ADCO CONTRACT NO. 6798.

01/ EC 10678
WASH WATER WELLS HEADER REPLACEMENT
AND PRODUCED WATER
RE-INJECTION PILOT

METHOD STATEMENT FOR

INSTALLATION OF GRE PIPES

Rev
No

DATE

DESCRIPTION

PREPARED

REVIEWED

APPROVED
(ADCO)

METHOD STATEMENT FOR INSTALLATION OF GRE PIPES

PAGE 1 OF 9

CONTENTS
1.

SCOPE

2.

RESPONSIBILITIES

3.

REFERENCES

4.

DOCUMENTS (DRAWINGS, SKETCHES ETC.)

5.

SEQUENCE OF WORK

6.

RESOURSES (MANPOWER, MATERIAL, EQUIPMENT)

7.

RISK RATING
7.1
7.2

SUPERVISION
HSE REQUIREMENT

8.

QA/QC REQUIREMENT

9.

TIME DURATION

10.

APPROVALS

11.

ATTACHMENT

1.

SCOPE

METHOD STATEMENT FOR INSTALLATION OF GRE PIPES

PAGE 2 OF 9

This document is intended to briefly describe general procedure to be adopted

for the installation of GRE pipes under the scope of this project.
2.

RESPONSIBILITIES
ADCO - Abu Dhabi Company for Onshore Oil Operations.
All technical support and guidance / assistance for safe and smooth execution
of the activities under the contract in ADCO restricted areas such as, issue of
required permits (including conducting gas tests etc), approval of drawings /
Documents, Safety / Quality surveillance, deputation of relevant
personnel
for inspection & testing as per QA/QC plans, commissioning of the new
installations with the assistance of the contractor etc.
XXXXXXXXXXXXXXXXXXXXXXXXXX
Complete execution of the work with proper workmanship and supervision as
per AFC Drawings, specifications / procedures / standards as applicable,
strictly abiding by ADCO PTW system and safety regulations as laid down in
ADCO HSE manual Volume 10.

3.

REFERENCES

4.

Construction Package
Specification for Piping Fabrication and
Installation

- 11-01-91-0602
- ADCO Doc. 11.99.12.604 &
- ADCO DOC No. 11.99.12.606

ADCO HSE Procedure Manual

ADCO Procedure Manual
XXXXX HSE & LP Manual
The Project HSE Plan
PQP

- No.10
- No. 10 / 3
- Doc. No. HSE/GAD/001
- HSE MSP-7037-026 Rev B
- PQP-7037-026 Rev B

DOCUMENTS
- 11/ 20/ 15/ 0601 (8 Sheets)

5.
5.5

SEQUENCE OF WORK
Calibration

5.5.1 Mark the required spigot length.

METHOD STATEMENT FOR INSTALLATION OF GRE PIPES
PAGE 3 OF 9

5.5.2 Assemble the desired mandrel to the shaft and insert the same into the pipe.
Keep the mandrel in position and rotate the handle clockwise until the mandrel
tightened against the inside of the pipe. Ensure the whole length of mandrel is
inserted inside the pipe.
5.5.3 Position the shaver main frame, power drive and collect nut over the shaft.
Rotate the collect nut anti-clock wise to disengage the feed and pull back the
main frame against the collect nut.
5.5.4 Adjust the cutting tool as per the required dimension.
5.5.5 Start the power drive for calibration. The tool post should be rotate in a clock
wise direction
5.5.6 As soon as the spigot end has been machined to the required length, stop the
power drive. Loosen the collect nut clock wise to disengage and pull out the
collect nut, power drive and main shaver frame.
5.5.7 Use PI tape to measure the OD of the machined end. If more machining is
required, repeat steps.
5.5.8 Rotate the shaft anti clockwise to loosen the mandrel, after which it can be
removed.
The following two sections apply only in the cases where the pipe has to be cut to suit
site conditions.
Ensure the machined ends are according to the required measurement and with in the
specified tolerance. Clean the calibrated spigot with a clean and dry cloth or use a dust
brush.
5.6

Factory shaved spigot

The factory-shaved spigot are in accordance with the required
measurements
With in the specified tolerance. The spigot shall be abraded using an emery
paper of grade 40 or 60.

