required) and spool clearance activities. After
completion of the hydro test and its acceptance by ILF, the external coating and the internal
cement of welded joints shall be done in accordance with the manufacturer’s instructions.
External coating inspection and internal cement for welded joints shall be made and recorded in
a specific format.
Hydrotest shall commence as follows:
18.1 HYDROTEST TESTING GENERAL REQUIREMENTS
• Provision of test equipment: All items for test have to be provided on-site before the test i.e.,
pressure gauges, instruments, water, etc.
• Carry out tests in the presence of the Engineer's Representative.
• Fittings and joints: Permanently anchor fittings before testing and leave all joints exposed for
checking.
• Test sections: Limit test sections to not more than 500 m.
• Test sections: Test pressure lines between valve chambers whenever possible.
• Test sections: No testing shall be carried out against or through the pressure-reducing valves.
The setting of the pressure-reducing valves shall not be changed for testing purposes.
• Test plug: Secure the end of the main and test plug by struts.
• Closed valve: Do not test against a closed valve unless there is no acceptable alternative.
• Apply pressure by manually operated test pump or, in the case of large diameter mains, by
power-driven test pump, if approved.
• Examine exposed joints and repair visible leaks.
• Failure: Should a test fail, locate and replace or make a good defective pipe or replace and
make good faulty joint. Retest main.
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• Records: keep test records in an approved form. Hand an original copy to the Engineer
immediately after completion of the test.
• Carry out hydrostatic test while the pipeline is partially backfilled
20 MECHANICAL COMPLETION:
The following Shall be added to the individual test procedure package files after testing.
Details of repairs and re-tests as well as reinstatement completion report and PIPELINE Material
Test Certificate. Mechanical completion clearance (including reinstatement of items removed for
pressure testing).
21 SAFETY & HAZARD PLAN
The Hazards, Risks, and control measures for the activities to which this Method Statement relates
are contained within Appendix C. PLEASE NOTE: The assessments in Appendix C are not only
for excavation they relate to works that are or could also be associated with the Excavation and
backfilling works.
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In addition, the MCL officer shall undertake a JSA (Job Safety Analysis), and brief the workforce,
to ensure all necessary precautions are in place and taken during the work.
In respect to excavations; dependent upon the Geotechnical Report Results for the excavation
areas / Shop Drawings, and the determination of the soil type/category - A, B, C, the MCL Site
Engineer shall ensure that the correct support mechanism is provided e.g. Shoring, Stepping,
Benching, Sloping and were appropriate – shielding. Were the support mechanism requiring
design approval, this shall be independently sourced/qualified.
Whichever support mechanism shall be utilized, shall be subject to a daily inspection by MCL
Site Engineer prior to workers being allowed to enter.
The Supervising Engineer must ensure safe access/egress for all excavations avoiding the use of
ladders and providing suitable staircases.
Increased Lighting levels should be considered on access/egress routes and internal to the
excavations
22 EMERGENCY ARRANGEMENTS:
Emergency arrangements shall be implemented by MCL in the event of either fire, flood, injury
to personnel, damage to plant/equipment and property, near miss, dangerous occurrence-
occurrence-or similar emergencies.
On-site for the duration of the work shall be MCL HSE Officers and Site Supervision who are
trained ‘First Responders for the purposes of Fire and First Aid and dealing with general
emergency situations. Their contact details shall be provided and posted at the worksite for the
duration of the works. In the event of requiring Ambulance Fire or the Police, the First Responders
Shall obtain this assistance.
The First Responders are also trained in engaging with the site security for the purposes of
controlling access to the site for the emergency services should they be required.
The First Responder shall immediately inform the client of any undesired event on site in line
with MCL -approved reporting procedures. All necessary Investigations and reporting (post-
event) Shall be undertaken by MCL and were required with the client.
