B May 1, 2018 For Approval JMTI RAP JZM

A April 12, 2018 For Approval JMTI RAP JZM

Rev Date DESCRIPTION MADE CHECKED APPR’D

Client

Katipunan Road, Balara, Quezon City, Philippines

Project

DESIGN & CONSTRUCTION OF PUTATAN WATER TREATMENT PLANT 2

Contractor

PMC Consultant

Key Plan
Method Statement:
Interconnection of Permeate Pipe to the
Existing Pipe

Project Discipline Issuing Document

Document Type Rev
Code Code Company Nº
PWTP2 IC PR CON 0049 B
Table of Contents
1. METHOD STATEMENT ................................................................................ 2

2. REFERENCE DOCUMENT ............................................................................ 2

3. EQUIPMENT REQUIREMENT ...................................................................... 2

4. MATERIAL REQUIREMENT ......................................................................... 2

5. MANPOWER REQUIREMENT ...................................................................... 2

6. RESPOSIBILITIES ..................................................................................... 3

7. PIPE INTERCONNECTION PROCEDURE ..................................................... 5

6.1 SITE PREPARATION ................................................................................ 5

6.2 REMOVAL OF DN1600 BLIND FLANGE ..................................................... 6

6.3 DEWATERING ......................................................................................... 6

6.4 INSTALLATION OF 1600 X 1000 REDUCER AND ITS APPURTENANCES ... 6

8. TIME INTERRUPTION................................................................................ 7

9. SAFETY ..................................................................................................... 7

8.1 SAFE WORK PRACTICE ............................................................................ 7

8.2 HAZARD IDENTIFICATION AND RISKS ASSESSMENT CONTROL (HIRAC) 8

8.3 PPE REQUIREMENT ............................................................................... 14

10. ANNEX A: BOLT TORQUE SEQUENCE ..................................................... 15

11. ANNEX B: TORQUE REQUIREMENTS ...................................................... 16

12. ANNEX C: AS BUILT DRAWING ............................................................. 17

13. ANNEX D: FLEXIBLE CONNECTOR ......................................................... 18

14. ANNEX E: REQUEST FOR WORK ACTIVITY ............................................ 19

DCPWTP-2
MS-049 1
1. METHOD STATEMENT

This method statement aims to describe the work procedure and methods to be adopted for
the interconnection of new DN1000 permeate pipe to the existing DN1600 steel pipe going
to existing PWTP1 reservoir.

2. REFERENCE DOCUMENT

1. PWTP2-QA-HD-CON-0019 Rubber Expansion Joint Data Sheet – Methods of

Installation
2. PWTP2-IC-PR-CON-0019 Pipe Laying and Welding Procedure

3. EQUIPMENT REQUIREMENT

The following equipment shall be arranged before starting the work:

1 unit Grove Crane, 50 ton Cap
1 set Set of Wrench
1 set Torque Wrench
31 set Impact Wrench

4. MATERIAL REQUIREMENT

1. Reducer - 1600 mm x 1000 m x 2.60m, F/F – 1PC

2. Flexible Connector, 1000 x 700, F/F – 1PC
3. Bolts, Nuts and Washers
a. For DN1600 Flange, 50mm diam. x 250mm long – 40 sets
b. For DN1000 Flange, 37mm diam. x 250mm long – 56 sets
4. Gasket
a. For DN1600 Flange – 1 pc
b. For DN1000 Flange – Not required/ built-in flexible connector
5. Standard PPE’s

5. MANPOWER REQUIREMENT

The following personnel shall be present at site during the implementation of the works:
1 QC Engineer (Mechanical Engineer)
1 Project Engineer (Mechanical Engineer)
2 Safety Officer
1 Surveyor
1 Crane Operator
2 Rigger
1 Truck Driver
1 Construction Foreman
4 Skilled Labor
4 Unskilled Labor

DCPWTP-2
MS-049 2
6. RESPOSIBILITIES

The following are the personnel are responsible for the execution of interconnection of pipes
and these shall be arranged prior to the execution of works:

PROJECT ENGINEER (MECHANICAL ENGINEER)

Responsible for the interconnection activities. See to it that the materials, equipment,
tools and personnel required are available at site. Oversee the work is done base on the
Plans and at the scheduled time.