5.7

Socket Preparetion
The bell end shall be abraded using an emery cup of grade 40 or 60 inserted in
a rubber mandrel and fixed to a drilling machine

5.8

Precautions.
The prepared bond surface area must not have any greese, oil, dust, moisture,
water etc.
If any greese or oil is noticed on the bonding surface, soak a piece of cloth with
acetone MEK (methyl ethyl ketone) or MIBK and clean the surface. If the
bond surfaces is cleaned with solvents re- sanding shall be carried out to
refresh the surface. Do not use paint thinner, petrol etc, for cleaning purpose

METHOD STATEMENT FOR INSTALLATION OF GRE PIPES

PAGE 4 OF 9

5.9

Cement application
5.9.1 Prior to the application of cement on the spigot and bell fix the latch
belts on both sides of pipes. Leave enough working space between the
pipes to be jointed. Use wooden blocks to prevent damage from come
along jack. Ensure the pipe supports are adaquately supported and
aligned properly. Check if the prepared bonding surface is clean and
free from dust, oil etc. sand it with an emery cloth
And made it fresh before applying the adhesive mixture. Mark the
required length to be inserted to the bell. The prepared bonding surface
should not be touched with a bare hand or with dirty hand gloves.
5.9.2 Add the hardner from the small container to the resin in the large
container and mix with the supplied spatula for about 3 minutes untill
the mixture has auniform colour. Adhesive components should not be
mixed parially from the container to avoid propotional mixing
variations. The expiary date of the adhesive components shall be
checked before using the prodect at all times
5.9.3 Once the adhesive is mixed properly, apply a thin, uniform layer of
adhesive mixture to the freshly preparated bond surface of the bond
end(approximat 0.5 mm thick). Do not apply excess quantity of
adhesive mixture to the bell end to avoid excessive formation inside the
joint.
5.9.4 Apply the adhesive mixture to the freshly prepared spigot. The initial
layer should be a thin and uniform to ensure the surface area is properly
wet with the mixture. Once the entire spigot area is wet with the
mixture apply enough quantity of the adhesive to the spigot (approx.
1.0 mm of thick). It is important to ensure that no dust/ sand or any
other particles are mixed with the adhesive or on the mixture spread of
the bonding surface.

5.10

Precautions
In humid environment the prepared joint may need to be warmed up to
avoid moisture contents on the bonding surfaces. Use a heating blanket to
warm up the joint. Once the warming process completed the joint shall be resanded before applying the adhesive mixture.
The bonding process shall be performed within one hour after preparing the
bond surface, if not re-sanding should be carried out.
Never use the adhesive, which has started curing or turened tacky.

METHOD STATEMENT FOR INSTALLATION OF GRE PIPES

PAGE 5 OF 9

The adhesive mixture will cure too fast if it is mixed above 40 degree C and
the work shall be carried out within the pot life after mixing the two
components.
A qualified technician shall perform the joining of all adhesive bonded joints.
5.11

Assembly
Pull the pipe sections together with the aid of the come-along-jack,
ensuring the required length of the spigot is entered in to the bell end. Ensure
that the vertical 7 the horizondal alighnment of the two sections during the
insertion of spigot end in to the bell. Clean the excess quantity of
adhesivformed around the joint. The bonded joint should not be distributed
under any circumstances during the curing period

5.12

Curing
5.12.1.

Ensure the bonded joint is self cured by ascertaining the applied

cement is tack free. Wrap the appropriate heating blanket around the
joint ensuring the bond area is fully covered (Tie up the heating
blanket with a securing wire ). Close all the open end of the pipe
section to avoid any air breezing into the section. Connect the
power cord in to a power socket. Switch on the temperature
controller supplied with heating blanket to the required temperature
of 90 C ensure the heatng devise is functioning throughout the
process of heating.

5.12.2.

The required curing time for Wavistrong EasyFit is 1.5 hoursthe

Curing the time starts when the cement reaches 90 C. Once the
heating process is completed allow the joint to cool down and
remove all fasteners and materials from the joint.

5.12.3

Once all the process is completed the joint is for use

5.12.4

Backfilling will start immediately after laying jointing curing of the

pipe leaving joint locations exposed. It will be laid in loose lifts not
exceeding 150 mm up to the crown level of the pipe, flooded with
water & compacted by hand tamping. Backfill will place
symmetrically to prevent centric loading and displacement of pipe.
Mechanical compaction (plate compactors) will only be used 300 mm
on top of pipe crown. Sand material will constitute the first layer of
fill on top of pipe crown followed by 300 mm layers.