First Aid Kits shall be available at key locations throughout the site for use as required, by First
Responders. In the event of the use of Hazardous Substances and Materials and were dictated by
the MSDS, additional First Aid arrangements shall be made available at the point of work e.g.
Eye Wash Stations etc.
Notwithstanding the above, there Shall be a central First Aid Room at the Office & Welfare area,
with First Aid supplies and a stretcher as required.
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Hazard / Issue Precautions
Spillage of oil 1. Spillage of oil Install drip tray wherever the generator used
2. Prepare oil spill kit for emergency response
3. Train all workers the emergency (SPILL) response procedure
Waste generations 1. Waste materials must be segregated into different types of waste
2. Maintain good housekeeping condition
Dust in yard and road 1. Spray water on the road using water tank frequently
2. Covering trucks carrying earth material
3. Minimize heights into the truck bed
4. During periods of high wind> 32 km/hr, dust control measure Shall be
adjusted. Stop all works in case of Heavy winds
Waste materials must be segregated into different types of waste. Maintain good housekeeping
condition.
Provision of earplugs to all personnel when noise is generated. Spray water on the road using a
water tank frequently.
Covering trucks carrying earth material and minimizing heights into the truck bed. During periods
of high wind, dust control measures Shall be adjusted.
MCL shall be responsible for safe storage and regular removal from the site of general rubbish
and redundant/surplus materials arising from their Project activities.
Personnel Shall be instructed by their supervisors for housekeeping.
All section supervisors shall conduct housekeeping inspections as daily duties.
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In addition, prior to work commencing the MCL Site Supervisor shall undertake a Job Safety
Analysis (JSA) at the location to identify any specific hazards and risks at the immediate work
location. Once this is done, he must determine any additional control measures and brief the
workforce on the JSA requirements
25 MONITORING:
Ensuring HSE compliance on site, rest firstly and firmly with MCL Supervision.
They shall ensure that the workforce is well briefed, and comply with the Method Statement
requirements, general HSE requirements of the site, and best practice.
A key role of the MCL Supervisor is NOT to condone unsafe practices or allow an unsafe place
of work to develop.
MCL Supervisor MUST intervene on every occasion that this becomes evident. ‘Unsafe
Behavior’ shall be dealt with by disciplinary action.
MCL HSE Engineer and Officers shall carry out daily observations of the site and complete a
Daily SOR – Site Observation Report. MCL HSE shall intervene on every occasion to ensure
compliance.
Where there is imminent danger from equipment damage or personal injury, MCL shall intervene
– STOP work, undertake the required remedial action and complete WPT ‘Unsafe Act / Condition
Report’
All Reports shall be shared with the client and shall form the basis of the MCL Monthly HSE
Performance Report.
26 UNSAFE BEHAVIOUR:
MCL HSE procedure for dealing with individuals or groups of individuals within the workforce
who display Unsafe Behaviours that could give rise to damage of equipment, personal injury or
similar undesired event. The process is formal and recorded.
The results of the process may result in instant dismissal, 1 or 2 written warnings, support training,
etc. All disciplinary actions shall be shared with the client.
27 RECORDS:
Inspection records generated by this procedure are to be managed in accordance with the project
procedure.
Records of monitoring, analysis, and improvement Shall be maintained on-site throughout the
contract period, following which they Shall be passed to the Corporate Quality Department.
Such records Shall be maintained for a period as per the contract, after which they may be
disposed of.
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28 Attachment:
ITP
Pipe welding traceability sheet
PWPS/WPS
- END OF TEXT –
Inspection of Surface Preparation for lean concrete surface for isolation valve
Quick Win CIV
chamber at Jaroudia station Quick win project.
inspection for primer application for lean concrete surface for isolation valve chamber
Quick Win CIV
at Jaroudia station quick win project.
inspection for bitumen membrane for lean concrete surface for isolation valve
Quick Win CIV
chamber at Jaroudia station quick win project.