QC ENGINEER (MECHANICAL ENGINEER)

Oversee the work is done according to the Plans and specifications.

SAFETY OFFICER
Responsible on site safety. Make sure that equipment and tool are safe for use. See to it
that personnel at site are wearing the required PPE’s, capable of handling work.

SURVEYOR
Responsible for establishing and monitoring correct elevation and alignment.

FOREMAN
Directly in charge of the site work. Take order from the Engineer in Charge. Direct workers
under him to perform the work needed until the duration of the work.

CRANE OPERATOR
For removing the existing pipe and replacing with new material by lifting using crane, the
operator shall be qualified to operate the crane in an acceptable and safe manner.

RIGGER
Assist crane operator in determining the crane positioning, responsible for
communicating with the crane operator by signalling in order to place the lifted load to
the appropriate locations, safely. Responsible for hooking and unhooking the load.

SKILLED LABOR
Responsible for the work as directed by the Engineer or Foreman.

UNSKILLED LABOR
Responsible for the work as directed by the Engineer or Foreman. Assist other workers as
needed.

DCPWTP-2
MS-049 3
Personnel Organization Chart

Project
Manager

Head, QC Project Engineer - Mechanical Head,

RAYMOND INQUINIA Safety

QC Inspector
Project Engineer - Mechanical
ROD MANUEL
RAUL CASTRO
TAYAO

Surveyor Foreman Crane Operator

Safety Officer
PABLING ZAMORA JR. FREDDIE OLYMPIO
NESTIE SEGUI
& CREW ROSETE SAMODIO

Skilled Workers Unskilled Worker Rigger

NORBERTO DACUTANAN ALLAN VELASCO ROLLY ROYALES
EDWIN BUO RONALD SANTILLAN & CREW
ROMIE VALLE ALEJANDRO TONDO
RONALD ANDEZA REYNALDO MONDALA

Process Flowchart

Supporting Documents: START

Approved Plan
Work Inspection Request Output Documents:
Special Permit from Maynilad Incoming PTW
Permit To Work (PTW)
Method Statement

Site Preparation

Removal of Existing
DN1600 Blind Flange

Draining of Water inside

the Existing Pipe

Installation of Reducer
and Flexible Connector
Supporting Documents:
Approved MIR of Reducer &
Flexible Connector

Tightening of DN1600
and DN1000 Bolts & Nuts
Output Documents:
Incoming Work Inspection Request

FINISH

DCPWTP-2
MS-049 4
7. PIPE INTERCONNECTION PROCEDURE

The sequence of activities is as shown in the Table hereunder, all these activities are explained briefly in the
subsequent part of the section.

Table 1.0: Sequence of Activities

No. Sequence of Activities

1 Site Preparation
2 Removal of DN1600 Blind Flange
3 Dewatering
Installation of 1600 x 1000 reducer and its
4
appurtenances

6.1 SITE PREPARATION

This consist of preparatory works that includes site clearing and mobilization of materials, tools and
equipment required as per Sec. 3.0, 4.0 and 5.0.

After the successful Hydro-testing undertaken by FFC and Chlorine Disinfection undertaken by ACCIONA
AGUA of the permeate line, the new line will now prepare for tapping to the existing DN 1600 pipe line
connected to the existing reservoir.

The surveyor shall check the alignment of each pipes prior to start of any activity.

Fig. 1.0 Plan Layout

The crane shall be position as shown in Fig. 1.0 in such a way it can easily hoisted all the necessary
materials needed for the execution of works.

DCPWTP-2
MS-049 5
 Fig. 2.0 Pipe Layout before Interconnection

6.2 REMOVAL OF DN1600 BLIND FLANGE

With the approval of the Engineer, for the tapping work and closure of valves connected to the DN1600
pipe, AJF crew shall remove the DN1600 blind flange of the existing pipe by removing bolts and nuts.

6.3 DEWATERING

After removing the blind flange, drain the remaining water inside the pipe. If the volume of water inside pipe
is big, pump shall be used and discharge it to the existing drainage manhole.