RESOURCE (Manpower and Equipment)

6.1

Man Power :
METHOD STATEMENT FOR INSTALLATION OF GRE PIPES
PAGE 6 OF 9

Services of following category of manpower is envisaged:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
6.2

Supervisor/Job Performer
Safety Officer
Fitter
Riggers
Labourers
Crane Operator
Trailer (H.D.) Driver
Hiab Truck Operator
Welder
Sk. Helper

1 No.
1 No
2 No.
2 Nos.
4 Nos.
1 No.
1 No.
1 No.
2 Nos.
2 Nos.

Equipment:

Measuring Tape
Marker pen
Pipe fitters wrap-a-round
Measuring gauge
Pipe clamp
Bench
Rubber strip (for use underneath the chain clamp)
Angle grinder with diagrit or carborundum cutting dise (grain 64)
Flapper sander
Sanding bobbin
Hand hacksaw with 24 teeth / inch blade

Jig saw with a 14 teeth / inch blade

Shaver
Cleaning rag
Adhesive, spatula (=rubber scraper plate ),
Emery cloth
Heating blanket
Hot air gun (paint stripper gun )
Digital temperature gauge
Variable energy condrol (rheostat)
Insulation blanket
Generator
Cleaning fluid / gloves / dust mask / safety glasses.
Shelter ( depending on the weadher conditions )
Hiab Truck

METHOD STATEMENT FOR INSTALLATION OF GRE PIPES

PAGE 7 OF 9

7.

Traior
Crane

RISK RATING
All required Safety pre-cautions identified by "risk analysis" shall be
implemented, so that the residual risk becomes "LOW".
7.1

SUPERVISION
A full time Supervisor / Job Performer shall be available at the
Workshop / Site to supervise the activities.
Contractor's Safety Officer shall oversee the safety precautions.

7.2

HSE REQUIREMENTS
1.

All members of the team shall undergo safety induction

relevant for the job. This shall include "Emergency
Response Procedure".

2.

All workmen shall have PPE (of approved brand) determined

for
the job (Viz: coverall, helmet, Safety shoes, hand
gloves, goggles
etc.).
3.
Conduct "Toolbox Talk" to brief all concerned about nature
of job, risk involved, contingency plan, course of action in
case of emergency etc.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Only experienced / skilled personnel shall be deployed for

the job.
Obtain required Work Permit along with relevant certificate,
if any, one day prior to commencement of the job.
Insist on Good House Keeping at all times.
A stand-by vehicle shall be available during erection at Site.
No work shall commence before obtaining the required
Permit to Work / Certificate.
Wind socks shall be installed at Cluster site.
No vehicle shall park within 30 M of the Cluster.
The Crane / Hiab shall have valid Test Certificate from
an ADCO approved third party.
All machinery will be safeguarded.
All lifting tackles shall have valid Test Certificates and
be colour coded.
Fire Extinguishers (Dry Powder) of approved brand shall be
available as per ADCO requirements.

METHOD STATEMENT FOR INSTALLATION OF GRE PIPES

PAGE 8 OF 9

15.
16.
17.
18.
19.
20.
21.
8.

Welding machines shall be provided with ELCBs and autolock safety device as per ADCO requirements.
Approved Project Safety Plan will be strictly followed.
Lighting shall be sufficient in accordance with ADCO
requirements.
Spark Arrestors shall be fixed to all machinery / vehicles.
Sufficient drinking water will be available for all the
workforce at all times.
Temporary shelters (tent) shall be provided on site to
safeguard workmen against high temperature.
Journey Management Plan shall be implemented for all
vehicles on site.

QA/QC REQUIREMENTS
As per relevant construction procedure / inspection and test plants.

9.

TIME DURATION
Time duration is depending upon the project work shedule

10.

APPROVALS
All relevant drawings pertaining to the job shall be approved by ADCO.
(Ensure "AFC" Status).

A general Inspection shall be carried out after completion of the activity and
relevant inspection report shall be signed off by ADCO.
11. ATTACHMENT
Risk Assessment

METHOD STATEMENT FOR INSTALLATION OF GRE PIPES

PAGE 9 OF 9