25 of 25
APPENDIX A
.WIR
b.Inspection Checklist for pipeline
As approved drawing routing and As approved drawing
3.1 Pipe Laying and Levelling QC & Construction Each Spool As approved drawing requirements setting out PMF-012-QUA-084-02. H W N/A
levelling requirements requirements
C.Inspection Checklist for pipeline
installation PMF-012-QUA087-02.
a. As NWC Specs Sec 331413 a.WIR
Pipe Fabrication and Fit up inspection Appendix B1 Approved WPS and approved Design b. Fit Up inspection report
3.2 QC & Construction Each Joint WPS & Drawing H W R
for welding release. b. AWWA C206 & Approved WPS. Drawing. CWC
c.Approved Design Drawing. c.Spool clean out
a. NWC Specs SECTION a. WIR
331413 para2.2 point 6 b. Visual inspection CWC
Welding and post weld visual
3.3 QC Engineer /WELDING INSPECTOR per joint b. Approved Drawing Awwa206 AWWA 206 H H N/A
inspection report
c. approved welding
procedure
a. NWC Specs SECTION a. WIR
331413 para2.2 point 6 b. Viusal inspection report
3.4 weld repair QC Engineer/WELDING INSPECTOR per joint b. Approved Drawing Awwa206 AWWA 206 Marmar -RE-CQC-005 H H N/A
c. approved welding
procedure
Surveyor / Project Engineer .WIR
b.Inspection Checklist for pipeline
As approved drawing routing and As approved drawing setting out PMF-012-QUA-084-02.
3.5 top pipe level check per joint As approved drawing requirements H H
levelling requirements requirements C.Inspection Checklist for pipeline
installation PMF-012-QUA087-02.
4.1 NDT : UT/PAUT/RT test QC Engineer/WELDING INSPECTOR 100% of 10% of the total joint AWWA206 AWwa206 as per AWWA206 a. WIR third party report H H H
a.NWC SECTION 331414 Para 3.12.3 NWC SECTION 331414 Para 3.12.3 NWC SECTION 331414 a.WIR
15 Hydrotest QC & Construction Package Wise b.Approved Hydrotest Procedure Approved Hydrotest Procedure Para 3.12.3 b.Approved Test Package H H
Approved Hydrotest c.Punch list MARAMER-RE-CQC-007
. .Approved Drawing Approved Drawing. WIR
b. Approved MS&Procedures. .b.Approved MS&Procedures b.Approved b.Re-instatment closing bunch list
16 Pipeline Re-instatement/Final QC & Construction Package Wise H H
c. NWC Specs SECTION c.NWC Specs SECTION 331413 MS&Procedures. report
c.NWC Specs SECTION
a. NWC Specs SECTION 331413 WIR
b. Approved Drawing -b. MCC Certificate MARAMER-RE
Compliance with the
17 Mechanical Completion QC & Construction Per System or partial c. Approvad Method Statement for NWC Specs SECTION 331414 Para 24 CQC-009 Rev.0 H R
applicable requirements
DI Pipe work
Notes:
- Technical Specification refers to Technical Speification for Water Network مرجعية المواصفات اي ل مواصفات م رشوعات المياه
- NWC Project Manager is Surveillance for all activities مراقبة جميع األنشطة- مدير الم رشوع رشكة المياه لوطنية
- These quality control measure must, as a minimum, cover the items stated on this form. The Contractor may need to implement other control measures not listed on this form. These additional measures must be added to the form. 'إجراءات التحكم يف الجودة الواردة يف النموذج أعاله يجب أن تغ يط البنود
الورادة يف هذا
وعىل المقاول إدراج هذه اإلجراءات اإلضافية، ما قد يتطلب أن يقوم المقاول بتطبيق إجراءات تحكم غري واردة ي ف النموذج.النموذج.