6.4 INSTALLATION OF 1600 X 1000 REDUCER AND ITS APPURTENANCES

Install the 1600mm x 1000 reducer by fixing bolts, nuts, washer and gasket. Install also the 1000 mm and
flexible connector that will connect 1000 reducer and the new 1000 mm and permeate pipe.

Fig. 3.1 Plan Layout After Interconnection

DCPWTP-2
MS-049 6
 Fig. 3.2 Pipe Elevation After Interconnection

8. TIME INTERRUPTION

The table below the sequence of operation and its estimated duration.

Duration
No. Operation
(Approximate)
Removal of 1600 mm and Blind Flange including
1 3 hours
draining of Water inside pipe
2 Installation of reducer and flexible connector 1 hour
4 Tightening of DN1600 Flange 3 hours
5 Tightening of DN1000 Flange 1 hours
Total 8 hours

9. SAFETY

Please refer AJF Health, Safety and Environment Plan for further details of
relevant safe work procedures that should be followed during the testing.

8.1 SAFE WORK PRACTICE

Safety of the personnel and properties is to be given prime importance

and all the works to be carried out causing any accidents of property
damages. Adequate access and egress shall be provided to the site for
work. All personnel shall wear proper PPE’s.

All the equipment, tools and tackles being used for the work shall be in
good condition and maintained. Regular toolbox meeting shall be
conducted regularly on the procedures to execute the work safely.

DCPWTP-2
MS-049 7
 Relevant Lock out, Tag out procedure shall be known to the working
personnel especially when dealing with the hazardous and pressurized
water coming from the existing PWTP1 Maynilad main valve as follows:

During the course of activity, after dewatering, instruct worker in charge

to close the valve with the use of pad lock and inspection tag, where in
the details of the activity, person in charge, contact number and the
date for proper identification. Use Extreme precautions and supervision
when dealing with pressurized water. Coordinate with Plant 1 operation
regarding the said activities before and after. And proper coordination
must be done in prior to turning on (re-start up) or off the pressurized
water, valves and pipes.

Always secure proper work permits applicable for the job (Special permit
from Maynilad, Hotworks permit, confined space permits, hydrotest
checklist and permits etc. or as needed)

8.2 HAZARD IDENTIFICATION AND RISKS ASSESSMENT CONTROL (HIRAC)

RISK LEVEL Before RISK LEVEL After ANTICIPATED

MITIGATION
MITIGATION Mitigation MEASURES TO
MEASURE TO BE
BE APPLIED BY
Hazard RISK
LIKELI
CON
SEQ
TAKEN BY THE
LIKELI
CONS
INDE THE
INDEX CONTRACTOR/ EQUE
HOOD UEN HOOD
NCE
X CONTRACTOR/
CE CONSORTIUM
CONSORTIUM
1.0 Site Preparation
Always secure
proper work
permits applicable Conduct toolbox
for the job (Special meeting prior to
permit from commence of
Failure to
Work Stoppage Maynilad, Hotwork work to discuss
secure proper
permits, confined the activities
work permit(
space permits, included in the
Maynilad
hydrotest checklist work permit
special permit
and permits etc. Or
if the activities
as needed)
is within the 4 5 20 1 4 4
Always coordinate Provide proper
Plant 1 area) /
with operations PPE, tools and
authorization
and other work equipment
and
Personnel groups for suitable for the
coordination
injury, property activities that may job at hand and
with plant 1
and interfere or interact as per indicated
operation
environmental with other with the work
department
damage discipline permit
Ensure that Ensure that
competent activities to be
personnel is performed on

DCPWTP-2
MS-049 8
 available for the what is indicated
job on the work
permit and is
properly
coordinated and
handover to
proper
authorities
2.0 Removal of DN1600 Blind Flange
Inhouse trainings
for workers,
regarding the
control and
handling of
chlorine at sites,
proper
use/appropriate
use of personal
protective
equipment, stand
first aider/nurse
for any incidents
proper awareness
of emergency
and knowledge on
involving or
Fire oxidizer, chorine/chemical
exposure to
skin and eye handling, correct
chlorine,
irritation, storage of
immediate
respirtory chemicals, area
interventions
Chlorine leak irritation and should be properly
4 4 16 2 4 8 such as first aid
exposure may damage ventilated, Fire
shoulde be
nervous system, fighting equipment
applied to the
and fatality, should always be
personnel.
stoppage of available with in
Emergency
work reach for
evacuation
emergency
should be
purposes.
estbalished and
identified by all
workers. Only
trained personnel
are allowed to
make contact or
rescuer to the
exposed areas,
specialized
equipment
required(SCBA)
full competency
trainings
Only authorized
Provide proper personnel
isolation/barricadin allowed in the
Lifting of Physical injury /
g of the work area. area. Wear
materials ( Property 4 4 16 2 4 8
Install appropriate appropriate PPEs
pipe ) damage
signages for the on the working
ongoing activities. area. Stand-by
First Aider / Site