SAC = Sectional Acceptance Certificate شهادة القبول الجز يئ لألعمالS = Surveillance المراقبة
Page No.1 OF 2
Bolt Torque Report Date:
Proc/MS:
NWC WATER IMPROVEMENT
Project: DAMMAM-1-PROJECT
Location:
Equipment:
WQIP-CWC -00 Rev.0
value value
N joint Bolt type Quality Number Drawing no Result
Required Aplied
Used Insrument:
type: capacity: certification no:
name
signe
Date
REPORT NUMBER: PAGE NO. 2/2
DATE:
REMARKS:
NWC: DATE:
Report No.:------
Date: -------------------------
------------------------------------------------------------------------------------------------------------------------------------------------------------- -----------------------------------
---------------------------------------------------------------------------------------------------------------------------
-------------------------
Comment: -------------------------------------------------------------------------------------------------------------------------
-------------------------------------------------------------------------------------------------------------------------
Performed By
(CWC/ QA/QC) Dep.: ----------------------------------
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------
Comment : -------------------------------------------------------------------------------------------------------------------------
Performed By Witnessed By
MCL. QC ---------------------------------- ILF.QC : ------------------------------------
DAILY FIT-UP REPORT
NWC WATER IMPROVEMENT
DAMMAM-1
SYSTEM: Pipeline:
ITEM:
REPORT NO: DATE :
MATERIAL : PAGE of
SPOOL WELD WELD DIA THICK WELDER
S.NO DRAWING DISCRAPTION FIT UP RESULT REMARKS
NO. NO. TYPE INCH MM NO.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
BW=BUTT WELD
FW= FILLET WELD
MANUFACTURER OWNER
MCL ILF NWC
NAME:
SIGN :
DATE:
DAMMAM- 1 PROJECT
NWC WATER IMPROVEMENT PROJECTS
DAMMAM-1
Pipeline No.:
AREA:
ITEM NO.:
MCL DATE:
ILF DATE:
NWC DATE:
NWC WATER IMPROVEMENT
DAMMAM-1 PROJECT REPORT No.:
COMMENTS:
Name
Sign
Date
Name
Sign
Date
PIPELINE COMPLETION STATUS
1 2 3 4 5 6 7 8 9 10
NDE PIPES EARTHING FLUSHED PRESSURE CHEMICAL PRESERVED VIDEO HOT OIL RE-
CLEARED SUPPORTED GRP.PIPES TESTED CLEANED INSPECTION FLUSHED INSTALLED
It is hereby certified that the plant/equipment referenced has been inspected, tested and accepted in accordance with the attached acceptable records and other
documents, but with the exception of the outstanding work according to attached punch list register.
Name
Sign
Date
Name
Sign
Date
<Project>
MCC CERTIFICATE
MC Package No.
MCC Description: MCC Area :
SCOPE OF ACCEPTANCE
Discipline code:
COMMENTS:
Name
Sign
Date
Name
Sign
Date
APPENDIX C
A Approval ME 24-June-23
Legend
Risk Index Low Medium High Very High
تصنيف الخطورة منخفض متوسط عالي عالي جدا
Risk Score
1 to 3 4 to 6 7 to 9 10 to 16
الخطورة درجة
الخطر
التأثير
Risk
No.
وصف املخاطرة تدابيرالسيطرة والتحكم بالخطر الشخص املسئول
الخطر
التأثير
Risk
No.
وصف املخاطرة تدابيرالسيطرة والتحكم بالخطر الشخص املسئول
الخطر
التأثير
Risk
No.
وصف املخاطرة تدابيرالسيطرة والتحكم بالخطر الشخص املسئول
الخطر
التأثير
Risk
No.
وصف املخاطرة تدابيرالسيطرة والتحكم بالخطر الشخص املسئول
الخطر
التأثير
Risk
No.
وصف املخاطرة تدابيرالسيطرة والتحكم بالخطر الشخص املسئول
الخطر
التأثير
Risk
No.
وصف املخاطرة تدابيرالسيطرة والتحكم بالخطر الشخص املسئول
Method Statement – must be drafted by the Contractor’s responsible person before passing it to the Contractor’s HSE
representative (pre-authorized, competent specialist in construction works HSE).
NWC Permit to Work – requirements for permits under NWC’s own system are to be highlighted on the checklist after the
Contractor’s HSE representative has recorded his assessment of the Method Statement.
(1) GENERAL
Refer to ‘HSE Guideline for Construction Sites – General’ for details of NWC’s requirements.
This is document number PMF-017-HSE-100 and is a supporting document from Section 15 of the Project Management Manual.
Existing NOCs and Permits adequately cover the scope of the Method
Statement
1.1 Coordination with Local Authorities or
The existing NOCs and Permits do not adequately cover the scope of the
Method Statement
Remedial action to be taken, if required, with regard to coordination with local authorities:
Site Handover Documents from government authorities is in the attachment.
The Method Statement does not need any additional training to be carried out
or update of induction training.................................................................
1.4 Inductions and Training or
Specific training needs to be carried out and/or changes to the site induction
materials need to be made..............................................................
Description of additional training to be carried out and/or updates to the site induction materials:
Induction training has been given to all workers.
Additional training will be provided whenever required according to the work condition.
Existing site boundaries and site access remain fit for purpose under the
Method Statement...........................................................................................
1.5 Site Boundaries and Site Access or
Changes need to be made to the site boundaries and site access arrangements
as a result of the Method Statement........................................
Description of changes required to the site boundaries and/or site access arrangements:
The existing welfare facilities remain fit for purpose under the Method
Statement.........................................................................................................
1.7 Welfare Facilities or
Changes need to be made to the welfare facilities as a result of the Method
Statement.........................................................................................................
Description of changes required to the welfare facilities:
The existing workplace lighting remains fit for purpose under the Method
Statement.........................................................................................................
1.8 Workplace Lighting or
Changes need to be made to the workplace lighting as a result of the Method
Statement...........................................................................................
Description of changes required to the workplace lighting:
Day time work will be conducted from (06:00 am to 17:00)
Lighting available in the night for clear visibility of the site.
The first aid provision remains fit for purpose under the Method
Statement.........................................................................................................
1.9 First Aid or
Changes need to be made to the first aid provision as a result of the Method
Statement...........................................................................................
The existing fire control measures remain fit for purpose under the Method
Statement.........................................................................................................
1.11 Fire or
Changes need to be made to the fire control measures as a result of the
Method Statement...........................................................................................
Description of changes required to the fire control measures:
The existing housekeeping controls remain fit for purpose under the Method
Statement...........................................................................................
1.12 Housekeeping or
Changes need to be made to the housekeeping controls as a result of the
Method Statement...........................................................................................
Description of changes required to the housekeeping controls:
Daily housekeeping done on the site.
The existing workplace communications remain fit for purpose under the
Method Statement...........................................................................................
1.13 Workplace Communications or
Changes need to be made to the workplace communications as a result of the
Method Statement.....................................................................................
The existing accident/incident reporting protocols remain fit for purpose under
the Method Statement..........................................................................
1.14 Accident/Incident Reporting or
Changes need to be made to the accident/incident reporting protocols as a
result of the Method Statement......................................................................
Description of changes required to the accident/incident reporting protocols:
All accident / Incidents will be immediately reported and documented.
The existing daily inspection routine covers the scope of the Method
Statement.........................................................................................................
1.15 Daily Inspection or
Changes need to be made to the daily inspection routine as a result of the
Method Statement...........................................................................................
Description of changes required to the daily inspection routine:
Site is daily inspected by HSE officer, PM, CM
The existing PPE provided on site remains fit for purpose under the Method
Statement.........................................................................................................
1.16 Personal Protective Equipment or
Changes need to be made to the PPE provision as a result of the Method
Statement.........................................................................................................