DCPWTP-2
MS-049 9
 Medical Facility /
Immediate
coordination with
the accredited
Hospital.
Educate workers
Use lifting tools
on proper lifting
Spine injury and equipment if
procedures and
possible
ergonomics
Provide adequate
Provide lifting tools manpower when
Back pain
and equipment lifting heavy
Manual objects
Handling / 3 4 12 2 3 6 Conduct in safety
Ergonomics toolbox meetings
the proper lifting
Provide the right
procedure and
size of tools and
Strain ergonomics
equipment for the
Wear proper
job
PPE: Hard hat,
Safety Shoes,
Gloves, Goggles
Monitor noise level Wear appropriate
hearing
Noise Hearing damage 4 3 12 Monitor proper use 3 2 6
protection: ear
of PPE plug / ear muffs
Provide proper
Barricade working
PPE for welding
Eye injury and area and provide
activities
burns signage and
(welding gloves,
bollard
apron and mask)
Provide cover on
Welding Arc
3 4 12 2 4 8 adjacent
and sparks
equipment (fire
Clear work area
blanket)
Fire from flammable
Provide fire
materials / debris
watch and
standby fire
extinguisher
Provide sufficient Provide proper
Respiratory ventillation and PPE for welding
Welding fumes irritation / 3 3 9 educate welders on 1 3 3 activities
desease proper positioning (welding gloves,
and use of PPE apron and mask)
3.0 Draining of water inside pipe (De-watering)
Barricade working Provide fire
area and provide watch and
Fire
signage and standby fire
bollard extinguisher
Clear work area
Oxy-acetylene Provide proper
Explosion 4 4 16 from flammable 2 4 8
cutting PPE for oxy-
materials / debris
acetylene
Check oxy-
activities
acetylene
Burns (welding gloves,
accessories prior to
apron and mask)
each use

DCPWTP-2
MS-049 10
 Install flash back
arrestor on oxy-
acetylene sets.
Oxy-acetylene sets
to be used shall be
in trolleys with
chain guard and
stand by fire
extinguisher
Adequate
number of
emergency
access ladders
Check and identify
Suffocation should be
confined space
installed inside
the
tank/confimed
space
Gas test work
Monitor works
Unconsciousnes area prior to
inside confined
s commence of
space
work
Provide blowers
for adequate air
Limit works inside
exchange and
Confined confined space
2 5 10 2 3 6 respirators (if
space entry
necessary)
Install sufficient
Work area should lighting on work
be properly area, access
illuminated ways and
(sufficient lighting) emergency
Fatality
facilities
Attendant -
entrant system
should be
Check for presence
followed
of toxic gases (if
ERP should be
any) and oxygen
established first
level
prior to
commence of
work
Provide liferings
with life lines
Install barricade
Drowning readily accessible
and signage
during water
tightness test
In cases where
Provision of covers direct contact
Water Hazard 3 5 15 2 4 8
Increase water for small storage with test water is
borne desease tanks and unavoidable,
or infection disinfection for proper personnal
large storage tanks hygiene should
be practiced
Accumulation/br Restrict entry to Regular
eeding of site (affected area) inspection of test