Description of changes required to the provision of PPE:
All workers have been provided mandatory PPE.
(2) EXCAVATION
Refer to ‘HSE Guideline for Construction Sites – Excavation’ for details of NWC’s requirements.
This is document number PMF-017-HSE-110 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
No............. Go to Section (3) Manual Handling
excavation works?
Unclear.... Clarify with the author and revise/reissue as required
Supervision Consultant
(3) MANUAL HANDLING
Refer to ‘HSE Guideline for Construction Sites – Manual Handling’ for details of NWC’s requirements.
This is document number PMF-017-HSE-120 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
No............. Go to Section (4) Confined Space
manual handling activities?
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
No............. Describe suitable controls below
adequate HSE controls with respect to
manual handling activities? Describe the controls below, plus outline of needed
Partially....
improvements
Description of HSE controls for manual handling activities, highlighting any need for improvements to be incorporated:
Supervision Consultant
Dammam 1 Method statement checklist for WELDING FOR CARBON STEEL 7 of 15
(4) CONFINED SPACE
Refer to ‘HSE Guideline for Construction Sites – Confined Space’ for details of NWC’s requirements.
This is document number PMF-017-HSE-130 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
No............. Go to Section (5) Scaffolding
confined space works?
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
No............. Describe suitable controls below
adequate HSE controls with respect to
confined space works? Describe the controls below, plus outline of needed
Partially....
improvements
Description of HSE controls for confined space works, highlighting any need for improvements to be incorporated:
Supervision Consultant
(5) SCAFFOLDING
Refer to ‘HSE Guideline for Construction Sites – Scaffolding’ for details of NWC’s requirements.
This is document number PMF-017-HSE-140 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
No............. Go to Section (6) Mechanical Lifting
scaffolding works?
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
No............. Describe suitable controls below
adequate HSE controls with respect to
scaffolding works? Describe the controls below, plus outline of needed
Partially....
improvements
Description of HSE controls for scaffolding works, highlighting any need for improvements to be incorporated:
Supervision Consultant
(6) MECHANICAL LIFTING
Refer to ‘HSE Guideline for Construction Sites – Mechanical Lifting’ for details of NWC’s requirements.
This is document number PMF-017-HSE-150 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require Go to Section (7) Material Handling, Storage, Use and
No.............
mechanical lifting activities? Disposal
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
No............. Describe suitable controls below
adequate HSE controls with respect to
mechanical lifting activities? Describe the controls below, plus outline of needed
Partially....
improvements
Description of HSE controls for mechanical lifting activities, highlighting any need for improvements to be incorporated:
Supervision Consultant
(7) MATERIAL HANDLING, STORAGE, USE & DISPOSAL
Refer to ‘HSE Guideline for Construction Sites – Material Handling, Storage, Use & Disposal’ for details of NWC’s requirements.
This is document number PMF-017-HSE-160 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
material handling, storage, use and No............. Go to Section (8) Safe Use of Electricity
disposal activities?
Unclear.... Clarify with the author and revise/reissue as required
Does the Method Statement describe Yes............ Confirm the controls below
adequate HSE controls with respect to No............. Describe suitable controls below
Dammam 1 Method statement checklist for WELDING FOR CARBON STEEL 9 of 15
material handling, storage, use and Describe the controls below, plus outline of needed
disposal activities? Partially....
improvements
Description of HSE controls for material handling, storage, use and disposal activities, highlighting any need for improvements
to be incorporated:
Supervision Consultant
(8) SAFE USE OF ELECTRICITY
Refer to ‘HSE Guideline for Construction Sites – Safe Use of Electricity’ for details of NWC’s requirements.
This is document number PMF-017-HSE-170 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
No............. Go to Section (9) Concrete and Masonry Construction
use of electricity?
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
No............. Describe suitable controls below
adequate HSE controls with respect to
use of electricity? Describe the controls below, plus outline of needed
Partially....
improvements
Description of HSE controls for use of electricity, highlighting any need for improvements to be incorporated:
Supervision Consultant
(9) CONCRETE AND MASONRY CONSTRUCTION
Refer to ‘HSE Guideline for Construction Sites – Concrete and Masonry Construction’ for details of NWC’s requirements.
This is document number PMF-017-HSE-180 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
concrete and masonry construction No............. Go to Section (10) Welding & Cutting Works
works?
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
adequate HSE controls with respect to No............. Describe suitable controls below
concrete and masonry construction
Describe the controls below, plus outline of needed
works? Partially....
improvements
Description of HSE controls for concrete and masonry construction works, highlighting any need for improvements to be
incorporated:
Supervision Consultant
(10) WELDING & CUTTING WORKS
Refer to ‘HSE Guideline for Construction Sites – Welding & Cutting Works’ for details of NWC’s requirements.
This is document number PMF-017-HSE-190 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
No............. Go to Section (11) Waste Management
welding and cutting works?
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
No............. Describe suitable controls below
adequate HSE controls with respect to
welding and cutting works? Describe the controls below, plus outline of needed
Partially....
improvements
Supervision Consultant
(11) WASTE MANAGEMENT
Refer to ‘HSE Guideline for Construction Sites – Waste Management’ for details of NWC’s requirements.
This is document number PMF-017-HSE-200 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
No............. Go to Section (12) Work at Height and Fall Prevention
waste management activities?
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
No............. Describe suitable controls below
adequate HSE controls with respect to
waste management activities? Describe the controls below, plus outline of needed
Partially....
improvements
Description of HSE controls for waste management activities, highlighting any need for improvements to be incorporated:
Supervision Consultant
Supervision Consultant
(13) EMERGENCY PREPAREDNESS AND RESPONSE
Refer to ‘HSE Guideline for Construction Sites – Emergency Preparedness and Response’ for details of NWC’s requirements.
This is document number PMF-017-HSE-220 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
emergency preparedness and No............. Go to Section (14) Machinery, Tools and Equipment
response?
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
adequate HSE controls with respect to No............. Describe suitable controls below
emergency preparedness and
Describe the controls below, plus outline of needed
response? Partially....
improvements
Description of HSE controls for emergency preparedness and response, highlighting any need for improvements to be
incorporated:
Emergency contact numbers displayed on the site.
Fire extinguisher has been placed in a potential places of the site.
Assembly point with clear signage available.
All workers has been trained for Emergency Evacuation.
Supervision Consultant only to complete this section:
Supervision Consultant
(14) MACHINERY, TOOLS & EQUIPMENT
Refer to ‘HSE Guideline for Construction Sites – Machinery, Tools and Equipment’ for details of NWC’s requirements.
This is document number PMF-017-HSE-110 and is a supporting document from Section 15 of the Project Management Manual.
Yes............ Go to the next question
Does the Method Statement require
working with machinery, tools and No............. End of HSE Assessment
equipment?
Unclear.... Clarify with the author and revise/reissue as required
Yes............ Confirm the controls below
Does the Method Statement describe
adequate HSE controls with respect to No............. Describe suitable controls below
working with machinery, tools and
Describe the controls below, plus outline of needed
equipment? Partially....
improvements
Description of HSE controls for working with machinery, tools and equipment, highlighting any need for improvements to be
incorporated:
Respect the tools manual lifting techniques to lift the equipment and ensure proper handling of unit, check protruding object that
might cause of trip / slip or fall.
Maintain proper ergonomic posture & body position during manual handling of materials.
Use of proper hand tool, machines, equipment must be in good condition & inspected, colour coded and maintain the record.
Use and maintain the machines as per manufacture instruction/manual.
Appropriate PPE shall be wears while handling tools and machines.
Workers must possess the tools relevant trainings.
Operator & drivers have valid 3rd party certification and equipment inspection whereas may require.
Supervision Consultant