DCPWTP-2
MS-049 11
 insects/mosquit water for
oes. Insect/ presence of
parasite bites / mosquito larvae
dengue fever or other water
borne insect and
parasites.
Disinfection of
test water if
necessary
Using of Lock out -
tag out system.
During the activity,
after de watering,
instruct worker or
person in charge
to close the valve
with the use of pad Using of
lock and inspection appropriate
tag , where in the signages for the
details of the said activity.
activity, person in Inhouse trainings
charge, contact for the workers
number and the involved to assist
Pressurized
date for proper in the
water resulting
identification. Use identification of
to physical
4 4 16 Extreme 2 4 8 hazards. Toolbox
injury, property
precautions and talks or pre job
damaged and
supervision when meeting
fatality
dealing with conducted by the
pressurized water. supervisor
Coordinate with incharge for the
Plant 1 operation detailed works.
regarding the said Observed safety
activities before checklist and
and after. And permits.
proper
coordination must
be done in prior to
turning on(re-start
up) or off the
pressurized water,
valves and pipes.
Provide sufficient
ligthing
Slip, Trips,
Work area should Proper and
Personnel being
Poor be properly regular
struck by, 4 4 16 2 3 6
Illumination illuminated inspection of
Personnel being
(sufficient lighting) emergengy
strucked against
ligthing on the
area
4.0 Installation of of 1600 X 1000 Reducer and its appurtances
unsafe lifting Site Engineer /
procedure, ( Slip, trip, Proper supervision Safety Officer to
damaged back and 5 5 25 will be provided till 2 3 6 ensure that any
lifting muscle pain end of the job. commencing
accessories, cause of works should

DCPWTP-2
MS-049 12
 improper improper Ensure workforce address the
maintenance position of complying required importance of
of the body, close and PPE HSE Tool Box
equipments,. open wound, Pre job discussion Talks / In-House
Personal finger body prior to start the Training.
Injury - injury or fatality job.
improper - struck by or Required TBT / In-
position of struck in, House Training to
body, caught in or be obtained from
caught by. HSE Department
Damage to the that should be in
equipment. or place & recorded.
to the pipe- Proper monitoring
Stoppage of and inspection of
work equipments'
accesories, follow
safe lifting
procedures,
avoiding
simlultaneous work
operations and
proper
coordination to all
personnel involved.

LIKELIHOOD
Consequence
Extremely unlikely to occur in Catastrophic- Death or Major Loss;
1 Improbable 5
relevant period Total System failure
Critical -Major injury, damage to
Unlikely to occur in relevant
2 Remote 4 property/infrastructure, environment
period
effect

Serious- Loss time injuries/illness,

Likely to occur in relevant
3 Occasional 3 minor damage to property/infra and
period
envi.

Likely to occur several times in

4 Probable 2 Marginal- Minor First Aid Incident
relevant period

Likely regular occurence in Insignificant- Unlikely to have impact

5 Frequent 1
relevant period on works.
INDEX/MATRIX
(16) -(25) VERY HIGH- Un acceptable, re-examine to lower risk
(9) -(15) HIGH- Apply further Mitigation measure to reduce risk
(6) -(8) MEDIUM-Tolerable only if further mitigation is not practical
(1) -(5) LOW-Broadly acceptable and control measure is applicable

DCPWTP-2
MS-049 13
8.3 PPE REQUIREMENT

Protective clothing (a jacket or protective suit)

Safety shoes

Personal hearing protectors

Protective gloves (canvas or leather)

Glasses / Eyes protection

Helmet

DCPWTP-2
MS-049 14
10. ANNEX A: BOLT TORQUE SEQUENCE

Sequential Rotation Order

Order
1–2 1 2
3–4 23 24
5–6 9 10
7–8 17 18
9 - 10 39 40
11 – 12 5 6
13 – 14 29 30
15 – 16 11 12
17 – 18 33 34
19 – 20 37 38
21 – 22 3 4
23 – 24 27 28
25 – 26 13 14
27 – 28 21 22
29 – 30 35 36
31 – 32 7 8
33 – 34 31 32
35 – 36 15 16
37 – 38 19 20
39 – 40 25 26

DCPWTP-2
MS-049 15
11. ANNEX B: TORQUE REQUIREMENTS

DCPWTP-2
MS-049 16
12. ANNEX C: AS BUILT DRAWING

DCPWTP-2
MS-049 17
13. ANNEX D: FLEXIBLE CONNECTOR

DCPWTP-2
MS-049 18
14. ANNEX E: REQUEST FOR WORK ACTIVITY

DCPWTP-2
MS-049 19